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
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
iii SAFETY 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 manufacturerʼsrecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ʻ93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contr...
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 .......................................................................................................A-1Safety Precaut...
Page 8 - vii
Page Troubleshooting ..............................................................................................Section E Safety Precautions ...............................................................................................................E-1Troubleshooting Guide .......................
Page 9 - POWER FEED 10 DUAL; INSTALLATION
POWER FEED 10 DUAL A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS – Power Feed 10 Dual Wire Drives & Control Boxes WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO * Also part of K1683-[ ] Boom package and K1686-[ ] Bench Feeder. Δ Dimensions do not include ...
Page 10 - SAFETY PRECAUTIONS; BOOM MOUNTING OF WIRE DRIVE UNIT
A-2 INSTALLATION POWER FEED 10 DUAL A-2 SAFETY PRECAUTIONS MOUNTING THE WIRE DRIVE UNIT BOOM MOUNTING OF WIRE DRIVE UNIT Mount the wire drive unit by means of the 4 holes inthe bottom of the wire drive c a s e . ( S e e F i g u r e A . 1 )The gearbox assembly is electrically “hot” when thegun trigge...
Page 11 - DETERMINING RECEPTACLE CONFIGURATION; CONTROL CABLE; CONTROL CABLE CONNECTIONS
A-3 INSTALLATION POWER FEED 10 DUAL A-3 5. Remove plug button taped to inside of Control Box and insert it into hole on front panel of the WireDrive. MOUNTING THE CONTROL BOX (BOOMOR SEPARATED BENCH MODELS) The back plate of the Control Box has four keyholeslots for mounting. See Figure A.2 for the ...
Page 12 - CONTROL CABLE SPECIFICATIONS
A-4 INSTALLATION POWER FEED 10 DUAL A-4 Typical Bench Feeder Connection: Control cable is connected from the Power Wave 455output receptacle to the input receptacle on the backof the Wire Drive. Typical Boom Feeder Connection: One control cable is connected from the Power Wave455 output receptacle t...
Page 13 - WORK CABLE CONNECTIONS; SELECTING THE PROPER GEAR RATIO; CHANGING THE WIRE DRIVE RATIO; Minimum Copper Work Cable Size, AWG
A-5 INSTALLATION POWER FEED 10 DUAL A-5 Connect the one end of the electrode cable, to thepower source output terminal of the desired polarity.Connect the other end of the electrode cable to theconnection bar at the front of the wire drive feed plateusing the provided bolt and lockwasher. The e l e ...
Page 15 - DIP SWITCH SETUP; CC modes override this switch regardless of position.
FIGURE A.3 A-7 INSTALLATION POWER FEED 10 DUAL A-7 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 O...
Page 16 - Setting Wire Drive Acceleration Rate Using
A-8 INSTALLATION POWER FEED 10 DUAL A-8 MSB - Most Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the left. LSB - Least Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the right. S2 DIP Switch Bank...
Page 18 - WIRE FEED DRIVE ROLL KITS; (including the Magnum 450 Water Cooled gun); ELECTRIC SHOCK can kill.
A-10 INSTALLATION POWER FEED 10 DUAL A-10 WIRE FEED DRIVE ROLL KITS 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 e sizes and selected drive ratios are shown onthe SPECIFICATIONS in the front of this sec-tion. The electrode sizes that can be fed with each roll andguide tube are...
Page 19 - Lincoln Innershield and Sub Arc Guns
A-11 INSTALLATION POWER FEED 10 DUAL A-11 Magnum 200 / 300 / 400 Guns The easiest and least expensive way to use Magnum200/300/400 guns with the Power Feed 10 Dual wirefeeder is to order them with the K466-10 connector kit,or to buy a completely assembled Magnum gun hav-ing the K466-10 connector (su...
Page 20 - GMAW SHIELDING GAS; Gas Guard Regulator -; WIRE SPINDLE PLACEMENT; CYLINDER may explode if damaged.
A-12 INSTALLATION POWER FEED 10 DUAL A-12 The upper location must be used for 50-60 lb. Readi-Reels, Spools and Coils. For smaller coils (44lb, 30lb, 10lb, etc.), the spindlecan be placed in either the upper or lower location.The goal is to make the wire path from the coil to thewire drive an entry ...
Page 21 - OPTIONAL FEATURES INSTALLATION; OPTIONAL PANELS FOR CONTROL BOX; BOOM AND BENCH CONVERSIONS
A-13 INSTALLATION POWER FEED 10 DUAL A-13 OPTIONAL FEATURES INSTALLATION A number of Optional Features are available for usewith Power Feed 10 Dual. 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 I...
Page 22 - OPERATION; RECOMMENDED PROCESSES; DUTY CYCLE; CONTROL BOX PANELS - UPPER PANEL
B-1 OPERATION POWER FEED 10 DUAL B-1 SAFETY PRECAUTIONS PRODUCT DESCRIPTION The Power Feed Wire Feeders are high performance,digitally controlled, modular wire feeders. Properlyequipped, they can support the GMAW, GMAW-P,FCAW, and SMAW processes. The Power Feed wirefeeders are designed to be a part ...
Page 23 - CONTROL BOX PANELS - “SMALL” OPTIONAL PANELS
B-2 OPERATION B-2 The user adjusts WFS according to factors such asweld size, penetration requirements, heat input, etc.The power source then uses the WFS setting to adjustits output characteristics (output voltage, output cur-rent) according to pre-programmed settings containedin the power source. ...
Page 24 - CONTROL BOX PANELS -- ʻLARGEʼ OPTION PANELS
B-3 OPERATION B-3 Memory has an advanced feature called ʻmemoryreminderʼ. When the Save key is hit, the memoryreminder function flashes the LED of the most recentlyused memory, so the operator can save procedures inthe most recently used memory if desired. It is notnecessary to save to the most rece...
Page 26 - Crater
B-5 OPERATION B-5 Crater - Used only when welding with the 4-Step trig- g e r m o d e . C a n b e s e t t o O f f o r O n . W h e n O n ,Adjustments can be made to WFS and Volts/Trim onthe Control/Display panel. These settings are thenused for ʻcrateringʼ when in the 4-Step trigger mode( s e e e x p...
Page 27 - WIRE DRIVE OPERATION; When using 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 located onthe gun side of the Status LED. This switch...
Page 28 - LOWER; 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 nee...
Page 30 - DRIVE ROLL PRESSURE SETTING
B-9 OPERATION B-9 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 31 - MAKING A WELD
B-10 OPERATION B-10 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 32 - COMPONENT STATUS LIGHTS; STATUS LIGHT STATES; ON and steady; LED State; Power Source LED
B-11 OPERATION B-11 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 33 - Normal Blinking LED -
B-12 OPERATION B-12 POWER FEED 10 DUAL STATUS LIGHT STATES (CONʼT) 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-re...
Page 34 - ACCESSORIES
C-1 ACCESSORIES C-1 POWER FEED 10 DUAL 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) KP1505 - 045S ...
Page 41 - Feeder Head Enclosure Procedure
C-8 ACCESSORIES C-8 K 1 5 4 8 - 1 L I N C N E T R E C E P TA C L EKIT (INPUT AND OUTPUT) LINC NET RECEPTACLE (OUTPUT) Optional Output Connector Installation into the ControlBox Cabinet and/or into the Feeder Head Enclosure. Control Box Cabinet Procedure 1. Turn off power. 2. Remove the screws from t...
Page 43 - GUNS AND GUN ADAPTERS; LINCOLN FUME EXTRACTION GUNS
C-10 ACCESSORIES C-10 GUNS AND GUN ADAPTERS The Power Feed 10 Dual wire feeder is equipped witha factory installed K1500-2 gun connection Kit. This kitis for guns having a Tweco™ #2-#4 connector. ThePower Feed 10 Dual has been designed to make con-necting a variety of guns easy and inexpensive witht...
Page 44 - CONDUIT ADAPTERS; K683-3 DUAL PROCEDURE SWITCH
C-11 ACCESSORIES C-11 CONDUIT ADAPTERS K1546-2 ADAPTER for use with Lincoln Magnum conduit and E-Beamconduit (wire sizes 1/16 - .120) For Magnum conduit: Install the K1546-2 gun adapter at the incoming end ofthe feed plate, secure with the set screw located atthe back of the feed plate. If a brass f...
Page 46 - Avoiding Wire Feeding Problems; MAINTENANCE; Safety Precautions
D-1 MAINTENANCE D-1 POWER FEED 10 DUAL 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 loadi...
Page 47 - TROUBLESHOOTING
E-1 TROUBLESHOOTING E-1 POWER FEED 10 DUAL 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 Troubleshoo...
Page 48 - PROBLEMS; Contact
E-2 TROUBLESHOOTING E-2 POWER FEED 10 DUAL 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 troublesh...
Page 51 - Local Lincoln Authorized Field Service Facility
E-5 TROUBLESHOOTING E-5 POWER FEED 10 DUAL 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 troublesh...
Page 56 - Err
E-10 TROUBLESHOOTING E-10 POWER FEED 10 DUAL 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 f...
Page 59 - DIAGRAMS; WIRING DIAGRAM - POWER FEED 10 DUAL FEED HEAD
F-1 DIAGRAMS F-1 POWER FEED 10 DUAL B G3582 WIRING DIAGRAM - POWER FEED 10 DUAL FEED HEAD 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....
Page 60 - CONTR
F-2 DIAGRAMS F-2 POWER FEED 10 DUAL 6.88 .218 4.25 .75 .75 .81 .90 12.07 12.96 18963 3.06 8.50 M 4.08 3.86 (4 KEYHOLE SLOTS) 10-17-97 CONTR OL BO X DIMENSION PRINT
Page 61 - WIRE FEEDER (BENCH MODEL) DIMENSION PRINT
F-3 DIAGRAMS F-3 POWER FEED 10 DUAL 19.89 A A 19. 9 A A 15.41 A A 30.61 A A L11044 7- 21 -2 00 0C WIRE FEEDER (BENCH MODEL) DIMENSION PRINT
Page 62 - WIRE DRIVE DIMENSION PRINT
F-4 DIAGRAMS F-4 POWER FEED 10 DUAL 8. 56 A A 14. 10 A A 15. 55 A A 6. 00 A A D O O R O PEN TY P . 5. 25 A A 19. 43 A A 11. 12 A A 2. 54 TY P. A A 4. 43 A A 2. 25 A A 2. 93 A A 4. 25 TY P . A A WIRE DRIVE DIMENSION PRINT 7-2000 M19304 •
Page 63 - NOTES