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Lincoln Electric IM849 manual

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Table of contents for the manual

  • Page 1

    • 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 • PO WER FEED ™ 10A CONTROLLER OPERA TOR’S MANUAL IM849 June, 2009 Safety Depends on You Lincoln arc welding a[...]

  • 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

    ii SAFETY ii ARC R A Y S can bur n. 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. Use suitable clothing made from durable flame-resistant material to protect your [...]

  • Page 4

    iii SAFETY iii FOR ELECTRIC ALL Y pow er ed 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. N[...]

  • Page 5

    iv SAFETY iv 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 circuits ?[...]

  • Page 6

    v v T T h h a a n n k k Y Y o o u u 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 fo[...]

  • Page 7

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

  • Page 8

    A-1 GENERAL INFORMA TION POWER FEED™ 10A CONTROLLER A-1 TECHNICAL SPECIFICA TIONS: POWER FEED™ 10A CONTROLLER SPEC.# TYPE 142:1 SPEED RATIO 95:1 SPEED RATIO Wire Size Wire Size POWER FEED™ 10A CONTROLLER Speed Solid Cored Speed Solid Cored with Power Feed 10SF K2362-1 10-200 IPM 7/32 in. 5/32 in. 10-300 ipm 1/8 in. 5/32 in. (0.25 -5.08 m/min.[...]

  • Page 9

    A-2 INST ALLA TION POWER FEED™ 10A CONTROLLER A-2 SAFETY PRECAUTION WELDING VOL T AGE Wire feed parts are electrically live while welding and while inching wire (with Touch Sense feature selection). The elec- trically live parts are listed below: Electrode Electrode Reel Wire Drive Motor Drive Rolls Gear Box Cross-seam Adjuster Wire Straightener [...]

  • Page 10

    A-3 INST ALLA TION POWER FEED™ 10A CONTROLLER A-3 Auxiliary Input Power Connection Instructions: 1. Remove two Phillips Head screws on right side of front panel of hinged door to access terminal strip. 2. Remove a plug button and install a box connector to provide strain relief for the input power leads. 3. Use the appropriate size leads, at leas[...]

  • Page 11

    A-4 INST ALLA TION POWER FEED™ 10A CONTROLLER A-4 4. Replace the Switch Panel on the POWER FEED™ 10A CONTROLLER with the blank panel inclu ded with the pendant box. 5. Connect the Switch Panel to the mating 10-pin con- nector inside the pendant box. 6. Fasten the Switch Panel to the pendant box. 7. Connect the 14-pin/9-pin pendant cable to the [...]

  • Page 12

    A-5 INST ALLA TION POWER FEED™ 10A CONTROLLER A-5 INCH DOWN # 47 SWITCH GROUP #2 SUPPLY #43 TRAVEL AUTO #44 TRAVEL ON #45 INCH UP #42 SWITCH GROUP #1 SUPPLY #39 START #40 STOP #41 FLUX FILL #46 N OTE: TRAVEL AUTO and TRAVEL ON should not be closed at the same time. Either one OR the other should b e closed at any time, and must remain closed to k[...]

  • Page 13

    A-6 INST ALLA TION POWER FEED™ 10A CONTROLLER A-6 8. Connect input supply voltage per the Auxiliary Input Power Connection Instructions listed earlier. 9. The relays could also be used to provide contact closure for any interfacing signals out using the nor- mally open conta cts. An e xternal auxiliar y suppl y voltage would not be necessary to u[...]

  • Page 14

    A-7 INST ALLA TION POWER FEED™ 10A CONTROLLER A-7 P OW ER WA VE AC /D C 1 00 0 K 2344-1 K 154 3-XX ARC LI NK CON TROL CA BL E WORK P IE CE ELECTR ODE SEN SE LEAD K1785- x x 1 4 — 14 P IN FEEDER C AB LE ARC ARC 1 C ONT ROL CONTROL P OW ER FE ED 10A CONTROLLER CON T ROL BOX K 2362-1 P OW ER FE E D 10S F WI RE D RI VE K2 312-1 W ORK W ORK S ENS E [...]

  • Page 15

    A-8 INST ALLA TION POWER FEED™ 10A CONTROLLER A-8 REMOTE SENSE LEAD SPECIFICA TIONS Welding with Multiple Arcs Special care must be taken when more than one arc is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. Do n[...]

  • Page 16

    B-1 OPERA TION B-1 POWER FEED™ 10A CONTROLLER SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. •[...]

  • Page 17

    B-2 OPERA TION B-2 POWER FEED™ 10A CONTROLLER PRODUCT DESCRIPTION General Physical Description The POWER FEED™ 10A CONTROLLER is a user interface. The control is used to set all welding para- meters and control any travel mechanisms. High- speed digital cables connect the control, wire drive, and the Power Wave power source together. The POWER [...]

  • Page 18

    B-3 OPERA TION B-3 POWER FEED™ 10A CONTROLLER LOCA TING FRONT P ANEL CONTROLS AND INPUT , OUPUT CONNECTIONS 5-PIN INPUT RECEPT ACLE 4-PIN TRA VEL RECEPT ACLE 14-PIN RECEPT ACLE 3-PIN FLUX RECEPT ACLE CONTROL BOX WITHOUT DOOR CONTROL BOX WITH DOOR[...]

  • Page 19

    B-4 OPERA TION B-4 CASE FRONT CONTROL DESCRIPTIONS 1. DUAL DIGITAL DISPLAYS – Bright 7-segment dis- plays showing welding parameter settings and actu- al levels while welding. 2. ARC ESTABLISH INDICATOR – Illuminates when a "true" arc has been established. (Flashes when open circuit voltage is applied. Not availiable on all units, upg[...]

  • Page 20

    B-5 OPERA TION B-5 Blinking green O c c u r s d u r i n g a r e s e t a n d i n d i - cates the power source is identify- ing each component in the system. This is normal for the first 10 sec- onds after power-up, or if the sys- tem confi guration is change d dur- ing operation. Alternating green N on - r e c ov e r a b le s ys t e m f a u l t. I f[...]

  • Page 21

    B-6 OPERA TION B-6 WELD MODE DESCRIPTION 1. Allows wireless machine configuration using a Palm OS based hand-held computer. 2. Consists of easy to read 36 segment alphanumeric LED display. 2 Thru 5 Allows for machine set-up/user preferences grouped into secure and non-secure categories. 6.- 7. Provides easy access to the multip le weld pro- grams i[...]

  • Page 22

    B-7 OPERA TION B-7 AC CONTROL Pressing the Left Mode Select Panel Pushbutton while in WELD MODE will illuminate the AC CONTROL LED (if AC parameters are available). Repeated pressing of the Left Mode Select Panel Pushbutton will scroll through the available parameters. The Mode Select Panel 7-segment display will show the current setting for the pa[...]

  • Page 23

    B-8 OPERA TION B-8 END OPTIONS Pressing the Right Mode Select Panel Pushbutton after scrolling through the Start Options will illuminate the END OPTIONS LED. Repeated pressing of the Right Mode Select Panel Pushbutton will toggle through the parameters. Turning the Mode Select Panel Knob while on a parameter will change its value. When the Crater T[...]

  • Page 24

    B-9 OPERA TION B-9 PARAMETER Arc Delay Time Strike Fault Time Strike WFS Strike Volts Restrike Time Start WFS/Amps Start Volts Start Time Start Arc Force Upslope Time Weld WFS/Amps Weld Volts Weld Arc Force Frequency (AC) Balance (AC) Offset (AC) Arc 2 Phase (if applicable) Arc 2 Balance (if applicable) Arc 3 Phase (if applicable) Arc 3 Balance (if[...]

  • Page 25

    B-10 OPERA TION B-10 GENERAL SETUP MODE OPTIONS The Setup Mode can be used to set more general welding configurations such as travel options or dis- play configurations and can be used to access diag- nostic tools. The POWER FEED™ 10A CONTROLLER can be configured to display the wire feed speed in inches per minute or meters per minute, andor dis[...]

  • Page 26

    B-11 OPERA TION B-11 INFRARED (IR) CONTROL The Mode Select Panel interface includes an infrared tran sceive r. Th is al lows wirel ess m achine conf igura- tion using a Palm OS based handheld computer. A proprietary Palm OS application, ALPalm, has been developed for this purpose. LOCKOUT/SECURITY The Power Feed 10A can be optionally configured to [...]

  • Page 27

    B-12 OPERA TION B-12 This panel performs these functions: limit setting and memory saving/restoring. There are six user memo- ries. PROCEDURE MEMOR Y VS. USER MEMOR Y Procedure memory is used while welding. Changes to the Power Feed 10A controls immediately change the contents of the selected procedure’s memory, such as Wire Feed Speed or Volts. [...]

  • Page 28

    B-13 OPERA TION B-13 LIMIT SETTING Each user memory can be optionally configured to limit the 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 and perform a memory save. Next, press and hold the mem- ory button for five seconds. Re[...]

  • Page 29

    C-1 ACCESSORIES C-1 GENERAL OPTIONS / ACCESSORIES K2311-1 Power Feed 10SM -Converts NA style wire drives into Power Feed-10S Wire Drives K2370-1 Power Feed 10S Wire Drive -Power Feed- 10S with hardwar e to connect to a TC-3 Travel Carriage. K2282-1 System Interface -Includes phase generator for multiple arcs. K1543-xx ArcLink Cables -ArcLink cable [...]

  • Page 30

    D-1 MAINTENANCE D-1 ROUTINE MAINTENANCE • Check weld cables, control cables and gas hoses for cuts. • Clean and tighten all weld terminals. • Inspect and clean drive rolls and inner wire guide and replace if worn. PERIODIC MAINTENANCE • Blow out or vacuum the inside of the feeder. • Every six months check the motor brushes. Replace them i[...]

  • Page 31

    E-1 TROUBLESHOOTING E-1 POWER FEED™ 10A CONTROLLER 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 locat[...]

  • Page 32

    E-2 TROUBLESHOOTING E-2 POWER FEED™ 10A CONTROLLER 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 Guidelines detailed throughout this m[...]

  • Page 33

    E-3 TROUBLESHOOTING E-3 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 Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POS[...]

  • Page 34

    E-4 TROUBLESHOOTING E-4 POWER FEED™ 10A CONTROLLER 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 Guidelines detailed throughout this m[...]

  • Page 35

    E-5 TROUBLESHOOTING E-5 POWER FEED™ 10A CONTROLLER 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. CA[...]

  • Page 36

    E-6 TROUBLESHOOTING E-6 POWER FEED™ 10A CONTROLLER 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. CA[...]

  • Page 37

    F-1 DIAGRAMS F-1 POWER FEED™ 10A CONTROLLER POW ER FEED 10A CONTROLLER J34 1 2 3 4 5 6 7 8 9 10 FLEX FLEX SWITCH GROUP #2 SUPPLY 3-PIN FL UX RECE PTA CLE A B C D E A B C J33 REMOTE P .C. BOARD J331 856 5-PIN INPU T REC EPT ACLE 858 851A 854A PURGE/FLUX 0 859 TRAVEL RELA Y #2 INCH UP 2 1 3 4 2 1 6 3 4 5 J83 2 1 3 4 2 1 6 3 4 5 J84 8 7 J85 7 2 1 3 [...]

  • Page 38

    F-2 DIMENSION PRINT F-2 POWER FEED™ 10A CONTROLLER W ARN ING M 20 41 4 A 14.121 .95 358.6 24.1 4.99 126.7 11.68 296.5 12.25 311.2 13.25 336.6[...]

  • Page 39

    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 MANUFACTURER ’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 P ARA EL [...]

  • Page 40

    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 P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out o f fumes . ● Use ventil atio n or e xhaust to remo ve fum[...]

  • Page 41

    • 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 •[...]