Page 2 - SAFETY; WARNING; Mar; 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
ii SAFETY 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...
Page 4 - iii
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 ’ s recommendations. 8.c. Ground the equipment in...
Page 5 - iv
iv SAFETY iv PR É CAUTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: S û ret é Pour Soudage A L ’ Arc 1. Prot...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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 an...
Page 7 - TABLE OF CONTENTS; Page
vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .......................................................................................................A-1Safety Precaution...
Page 8 - vii
Page Troubleshooting ..............................................................................................Section E Safety Precautions ...............................................................................................................E-1Troubleshooting Guide .......................
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS
A-1 INSTALLATION POWER FEED 11 A-1 TECHNICAL SPECIFICATIONS – Power Feed 11 COMPLETE UNITS SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO The PF-11 is environmentally rated IP21S per IEC60529 Wire Size Wire Size Speed Solid Cored Speed Solid Cored K1635-1 Power Feed 11 50-625 IPM .025 - 1/16 in. .030 ...
Page 10 - SAFETY PRECAUTION; MOUNTING ON TOP OF THE POWER SOURCE
A-2 INSTALLATION POWER FEED 11 A-2 SAFETY PRECAUTION WIRE FEEDER TO POWER SOURCECONFIGURATIONS The Wire Feeder is equipped to operate in the verticalor horizontal position. It is shipped ready for use in thein the vertical position. MOUNTING ON TOP OF THE POWER SOURCE The Wire Feeder is shipped with...
Page 11 - CABLE CONNECTIONS
A-3 INSTALLATION POWER FEED 11 A-3 CABLE CONNECTIONS CONTROL CABLE CONNECTIONS • All system control cables are the same. • All control cables can be connected end to end to extend their length. • All system equipment must be connected to a con- trol cable. Welding systems using the Power Feed 11 off...
Page 12 - WORK CABLE CONNECTIONS; even if; SELECTING THE PROPER GEAR RATIO; - When operating at wire feed speeds; CHANGING THE WIRE DRIVE RATIO
A-4 INSTALLATION POWER FEED 11 A-4 WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length (perthe following table) between the proper output termi-nal on the power source and the work. Be sure theconnection to the work makes tight metal-to-metalelectrical contact. To avoid interfer...
Page 13 - RATIO CHANGE PROCEDURE:
A-5 INSTALLATION POWER FEED 11 A-5 RATIO CHANGE PROCEDURE: 1) Power down the Power Feed by turning OFF its companion PowerWave power source. For maxi-mum safety, disconnect the control cable from thePower Feed. 2) Pull open the Wire Feeder ’ s Compartment Door. 3) Remove the Feedplate per the follow...
Page 14 - DIP SWITCH SETUP; CC modes override this switch regardless of position.
A-6 INSTALLATION POWER FEED 11 A-6 FIGURE A.3 DIP SWITCH SETUP S E T T I N G D I P S W I T C H E S I N T H ECONTROL BOX There are two DIP switch banks on the mother boardof the Control Box. They are labeled S1 and S2 andare located and oriented as shown in Figure A.3. S1 ON 1 2 3 4 5 6 7 8 S2 ON 1 2...
Page 15 - Switch position must match actual gear box ratio of wire drive.
A-7 INSTALLATION POWER FEED 11 A-7 S E T T I N G D I P S W I T C H E S I N T H E W I R EDRIVE There is one DIP switch bank on the control board ofthe wire drive. It ’ s labeled S1 and is located and ori- ented as shown in Figure A.4. FIGURE A.4 S2 DIP Switch Bank on Control Box Motherboard (For soft...
Page 16 - G U N A DA P T E R; G U N A DA P T E R G U I D E; Guide Tubes for Steel Wire:; ELECTRIC SHOCK can kill.
A-8 INSTALLATION POWER FEED 11 A-8 WIRE FEED DRIVE ROLL KITS ANDFA S T- M AT E ™ G U N A DA P T E R GUIDE TUBES NOTE: T h e m a x i m u m r a t e d s o l i d a n d c o r e d w i r esizes and selected drive ratios are shown on theSPECIFICATIONS in the front of this section. Theelectrode sizes that ca...
Page 17 - GUN AND CABLE ASSEMBLIES; MAGNUM GUNS; General Guidelines
A-9 INSTALLATION POWER FEED 11 A-9 7) Insert inner Wire Guide, groove side out, over the two locating pins in the feed plate. 8) Install each drive roll by pushing over shaft until it butts up against locating shoulder on the drive rollshaft. (Do Not exceed maximum wire size rating ofthe wire drive)...
Page 18 - LIFTING HANDLE; CYLINDER may explode if damaged.
A-10 INSTALLATION POWER FEED 11 A-10 LIFTING HANDLE The Power Feed 11 is shipped with a insulated LiftingHandle which can be mounted on the top or back ofthe Wire Feeder. This handle is intended to be primar-ily used for short term carrying of the Feeder. Whilethis handle is suitable for hanging the...
Page 19 - OPTIONAL FEATURES INSTALLATION; A number of Optional Features are available for; OPTIONAL PANELS FOR CONTROL BOX; Note: The CD panel must be installed in the upper
A-11 INSTALLATION POWER FEED 11 A-11 OPTIONAL FEATURES INSTALLATION A number of Optional Features are available for use with Power Feed 11. Some Installation informa-t i o n i s p r o v i d e d i n t h i s s e c t i o n , R E F E R T O T H EINSTRUCTIONS THAT COME WITH EACH KIT FORDETAILED INFORMATIO...
Page 20 - OPERATION; SAFETY PRECAUTIONS; talk with; on the European and a Lug on the World. See; RECOMMENDED PROCESSES; DUTY CYCLE; CONTROL BOX PANELS - UPPER PANEL
B-1 OPERATION POWER FEED 11 B-1 SAFETY PRECAUTIONS PRODUCT DESCRIPTION The Power Feed 11 is a high performance, digitallyc o n t r o l l e d , m o d u l a r c a b i n e t s t y l e w i r e f e e d e r .Properly equipped, it can support the GMAW, GMAW-P, FCAW, and SMAW processes. The Power Feedwire f...
Page 21 - Control Box Panels - Lower Panels; Setting DIP Switches in
B-2 OPERATION B-2 The user adjusts WFS according to factors such as weldsize, penetration requirements, heat input, etc. The powersource then uses the WFS setting to adjust its output char-acteristics (output voltage, output current) according to pre-programmed settings contained in the power source...
Page 24 - Setting DIP
B-5 OPERATION B-5 CONTROL BOX -- SETTING OPERATING LIMITS Upper and lower operating limits can be set for theWFS/Amps setting and the Volts/Trim setting. Doingso requires knowledge of how to set the limits, andaccess to the PC board in the Control Box. There are two independent sets of limits, Proce...
Page 25 - WIRE DRIVE OPERATION; Europe and World 2 Step Logic:
B-6 OPERATION B-6 WIRE DRIVE OPERATION The most frequently used Wire Drive settings areexternal; some features are accessed by internal set-tings. WIRE DRIVE SETTINGS -- EXTERNAL 2 STEP/4 STEP SWITCH: The Wire Drive has a 2 Step/ 4 Step switch locatednear the gun connector. This switch has no effect...
Page 26 - CAUTION
B-7 OPERATION B-7 WIRE DRIVE -- PC BOARD ADJUSTMENTS ELECTRODE POLARITY: The system needs to be aware of the electrode polari-ty. A DIP switch setting on the Wire Drive PC board isused for this purpose. See INSTALLATION Section “ Setting DIP Switches in the Wire Drive ” . GEAR BOX RATIO: The systems...
Page 27 - DRIVE ROLL PRESSURE SETTING
B-8 OPERATION B-8 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 proper...
Page 28 - MAKING A WELD
B-9 OPERATION B-9 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...
Page 29 - COMPONENT STATUS LIGHTS; ON and steady
B-10 OPERATION B-10 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...
Page 30 - STATUS LIGHT STATES (CON; LED State; System normal and functional.; Normal Blinking LED -; Each illumination should exist for 0.5 seconds.
B-11 OPERATION B-11 POWER FEED 11 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 source has a non-recov...
Page 31 - ACCESSORIES
TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll 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 - 045S* 0.045 ” (1.2 mm) KP1505 - 045S* 0.052 ” (1.4 mm) KP1505 - 052S 1/1...
Page 32 - GENERAL PANEL INSTALLATION GUIDELINES:
C-2 ACCESSORIES C-2 DESCRIPTION OF OPTIONAL CON-TROL BOX PANELS A number of Optional Features are available for usewith Power Feed 11. Some Installation information isprovided in this section, REFER TO THE INSTRUC-TIONS THAT COME WITH EACH KIT FOR DETAILEDINFORMATION REGARDING INSTALLATION. OPTIONAL...
Page 33 - WIRE SPINDLE ADAPTERS; - Adapts Lincoln Readi-Reel coils of electrode; blow; K 1 6 4 9 - 1 M O U N T I N G B R AC K E T-
C-3 ACCESSORIES C-3 WIRE SPINDLE ADAPTERS K435 - Permits 14 lb. (6 kg) Innershield coils to be mounted on 2" (51 mm) O.D. spindles. K363P - Adapts Lincoln Readi-Reel coils of electrode 30 lb. (14 kg) and 22 lb. (10 kg) to a 2" (51 mm) spin-dle. Durable molded plastic one piece construction.D...
Page 34 - Avoiding Wire Feeding Problems; Wire Drive Motor and Gearbox; MAINTENANCE; Safety Precautions; Drive Rolls and Guide Tubes
D-1 MAINTENANCE D-1 POWER FEED 11 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 welding or loading el...
Page 35 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; Step 3. R E C O M M E N D E D C O U R S E O F; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 POWER FEED 11 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 This Troubleshooting ...
Page 36 - PROBLEMS; Contact
E-2 TROUBLESHOOTING E-2 POWER FEED 11 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 technical troubleshootin...
Page 39 - Observe all Safety Guidelines detailed throughout this manual; for technical troubleshooting assistance before you proceed.; a. Defective motor tach or control
E-5 TROUBLESHOOTING E-5 POWER FEED 11 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 technical troubleshootin...
Page 41 - a. The encoders or switches may be
E-7 TROUBLESHOOTING E-7 POWER FEED 11 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 technical troubleshootin...
Page 44 - Display shows any of the following:; Err; Too many objects in group.
E-10 TROUBLESHOOTING E-10 POWER FEED 11 Observe all Safety Guidelines detailed throughout this manual Note: For any Err # listed below write down the error number for reference and try cycling power to see if theerror clears itself. If not, refer to the What to Do column for the given Err. If for an...
Page 45 - See what to Do on Err 006.
E-11 TROUBLESHOOTING E-11 POWER FEED 11 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 Observe all Safety ...
Page 47 - DIAGRAMS
F-1 DIAGRAMS F-1 POWER FEED 11 4 5 6 55 9 51 2A 51 2 558 5 6 4 1 2 51 2 55 7 51 2 55 7 55 8 55 6 55 8 55 6 55 9 6 P1 1 P1 3 1 3 A 3 4 A 12 5 1 6 4 C A V ITY N U M B E R ING SEQ U E N C E (AS V IEW E D F R O M L E AD S IDE OF CO N N EC TO R ) B 2 ST EP/ 4 ST EP 7-2 00 0 512 B 67 A 55 0 542D 500D 540D...
Page 50 - NOTES
Page 51 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P ...
Page 52 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilati...