Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resist...
Page 4 - iii; Refer to
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - PRÉCAUTIONS DE SÛRETÉ; iv
PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique:...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TAbLE OF CONTENTS
vi vi TAbLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation .......................................................................................................................Section A Technical Specifications ..........................
Page 9 - INSTALLATION; POWER FEEDTM 10M SINGLE WIRE FEEDER; TECHNICAL SPECIFICATIONS: Power FeedTM 10M Single Wire Feeder; WELDING CAPACITY RATING
A-1 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-1 TECHNICAL SPECIFICATIONS: Power Feed™ 10M Single Wire Feeder WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO ∆ Dimensions do not include wire reel. Wire Size Wire Size Low Speed Solid Cored High Speed Sol...
Page 10 - SAFETY PRECAUTION; LOCATION
A-2 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-2 SAFETY PRECAUTION LOCATION • The Power Feed™ 10M Single Wire Feeder has an IP21 rating, suitable for indoor use. • The Power Feed™ 10M Single Wire Feeder should be operated in a substantially upright position. • Do not submerge the Power Feed™ ...
Page 11 - WELD CAbLE SIzES; Minimum work and electrode cables sizes are as follows:; WELD CAbLE CONNECTION; CAUTION
A-3 INSTALLATION A-3 POWER FEED™ 10M SINGLE WIRE FEEDER SAFETY PRECAUTION E L E C T R I C S H O C K c a nkill. • Only qualified personnel should perform this installation. • Turn off the input power to the power source at the disconnect switch or fuse box before work-ing on this equipment. Turn off ...
Page 12 - NEGATIVE ELECTRODE POLARITY; • Do not touch electrically live parts; COAxIAL WELD CAbLES
Electrode Work Work Power Source Work Electrode Wire Feeder Electrode Work Coaxial Weld Cable Electrode Work Work Power Source Work Electrode Wire Feeder Electrode Work Coaxial Weld Cable CHANGING ELECTRODE POLARITYSETTING The Power Feed™ 10M Single Wire Feeder is presetat the factory for Electrode ...
Page 13 - Trigger Lead; CONTROL CAbLE; CONTROL CAbLE CONNECTIONS
Welding Gun/Wire Feeder Trigger Connector Wire Feeder Pin Function A Gun Trigger B - C Common D Dual ProcedureE Common CONTROL CAbLE SPECIFICATIONS It is recommended that only genuine Lincoln controlcables be used at all times. Lincoln cables are specifi-cally designed for the communication and powe...
Page 14 - WIRE DRIVE SYSTEMS
C H A N G I N G D R I V E R O L L S A N D W I R EGUIDES FIGURE A.4 ITEM DESCRIPTION 1 Inner Wire Guide 2 Drive Rolls 3 Outer Wire Guide To change drive rolls and wire guides: 1. Turn off power at the welding power source. 2. Open wire drive door. 3. Remove the outer wire guide. (Item #3) 4. Remove t...
Page 15 - DRIVE ROLL PRESSURE SETTING
To change the gun bushing: 1. Turn off power at the welding power source. 2. Remove the welding wire from the wire drive. 3. Remove the thumb screw from the wire drive. 4. Remove the welding gun from the wire drive. 5. Loosen the socket head cap screw that holds the con- nector bar against the gun b...
Page 16 - Turn off power at the welding power source.
A-8 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-8 WELDING GUNS, TORCHES AND ACCES-SORIES GUN RECEIVER bUSHING The Power Feed™ 10M Single Wire Feeder comeswith a K1500-2 gun receiver bushing, for use with theMagnum gun with a K466-10 connector kit which . The Power Feed™ 10M Single Wire Feeder ...
Page 17 - WIRE FEED SHUT DOWN CIRCUIT; ITEM
A-9 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-9 WIRE FEED SHUT DOWN CIRCUIT The wire feed shut down circuit is used to stop thewire feed in the event of a fault. The most commonuse of the circuit is with water cooled guns. A flowsensor is connected to the circuit to protect the weld-ing gun ...
Page 18 - WIRE REEL LOADING; Spindle Placement; DIP Switch #8 Position
WIRE REEL LOADING Spindle Placement The wire reel stand provides two mounting locationsfor the spindle. Each mounting location consists of atube in the center of the mast and locating slots. Loading 16 to 44 lb. (7.3 – 20kg) Spools 1. Squeeze the release bar on the retaining collar and remove it fro...
Page 20 - WELD WIRE ROUTING
A-12 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-12 Loading 30 lb. (13.6 kg) Readi-Reels (See Figure A.11) A K363-P Readi-Reel adapter is required for loadingthese spools on 2" (51mm) spindles. 1. Squeeze the release bar on the retaining collar and remove it from the spindle. 2. Place the ...
Page 21 - SHIELDING GAS CONNECTION
A-13 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-13 SHIELDING GAS CONNECTION NOTE: Gas supply pressure must be regulated to a maximum of 80 psi(5.5 bar). Install the shielding gas supply as follows: 1. Secure the cylinder to prevent it from falling. 2. R e m o v e t h e c y l i n d e r c a p ....
Page 23 - bENCH MODEL FEATURES; WIRE DRIVE; Pulse Welding or STT Welding:
A-15 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-15 bENCH MODEL FEATURES bOOM CONFIGURATION WIRE DRIVE CONTROL bOx Digital Control Cable Work Cable Electrode Cable Shielding Gas Hose Wire Feeder Control Box Welding G un Power Source + - Drive Roll Kit Tigger lead Work Connection Digital Contro...
Page 24 - OPERATION; WIRE FEEDER; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
b-1 OPERATION b-1 POWER FEED™ 10M SINGLE WIRE FEEDER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT PROTECTIVEGROUND WARNING ORCAUTION SAFETY PRECAUTIONS Read this entire section of operating instructionsbefore operating the machine. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or el...
Page 25 - DEFINITIONS OF WELDING MODES
b-2 OPERATION b-2 POWER FEED™ 10M SINGLE WIRE FEEDER DEFINITIONS OF WELDING MODES NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. ...
Page 26 - REQUIRED EQUIPMENT; • Power Wave 455M STT; ADDITIONAL REQUIRED EQUIPMENT; EQUIPMENT LIMITATIONS; • The Power FeedTM 10M Single Wire Feeder does
b-3 OPERATION b-3 POWER FEED™ 10M SINGLE WIRE FEEDER PROCESS LIMITATIONS The Power Feed™ 10M Single Wire Feeder is notsuitable for: • SAW• GTAW with HF Not all weld modes or processes described in this manual are avail-able on all Power Wave power sources. REQUIRED EQUIPMENT Lincoln’s Power Feed™ 10...
Page 27 - Status LED indicates system status.; Operation Section; if your machine is equipped; Accessories Section; FRONT PANEL CONTROLS AND CONNECTIONS; CASE FRONT CONTROLS
b-4 OPERATION b-4 ITEM DESCRIPTION 1 Status LED indicates system status. 2 Digital Meter Display is a bright LED display of key welding information. Adjusting Parameter Knobs. 3 MSP4 Panel is used to set the weld mode, adjust the arc, change arc start/end parameters and for set-up information. 4 Col...
Page 29 - PRIOR TO WELDING; Weld Process; • Preset voltage above ideal
AFTER WELDINGWeld Process Volt/Trim Display All Processes After welding, the meter holds the actuala v e r a g e a r c v o l t a g e f o r 5 s e c o n d s .During this time, the display flashes toindicate the wire feeder is in the "Hold"period. Output adjustment while in the"Hold" pe...
Page 30 - LAYOUT-DIGITAL DISPLAY; Weld Mode Description.
• Limit setting for restricting the operators range of control. • L o c k o u t t o p r e v e n t u n a u t h o r i z e d c h a n g e s t o machine configuration. Additionally, the MSP4 includes an infrared (IR) portfor wireless communication and configuration using aPalm OS based hand held computer...
Page 32 - • Pressing the left MSP4 pushbutton will exit the entire Machine
b-9 OPERATION b-9 POWER FEED™ 10M SINGLE WIRE FEEDER LIMIT SETTING The MSP4 can be optionally configured to limit the operator’srange of control of any weld parameter (weld WFS, arc control,etc.). Limits are only available with the Dual Procedure/MemoryPanel. MACHINE SETUP/USER PREFERENCES The MSP4 ...
Page 33 - PARAMETER
b-10 OPERATION b-10 POWER FEED 10M SINGLE WIRE FEEDER SET-UP FEATURES MENU (See Figure B.3a) 1. To access the set-up menu, press the Right and Left buttons of the MSP4 panel simultaneously. Note that the set-up menu cannot be accessed if the system is welding, or if there is a fault (The sta-tus LED...
Page 34 - This setup menu parameter can be used to exit the setup menu. When
b-11 OPERATION POWER FEED™ 10M SINGLE WIRE FEEDER b-11 Parameter Definition Exit Setup Menu P.0 This setup menu parameter can be used to exit the setup menu. When P.0 is displayed, press the left Mode Select button to exit the setup menu. P.1 Wire Feed Speed Units P.1 selects which units wire feed s...
Page 35 - Parameter; The possible values for this parameter are:; Stall Factor Adjustment
b-12 OPERATION b-12 POWER FEED™ 10M SINGLE WIRE FEEDER Parameter Definition P.5 Procedure Change Method Selects how remote procedure selection (A/B) will be made. The selected procedure can bechanged locally at the user interface by pressing the 'A-Gun-B' button. The following methodscan be used to ...
Page 36 - trolled by an external valve.
b-13 OPERATION b-13 POWER FEED™ 10M SINGLE WIRE FEEDER Parameter Definition P.7 Gun Offset Adjustment Range: -30 to 30 (default = 0) Adjusts the wire feed speed calibration of the pull motor of a push-pull gun. This should only beperformed when other possible corrections do not solve any push-pull f...
Page 37 - POWER FEED 10M SINGLE WIRE FEEDER; GMAW welding procedures.
b-14 OPERATION b-14 POWER FEED 10M SINGLE WIRE FEEDER Parameter Definition P.16 Push-Pull Gun Knob behavior Determines how the potentiometer on the Push/Pull torch will behave.• Gun Pot Enabled = The welding wire feed speed is always controlled by the potentiometer on the push- pull gun (default). T...
Page 39 - Step Trigger
4. COLD FEED / GAS PURGE SWITCH Cold Feed and Gas Purge are combinedinto a two position momentary toggleswitch. To activate Cold Feeding, hold the switchin the UP position. The wire drive willf e e d e l e c t r o d e b u t n e i t h e r t h e p o w e rsource nor the gas solenoid will be ener-gized....
Page 40 - STEP TRIGGER OPERATION; SEQUENCE OF OPERATION; ately when the gun trigger is pulled.
S Shhiieelldd iinngg G Gaass IIddllee P Prreefflloow w S Sttrrii kkee U U ppsslloo ppee W Weelldd B Buu rrnnbbaa cckk P Poossttfflloow w IIddll ee W WF FS S O Onn O Offff R Ruunn --iinn O Offff W Wee lldd O Offff W Wee lldd Ar c Arc Est abli shed Established Tr igger Trigger Pull ed Pulled Tr igger ...
Page 41 - STEP TRIGGER OPERATION; SEQUENCE OF OPERATION
b-18 OPERATION b-18 POWER FEED™ 10M SINGLE WIRE FEEDER 4 STEP TRIGGER OPERATION (See Figure B.5)The 4 step trigger sequence gives the most flexibilitywhen the Start, Crater and Burnback functions areactive. This is a popular choice when welding alu-minum because extra heat may be needed duringStart ...
Page 42 - PROCESS SETUP AND OPERATION; The Power Feed; Synergic Modes
PROCESS SETUP AND OPERATION The Power Feed ™ /Power Wave ® system delivers world class arc performance for a wide variety of processes.U s i n g t h e f o u n d a t i o n o f W a v e f o r m C o n t r o lTechnology™, each weld mode is precisely tuned tomeet exacting standards for low spatter, weld b...
Page 43 - ARC CONTROL
b-20 OPERATION b-20 POWER FEED™ 10M SINGLE WIRE FEEDER STEEL AND STAINLESS SYNERGIC GMAW-P (PULSED MIG) WELDING Synergic GMAW-P (Pulsed MIG) welding is ideal for low spatter, out of position and reduced heat input applica-tions. During pulse welding, the welding current continuously switches from a ...
Page 44 - The Power Wave
b-21 OPERATION b-21 POWER FEED™ 10M SINGLE WIRE FEEDER ALUMINUM SYNERGIC GMAW-P (PULSEDMIG)AND GMAW-PP (PULSE ON PULSE)WELDING T h e P o w e r F e e d ™ 1 0 M S i n g l e W i r e F e e d e r a n dPower Wave welding power source combine to readilyproduce top quality aluminum welds with excellentappea...
Page 45 - DESCRIPTION; MACHINE FUNCTIONALITY bY WELD PROCESS; CC STICK MODES
b-22 OPERATION b-22 POWER FEED™ 10M SINGLE WIRE FEEDER ARC FORCE(Soft)-10.0 to(Crisp)+10.0 DESCRIPTION Arc Force adjusts the short cir-cuit current for a soft arc, or fora forceful, driving arc. It helpsto prevent sticking and shortingorganic coated electrodes, par-ticularity globular transfer types...
Page 46 - CV NON-SYNERGIC MODES
EFFECT / RANGE Postflow Time0 to 25.0 seconds Crater Procedure(0 TO 10.0 SECONDS) Burnback: 0 to .25 Seconds Spot Timer:0 to 120.0 Seconds DESCRIPTION Adjusts the time that shieldinggas flows after the welding out-put turns off.Crater Procedure controls theWFS and Volts for a specifiedt i m e a t t ...
Page 47 - SYNERGIC CV MODES
b-24 OPERATION b-24 MACHINE FUNCTIONALITY bY WELD PROCESS GMAW (SYNERGIC) Use the following tables to review how the machine functions (output controls, arc control, Start options and weldoptions) for the weld modes listed in the top table. POWER FEED™ 10M SINGLE WIRE FEEDER EFFECT / RANGEPINCH EFFE...
Page 49 - STT AND STT II MODES
b-26 OPERATION b-26 POWER FEED™ 10M SINGLE WIRE FEEDER 200 ---- WFS AMPS VOLTS TRIM LESSDEPOSITION MOREDEPOSITION 200 ---- WFS AMPS VOLTS TRIM LESSDEPOSITION MOREDEPOSITION EFFECT / RANGE PEAK CURRENT B A C K G R O U N DCURRENT TAIL OUT( S T T l l M O D E SONLY) DESCRIPTION Peak Current acts similar...
Page 50 - OFF; TOUCH START TIG
b-27 OPERATION b-27 POWER FEED™ 10M SINGLE WIRE FEEDER MACHINE FUNCTIONALITY bY WELD PROCESS GTAW (Touch Start TIG) Welding Use the following tables to review how the machine functions (output controls, arc control, Start options and weldoptions) for the weld modes listed in the top table. 120 OFF W...
Page 51 - USER MEMORIES; There are two procedure memories (A and B) and six; showns that Dip Switchs are in the
b-28 OPERATION b-28 POWER FEED™ 10M SINGLE WIRE FEEDER USER MEMORIES Recall a memory with memory buttons To recall a user a memory, press one of the six usermemory buttons. The memory is recalled when thebutton is released. Do not hold the button for morethan two seconds when recalling a user memory...
Page 52 - LIMIT SETTING; Memory Value; WELD WFS; Yes; Enable
b-29 OPERATION b-29 POWER FEED™ 10M SINGLE WIRE FEEDER LIMIT SETTING Each user memory can be optionally configured to limitthe user’s range of control over some user interface set-tings. By default, user limits are not enabled. To set lim-its for a selected memory, first select a weld mode andperfor...
Page 53 - ACCESSORIES
C-1 ACCESSORIES C-1 POWER FEED™ 10M SINGLE WIRE FEEDER OPTIONAL: K2339-1 K2429-1 K2360-1 K1543-xx K1796-xx K1842-xx K1500-1 K1500-2 K1500-3 Push-Pull Connection Kit ArcLink “T” Cable Connector Dual Procedure/Memory Panel ArcLink Cables Co-Axial Power Cable Weld Power Cable Gun Receiver Bushing (for ...
Page 56 - MAINTENANCE; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 POWER FEED™ 10M SINGLE WIRE FEEDER SAFETY PRECAUTIONS WARNING Observe all additional Safety Guidelines detailedthroughout this manual. ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • When inching with gun trigger, ele...
Page 57 - TROUbLESHOOTING; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUbLESHOOTING GUIDE
E-1 TROUbLESHOOTING E-1 POWER FEED™ 10M SINGLE WIRE FEEDER If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ...
Page 58 - PRObLEMS
Err 004 More than 1 object of the sameeqipment type with the same group# and feed head #. Adjust the dip switch setting to makeeither the group # or feed head #unique for all oobjects of the sameequipment type. Err 003 Too many objects in group. A given group can only support upto 7 objects. Remove ...
Page 59 - EEPROM
Display shows any of the following: Err 020 An attempt was made to reprograma CB or feed head but the programdid not verify. Check for potential electrical HFnoise generators in the area. Tryremoving the noise source and pro-gramming again. If the Err 020 stilloccurs, either replace the EEPROM chop(...
Page 60 - ERROR CODES FOR THE POWER WAVE 455
E-4 TROUbLESHOOTING E-4 POWER FEED™ 10M SINGLE WIRE FEEDER If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ...
Page 62 - ERROR CODES FOR THE POWER WAVE; Other
E-6 TROUbLESHOOTING E-6 POWER FEED™ 10M SINGLE WIRE FEEDER If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ...
Page 63 - Display shows any of the following:
E-7 TROUbLESHOOTING E-7 POWER FEED™ 10M SINGLE WIRE FEEDER If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ...
Page 64 - not; Power Wave 455 Status LED; LINC-NET SYSTEM ERROR CODES
E-8 TROUbLESHOOTING E-8 POWER FEED™ 10M SINGLE WIRE FEEDER Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for tec...
Page 65 - Contact
E-9 TROUbLESHOOTING E-9 POWER FEED™ 10M SINGLE WIRE FEEDER Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for tec...
Page 66 - ARCLINK SYSTEM ERROR CODES
E-10 TROUbLESHOOTING E-10 POWER FEED™ 10M SINGLE WIRE FEEDER Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for t...
Page 67 - OUTPUT PRObLEMS
E-11 TROUbLESHOOTING E-11 POWER FEED™ 10M SINGLE WIRE FEEDER Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for t...
Page 70 - DIAGRAMS; Enhanced Diagram
F-1 DIAGRAMS F-1 POWER FEED™ 10M SINGLE WIRE FEEDER NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to...
Page 72 - DIMENSION PRINT; WIRE FEEDER (bENCH MODEL) DIMENSION PRINT
F-3 DIMENSION PRINT F-3 POWER FEED™ 10M SINGLE WIRE FEEDER 15.80 18.48 30.46 DIMENSION PRINT 12/05 14.56 WIRE FEEDER (bENCH MODEL) DIMENSION PRINT