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 outdoor...
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; Refer to
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 manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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...
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-1 Safet...
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; CAUTION
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 - COAxIAL WELD CAbLES; WORK; Turn the input power off at the welding power
A-3 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-3 Excessive voltage drops caused by poor workpiece connections often result in unsatisfactorywelding performance. ------------------------------------------------------------------------ COAxIAL WELD CAbLES Coaxial welding cables are specially de...
Page 12 - NEGATIVE ELECTRODE POLARITY
DIP Switch #7 Position ON OFF Polarity (negative) - polarity (positive) + polarity FIGURE A.3 CHANGING ELECTRODE POLARITYSETTING The Power Feed™ 10M Single Wire Feeder is presetat the factory for Electrode Positive welding. (SeeFigure A.3) NOTE: Changing this DIP Switch does not change theactual wel...
Page 13 - Trigger Lead; CAbLES
Wire Feeder Pin Function A ArcLinkB ArcLinkC 67 voltage senseD 40 VDCE Common Power Source Pin Function A ArcLink B ArcLink C 67 voltage sense D 40 VDC E Common Welding Gun/Wire Feeder Trigger Connector Wire Feeder Pin Function A Gun Trigger B - C Common D Dual ProcedureE Common A B C D E Trigger Le...
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. MAGNUM GUN AND CAbLE ASSEMbLIES The Power Feed...
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; DO NOT ATTACH THE REGULATOR
A-13 INSTALLATION POWER FEED™ 10M SINGLE WIRE FEEDER A-13 SHIELDING GAS CONNECTION Maximum inlet pressure is 100 psi. (6.9 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 . I n s p e c t t h e c y l i n ...
Page 23 - OPERATION; SAFETY PRECAUTIONS; NON-SYNERGIC WELDING MODES; welding mode requires all welding; SYNERGIC WELDING MODES; welding mode offers the simplicity of; WFS
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 24 - REQUIRED EQUIPMENT
b-2 OPERATION b-2 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 25 - bENCH MODEL FEATURES; Pulse Welding or STT Welding:
b-3 OPERATION b-3 POWER FEED™ 10M SINGLE WIRE FEEDER bENCH MODEL FEATURES Pulse Welding or STT Welding: CV Welding: bASIC Power Feed™ 10M Single Wire Feeder WELDING SYSTEM CONFIGURATION
Page 26 - Status LED indicates system status.; 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 ParameterKnobs. 3 MSP4 Panel is used to set the weld mode, adjust the arc, change arc start/end parametersand for set-up information. 4 Cold ...
Page 28 - PRIOR TO WELDING; • 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 29 - 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 30 - CHANGING WELD MODES
CHANGING ARC WAVE CONTROL If the selected weld mode uses any of the four availablewave controls, users can press the left MSP4 pushbuttonuntil the ARC CONTROL LED is illuminated. The value,name and units (if applicable) of the available wave con-trols will appear. Note that the name of the control i...
Page 31 - • Pressing the left MSP4 pushbutton will exit the entire
b-9 OPERATION b-9 POWER FEED™ 10M SINGLE WIRE FEEDER LIMIT SETTING The MSP4 can be optionally configured to limit the opera-tor’s range of control of any weld parameter (weld WFS, arcc o n t r o l , e t c . ) . L i m i t s a r e o n l y a v a i l a b l e w i t h t h e D u a lProcedure/Memory Panel. ...
Page 32 - SETUP MENU FEATURES; 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 LE...
Page 33 - This setup menu parameter can be used to exit the setup menu. When
b-11 OPERATION POWER FEED™ 10M SINGLE WIRE FEEDER b-11 USER DEFINED PARAMETERS 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 This option...
Page 34 - USER DEFINED PARAMETERS
b-12 OPERATION b-12 POWER FEED™ 10M SINGLE 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. ...
Page 39 - Parameter
b-17 OPERATION b-17 POWER FEED™ 10M SINGLE 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...
Page 40 - Step Trigger
4. COLD FEED / GAS PURGE SWITCH Cold Feed and Gas Purge are combinedi n t o a t w o p o s i t i o n m o m e n t a r y t o g g l eswitch. To activate Cold Feeding, hold the switchin the UP position. The wire drive will feedelectrode but neither the power source nort h e g a s s o l e n o i d w i l l ...
Page 41 - STEP TRIGGER OPERATION; SEQUENCE OF OPERATION; ately when the gun trigger is pulled.
Run-In 2.5 Run-In 2.5 FIGURE b.4 b-19 OPERATION b-19 2 STEP TRIGGER OPERATION (See Figure B.4)Sometimes it is advantageous to set specific arc start,crater and arc ending parameters for the ideal weld.Many times when welding aluminum crater control isnecessary to make a good weld. This is done by se...
Page 42 - STEP TRIGGER OPERATION; SEQUENCE OF OPERATION
b-20 OPERATION b-20 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 43 - PROCESS SETUP AND OPERATION; Synergic Modes
PROCESS SETUP AND OPERATION The Power Feed/Power Wave system delivers worldclass 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 beadpro...
Page 44 - ARC CONTROL
b-22 OPERATION b-22 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 45 - Wide weld and ripple spacing, slow travel speed.
b-23 OPERATION b-23 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 46 - DESCRIPTION; MACHINE FUNCTIONALITY bY WELD PROCESS; CC STICK MODES
b-24 OPERATION b-24 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 47 - CV NON-SYNERGIC MODES
Material SteelSteelSteel PROCESS GMAW, CV GMAW, POWER MODE FCAW, CV WELD MODE 5 40 6 CV NON-SYNERGIC MODES b-25 OPERATION b-25 POWER FEED™ 10M SINGLE WIRE FEEDER DESCRIPTION Arc Force adjusts the short cir-cuit current for a soft arc, or fora forceful, digging arc. ARC CONTROL 300 25.3 WFS AMPS VOLT...
Page 48 - SYNERGIC CV MODES
b-26 OPERATION b-26 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 50 - START OPTIONS; MA T E R IA L
b-28 OPERATION b-28 POWER FEED™ 10M SINGLE WIRE FEEDER 200 ---- WFS AMPS VOLTS TRIM LESSDEPOSITION MOREDEPOSITION 200 ---- WFS AMPS VOLTS TRIM LESSDEPOSITION MOREDEPOSITION EFFECT / RANGE PEAK CURRENT BACKGROUND CUR-RENT TAIL OUT(STT ll MODES ONLY) DESCRIPTION Peak Current acts similar to an arcpinc...
Page 51 - OFF; TOUCH START TIG
b-29 OPERATION b-29 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 52 - WELD MODE SEARCHING; Recall a memory with memory buttons
b-30 OPERATION b-30 WELD MODE SEARCHING The Weld Mode Search feature allows the selection ofa welding mode based on certain criteria (wire size,process type, etc.). SEARCHING FOR A WELD MODE To search for a mode, turn the control knob until“Weld Mode Search” is displayed. This will appear inbetween ...
Page 53 - There are two procedure memories (A and B) and six; LIMIT SETTING; WELD WFS
b-31 OPERATION b-31 POWER FEED™ 10M SINGLE WIRE FEEDER 6. OPTIONAL DUAL PROCEDURE/MEMORYPANEL OPERATION The Dual Procedure/Memory Panel performs threefunctions: • Weld procedure selection• Memory save and recall• Limits setting There are two procedure memories (A and B) and six user memories (1-6). ...
Page 54 - Enable
b-32 OPERATION b-32 POWER FEED™ 10M SINGLE WIRE FEEDER One of these four items will blink to indicate which itemwill change when the Mode Select Panel Knob is rotated.Initially, the selected item will be the attribute. To selectthe high limit, press either Mode Select Panel button andthe high limit ...
Page 55 - 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 58 - MAINTENANCE; ELECTRIC SHOCK can kill.; 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 59 - 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 60 - PRObLEMS; Contact
E-2 TROUbLESHOOTING E-2 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 - DIAGRAMS
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 diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to ...
Page 67 - DIMENSION PRINT; WIRE FEEDER (bENCH MODEL) DIMENSION PRINT
F-2 DIMENSION PRINT F-2 POWER FEED™ 10M SINGLE WIRE FEEDER 15.80 18.48 30.46 DIMENSION PRINT 12/05 14.56 WIRE FEEDER (bENCH MODEL) DIMENSION PRINT
Page 68 - NOTES