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Lincoln Electric 4R220 manual

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Table of contents for the manual

  • Page 1

    OPERA TOR’S MANUAL • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • Copyright © Lincoln Global Inc. AutoDrive ™ 4R220 IM945 May, 2009 For use with machines [...]

  • Page 2

    FOR ENGINE powered 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

    ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Us e suitable clothing made from durable flame-resistant material to protect your skin and that of[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the 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 accordance with the U.S. National Electrical C[...]

  • Page 5

    iv SAFETY iv Mar. ‘93 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 L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

  • Page 6

    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 and keep it handy for quick reference. Pay[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation ..................................................................[...]

  • Page 8

    A-1 INST ALLA TION A-1 AutoDrive™ 4R220 TEMPERA TURE RANGE OPERATION: -40°F to 104°F (-40°C to 40°C) STORAGE: -40°F to 185°F (-40°C to 85°C) INPUT VOL T AGE, CURRENT TECHNICAL SPECIFICA TIONS – AutoDrive™ 4R220 (K2685-1) HEIGHT WIDTH LENGTH WEIGHT 10.43 Inches 10.07 Inches 9.92 Inches 20.9 lbs. (265 mm) (256 mm) (252 mm) (9.5 kg.) PHY[...]

  • Page 9

    LOCA TION Firmly secure the AutoDrive™ 4R220 wire feeder to a robot arm or fixture. See L15169 iB and L15169-1 iC Mechanical Installation Instructions which are supplied with this Instruction Manual in the literature package. Mount only in a dry environment. ** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Ap[...]

  • Page 10

    A-3 INST ALLA TION AutoDrive™ 4R220 A-3 COAXIAL WELD CABLE Coaxial welding cables are specially designed welding cables for STT™ and pulse welding. Coaxial weld cables feature low inductance, allowing fast changes in the weld current. Regular cables have a higher inductance which may distort the STT™ waveshape. Inductance becomes more severe [...]

  • Page 11

    A-4 INST ALLA TION AutoDrive™ 4R220 A-4 A B K H N L C D M G F E J I POWER SOURCE WIRE FEEDER A B K H N L C D M G F E J I Function Motor Power Motor Power Gas Solenoid Gas Solenoid Reserved Reserved “2A” Differential Tachometer “2B” Differential Tachometer Reserved Reserved “1A” Differential Tachometer “1B” Differential Tachometer [...]

  • Page 12

    A-5 INST ALLA TION AutoDrive™ 4R220 A-5 SHIELDING GAS CONNECTION CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or oth[...]

  • Page 13

    A-6 INST ALLA TION AutoDrive™ 4R220 A-6 PROCEDURE TO INST ALL DRIVE ROLLS AND WIRE GUIDES ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- ing power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are [...]

  • Page 14

    A-7 INST ALLA TION AutoDrive™ 4R220 A-7 CONDUIT INST ALLA TION The K1546-xx series of conduits are compatible with K515-xx, K565-xx, Wire Wizard and Electron Beam Technologies conduits. To install conduit to the wire drive: 1. Slide the conduit bushing into the feed plate and secure with the set screw. 2 . Slide the conduit into the bushing and l[...]

  • Page 15

    A-8 INST ALLA TION AutoDrive™ 4R220 A-8 SYSTEM SET -UP ArcLink XT Connection ArcLink (5 Pin) Wor k Sense Wire Feeder (14 Pin) Robotic Torch Power Wave i400 K2669-1 Wor k Pie ce FANUC R-J 30iA Controller with Integrated Op Box Opt iona l Wo rk Sense Le ad (21) K1785- XX W ire Feeder K884-5,-6 Control Cable * Work Cable (-) Internal ArcLi nk X T Co[...]

  • Page 16

    B-1 OPERA TION AutoDrive™ 4R220 B-1 • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri- cally energized and could remain energized several sec- onds after the welding ceases.. • Do not touch electrically live part or electrode with skin or wet clot[...]

  • Page 17

    B-2 OPERA TION B-2 AutoDrive™ 4R220 DEFINITION OF WELDING TERMS GMAW • Gas Metal Arc welding FCAW • Flux Core Arc Welding STT™ • Surface Tension Transfer PRODUCT DESCRIPTION General Physical Description The AutoDrive™ 4R220 wire feeders are powerful yet compact wire drives for robotic and hard automation applications. The MAXTRAC 4 roll[...]

  • Page 18

    C-1 ACCESSORIES C-1 AutoDrive™ 4R220 WIRE TYPE Steel Wires: Cored Wires: Aluminum Wires: KITS ELECTRODE SIZE KP1505-030S .023-.030 (0.6-0.8mm) KP1505-035S .035 (0.9mm) KP1505-040S .040 (1.0mm) KP1505-045S .045 (1.2mm) KP1505-035C .030-.035" (0.8-0.9mm) KP1505-045C .040-.045" (1.0-1.2mm) KP1507-3/64A 3/64" (1.2mm) OPTIONAL KITS AND [...]

  • Page 19

    C-2 ACCESSORIES C-2 AutoDrive™ 4R220 K1500-4 K1500-5 K489-7 K515-xx K565-xx K1546-1 Gun Receiver Bushing (for gun with K466-3 Lincoln gun connec- tors; compatible with Miller® guns.) Gun Receiver Bushing (compatible with Oxo® guns.) Gun Receiver Bushing (for Lincoln Fast-Mate guns.) Wire Conduit Wire Conduit Incoming Bushing, for Lincoln Condui[...]

  • Page 20

    C-3 ACCESSORIES C-3 AutoDrive™ 4R220 K2175-1 K2175-2 K895-2 K836-1 K884-5 K884-6 K1796-xx K2593-xx K1785-xx K2709-xx K1733-1 500 lb Accu-Pak Box Payoff Kit 1000 lb Accu-Pak Box Payoff Kit Rotary Wire Dispenser Dereeler Adapter Accu-Trak Drum Payoff Kit – 20 inch diameter Accu-Trak Drum Payoff Kit – 23 inch diameter Coaxial Cables Coaxial Cabl[...]

  • Page 21

    D-1 MAINTENANCE D-1 AutoDrive™ 4R220 ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain ene[...]

  • Page 22

    E-1 TROUBLESHOOTING E-1 AutoDrive™ 4R220 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 Guide is provided to help you locate and repa[...]

  • Page 23

    E-2 TROUBLESHOOTING E-2 AutoDrive™ 4R220 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 troubleshooting assistance before you proceed. CAUTION PROB[...]

  • Page 24

    E-3 TROUBLESHOOTING E-3 AutoDrive™ 4R220 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 troubleshooting assistance before you proceed. CAUTION PROB[...]

  • Page 25

    F-1 DIAGRAMS F-1 AutoDrive™ 4R220 B M 215 62 552A TACH I NTERF ACE PC BD WIR ING DIA GR AM A UTOD RIV E 4R 220 FE ED ER FEED PLATE P1 8 MOTOR / GEARBOX W TAC H 531 B B W BR 537 534 551 A 550A 7 6 5 4 3 2 1 L2 L1 A J2 B C D E F G H I J K L M N P3 8 7 6 5 4 3 2 1 551 550A 552A 553 A 500A 515 A 842 A 843A 551A GAS SOL ENOID 553A ELECTRICAL SYMBOLS P[...]

  • Page 26

    F-2 DIMENSION PRINT F-2 AutoDrive™ 4R220 L15157 A.0 1 4.09 1.97 2.76 1.97 1.49 10.22 1.24 2.04 4.72 10.43 9.40 10.07 9.92[...]

  • Page 27

    NOTES AutoDrive™ 4R220[...]

  • Page 28

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL U[...]

  • Page 29

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro[...]

  • Page 30

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]