Lincoln Electric IM916 - Manuals

iv SAFETY 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 secouss...

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...

vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .......................................................................................................A-1Safety Precaut...

POWER FEED™ 10M DUAL WIRE FEEDER A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS – Power Feed™ 10M Dual 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 Speed Solid Cored Speed Solid Cored K22...

A-2 INSTALLATION POWER FEED™ 10M DUAL WIRE FEEDER A-2 SAFETY PRECAUTION ELECTRODE ROUTING The electrode supply may be either from reels, Readi-R e e l s , s p o o l s , o r b u l k p a c k a g e d d r u m s o r r e e l s .Observe the following precautions: a) The electrode must be routed to the wire...

A-3 INSTALLATION POWER FEED™ 10M DUAL WIRE FEEDER A-3 NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required, such asin some Innershield applications, reverse the outputconnections at the power source (electrode cable tothe negative (-) stud, and work cable to the positive(+) stud)...

A-4 INSTALLATION POWER FEED™ 10M DUAL WIRE FEEDER A-4 VOLTAGE SENSING The best arc performance occurs when the PowerWaves® have accurate data about the arc conditions.Depending upon the process, inductance within theelectrode and work lead cables can influence the volt-age apparent at the studs of t...

A-5 INSTALLATION POWER FEED™ 10M DUAL WIRE FEEDER A-5 W I R E D R I V E G E A R R AT I O ( H I G HOR LOW SPEED) The speed range capability and drive torque of thePower Feed™ wire drives can be easily and quicklychanged by changing the external drive gear. ThePower Feed™ Wire Feeders are shipped with...

A-6 INSTALLATION POWER FEED™ 10M DUAL WIRE FEEDER A-6 GEAR RATIO RECOGNITION: 1. Remove the rear access door from the wire feeder case. 2. Locate the dip switch bank on the P.C. board (refer to table A.3) 3. Locate dip switch # 8 and move it to the appropriate gear ratio setting as described below: ...

A-7 INSTALLATION POWER FEED™ 10M DUAL WIRE FEEDER A-7 PROCEDURE TO INSTALL DRIVEROLLS AND WIRE GUIDES Drive Roll Kit Installation (KP1505-[ ]) • Turn OFF Welding Power Source. • Pull open Pressure Door to expose rolls and wire guides. • Remove Outer Wire Guide by turning knurled thumb screws counter...

A-8 INSTALLATION POWER FEED™ 10M DUAL WIRE FEEDER A-8 Magnum 550 Guns T h e e a s i e s t a n d l e a s t e x p e n s i v e w a y t o u s e t h eMagnum 550 guns with Power Feed™ 10 Dual wirefeeders is to order the gun with the K613-7 connectorkit, and install a K1500-3 gun connection kit to thewire ...

A-9 INSTALLATION POWER FEED™ 10M DUAL WIRE FEEDER A-9 Flow Sensor Kit installation is as follows: 1. Remove rear access door of the wire feeder case.2. Locate the shutdown circuit leads inside feeder case cavity (refer to table A.4).Note: The leads will be connected together withinsulated (pink) qui...

b-1 OPERATION b-1 POWER FEED™ 10M DUAL WIRE FEEDER COMMON WELDING AbbREVIATIONS WFS • Wire Feed Speed CC • Constant Current CV • Constant Voltage GMAW (MIG) • Gas Metal Arc welding GMAW-P (MIG) • Gas Metal Arc welding-(Pulse) GMAW-PP (MIG) • Gas Metal Arc welding-(Pulse-on-Pulse) GTAW (TIG) • Gas Tu...

b-2 OPERATION POWER FEED™ 10M DUAL WIRE FEEDER b-2 PRODUCT DESCRIPTION The Power Feed™ 10M Dual Wire Feeder unit con-sists of a user interface and two wire drives. This unitwill be available as a bench model or a boom model. The Power Feed™ 10M Dual Wire Feeder is a highperformance, digitally contro...

FIGURE b.2 b-3 OPERATION b-3 O P E R AT I O N A L F E AT U R E S A N D CONTROLS POWER FEED™-10M SERIES SYSTEM CONFIGURA-TION The specific system component function of the pc board willbe configurable by dip switch or by software configurationtool. Dip switch configuration is as follows: Refer to DIP...

3. OUTPUT CONTROLS • The Power Feed™ 10M Dual Wire Feeder has 2 encoder knobs to adjust weld parameters. • Each encoder changes the displayed value of the meter located directly above that encoder. • In CC-GTAW modes when equipped with a foot or hand amptrol, the left encoder sets the maximumwelding...

b-7 OPERATION b-7 POWER FEED™ 10M DUAL 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 is...

b-9 OPERATION b-9 POWER FEED™ 10M DUAL WIRE FEEDER USER DEFINED PARAMETERS Parameter Definition P.5 Procedure Change Method This option selects how remote procedure selection (A/B) will be made. The selected procedurecan be changed locally at the user interface by pressing the 'A-Gun-B' button. The ...

b-14 OPERATION b-14 POWER FEED™ 10M DUAL WIRE FEEDER Parameter Definition P.506 Set User Interface Passcode Prevents unauthorized changes to the equipment. The default passcode is zero which allows full access.A nonzero passcode will prevent unauthorized: changes to memory limits, saving to memory (...

b-15 OPERATION b-15 POWER FEED™ 10M DUAL WIRE FEEDER M emory #4Me mor y #5 M em ory #6 Me mor y #1 - W eld P arame ters - Mode - Pref low /P ostf low - Run i n - St ar t Par ame ters -Arc Contr ol - Cra ter Para me ters M em ory #2 Me mor y #3 Procedu re B - We ld Para me ters - Mode - Pref low /Pos...

b-16 OPERATION b-16 Each procedure contains/stores the following informa-tion: • Basic weld parameters as applicable - WFS, Volts, Trim, Amps • Weld Mode - Mode Number• Preflow/Postflow - Time in Seconds• Run in - WFS Only (work point determined by next active sequence state) • Start Parameters - St...

b-17 OPERATION b-17 Recalling from Memory To recall the contents of a memory into the active proce-dure, momentarily push the desired memory button (forless than 2 seconds). The saved parameters will becopied into the active procedure, and the LED of thememory button will light indicating the source...

b-18 OPERATION b-18 4 Step Synergic Operation:Without Start/Crater/burnback functions active Waveform Functionality: 1. Trigger is pulled and released; Preflow sequence begins and runs until Preflow timer expires. 2. Run-In sequence begins and runs until Arc is estab- lished 3. Arc established; Weld...

WIRE REEL LOADING - READI-REELS,SPOOLS OR COILS To Mount a 30 Lb. (14 kg) Readi-Reel Package(Using the Molded Plastic K363-P Readi-ReelAdapter:) The Spindle should be located in the LOWER mounting hole. 1) Depress the Release Bar on the Retaining Collar and remove it from the spindle. See Figure b.1...

b-21 OPERATION b-21 FEEDING ELECTRODE AND bRAKEADJUSTMENT 1) Turn the Reel or spool until the free end of the electrode is accessible. 2) While tightly holding the electrode, cut off the bent end and straighten the first 6" (150 mm). Cut offthe first 1" (25 mm). (If the electrode is not prop...

b-22 OPERATION b-22 MAKING A WELD 1) Use only a network compatible power source. 2) Properly connect the electrode and work leads for the correct electrode polarity. 3) Set all desired parameters such as trigger logic, Run-in Speed, Acceleration, Electrode polarity, etc.per “DIP SWITCH SETUP” in the...

b-23 OPERATION b-23 COMPONENT STATUS LIGHTS Each network component has a single status light.The light is a bicolor, Green/Red, LED. The purposeof the status light is to allow the operator to quicklyidentify that the system is working properly or, if not, which component is causing the problem. By u...

b-24 OPERATION b-24 POWER FEED™ 10M DUAL WIRE FEEDER STATUS LIGHT STATES (CON’T) LED State Red LED blinkingat a fast rate Red LED ON andsteady G r e e n L E D O Nand steady Power Source LED Power source needs to be reprogrammed.Contact your Local Authorized Lincoln FieldService Facility. Power sourc...

b-25 OPERATION b-25 POWER FEED™ 10M DUAL 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 andperform ...

C-1 ACCESSORIES C-1 POWER FEED™ 10M DUAL WIRE FEEDER TAbLE C.1 – DRIVE ROLL AND GUIDE TUbE KITS Wire Size 4-Roll DH Drive (4-Driven) Solid Steel Electrode 0.023” - 0.025” (0.6 mm) KP1505 - 030S 0.030” (0.8 mm) KP1505 - 030S 0.035” (0.9 mm) KP1505 - 035S 0.040” (1.0 mm) KP1505 - 040S 0.040” (1.0 mm) ...

• Readi-Reel Adapters - Adapts 22-30 lb. Readi-Reels to a 2" Spindle K363P - Adapts 50-60 lb. Readi-Reels to a 2" Spindle K438 • Coil Adapter - Adapts 50-60 lb. Lincoln coils to a 2" Spindle K1504-1 • Plastic Wire Cover for 30-44 lb. Wire Packages K1634-3 • Plastic Wire Cover for up to 6...

C-3 ACCESSORIES C-3 POWER FEED™ 10M DUAL WIRE FEEDER K435 - COIL ADAPTER Permits 14 lb. (6 kg) Innershield coils to be mountedon 2” (51 mm) O.D. spindles. K363P - READI-REEL ADAPTER Adapts Lincoln Readi-Reel coils of electrode 30 lb. (14k g ) a n d 2 2 l b . ( 1 0 k g ) t o a 2 ” ( 5 1 m m ) s p i n...

C-4 ACCESSORIES C-4 POWER FEED™ 10M DUAL WIRE FEEDER K1500-4 (MILLER CONNECTION) For any gun having a newer style Miller connector.Install gun adapters per the instructions shipped withit. K1500-5 (OxO CONNECTION) For any gun having an OXO style connector. Installgun adapters per the instructions sh...

D-1 MAINTENANCE D-1 POWER FEED™ 10M DUAL WIRE FEEDER Avoiding Wire Feeding Problems Wire feeding problems can be avoided by observingthe following gun handling and feeder set up proce-dures:a) Do not kink or pull cable around sharp corners. b) Keep the electrode cable as straight as possible when we...

E-1 TROUbLESHOOTING E-1 POWER FEED™ 10M DUAL 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 Ob...

E-2 TROUbLESHOOTING E-2 POWER FEED™ 10M DUAL 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 techn...

E-7 TROUbLESHOOTING E-7 POWER FEED™ 10M DUAL WIRE FEEDER Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455: Code 10555 and below Note: For any Err # listed below write down the error number for reference and try cycling power to see if theerror clears i...

E-10 TROUbLESHOOTING E-10 POWER FEED™ 10M DUAL 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 ...

E-12 TROUbLESHOOTING E-12 POWER FEED™ 10M DUAL 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 ...

F-1 DIAGRAMS F-1 POWER FEED™ 10M DUAL WIRE FEEDER NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to th...

F-2 DIAGRAMS F-2 POWER FEED™ 10M DUAL WIRE FEEDER 6.8 8 .2 18 4.2 5 .7 5 .7 5 .8 1 .9 0 12 .0 7 12 .9 6 18 96 3 3.0 6 8.5 0 M 4.0 8 3.8 6 (4 K E Y H O L E S L O T S ) 1 0-1 7-9 7 C O N TR O L B O X D IM E N S IO N P R IN T 6 .8 8 .2 1 8 4 .2 5 .7 5 .7 5 .8 1 .9 0 1 2 .0 7 1 2 .9 6 1 8 9 6 3 3 .0 6 8...

F-3 DIAGRAMS F-3 POWER FEED™ 10M DUAL WIRE FEEDER 19.8 9 A A 19.9 1 A A 15.4 1 A A 30.6 1 A A L11 044 7-21 -20 00C 1 9 .8 9 A A 1 9 .9 1 A A 1 5 .4 1 A A 3 0 .6 1 A A L 1 1 0 4 4 7 -2 1 -2 0 0 0 C WIRE FEEDER (bENCH MODEL) DIMENSION PRINT

F-4 DIAGRAMS F-4 POWER FEED™ 10M DUAL WIRE FEEDER 8.5 6 A A 14 .1 0 A A 15 .5 5 A A 6.0 0 A A D O O R O P E N TY P . 5.2 5 A A 19 .4 3 A A 11 .1 2 A A 2.5 4TY P. A A 4.4 3 A A 2.2 5 A A 2.9 3 A A 4.2 5TY P . A A W IR E D R IV E D IM E N S IO N P R IN T 7 -2 0 0 0 M 19 30 4 8 .5 6 A A 1 4 .1 0 A A 1 ...