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Lincoln Electric POWER FEED 10M SINGLE/DUAL SVM172-A manual

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Table of contents for the manual

  • Page 1

    PO WER FEED 10M SINGLE/DU AL SVM172-A January , 2007 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation ... and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS [...]

  • Page 2

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, [...]

  • Page 3

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 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 st[...]

  • Page 4

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C FOR ELECTRICALL Y powered equipment. 8.a. T urn of f 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[...]

  • Page 5

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 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:[...]

  • Page 6

    POWER FEED 10M SINGLE/DUAL MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation PF-10M Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Installation PF-10M[...]

  • Page 7

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section A-1 Section A-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ..............................................................................................................Section A T echnic[...]

  • Page 8

    POWER FEED 10M SINGLE/DUAL Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C A-2 INST ALLA TION A-2 TECHNICAL SPECIFICA TIONS : Power Feed 10M Single Wire Feeder W IRE [...]

  • Page 9

    A-3 A-3 POWER FEED 10M SINGLE/DUAL Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C INST ALLA TION SAFETY PRECAUTION LOCA TION • The Power Feed 10M Single Wire Feede[...]

  • Page 10

    INST ALLA TION POWER FEED 10M SINGLE/DUAL A-4 A-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C SAFETY PRECAUTION ELECTRIC SHOCK can kill. • Only qualified person[...]

  • Page 11

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A -5 A-5 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C E lec tr ode Wo r k Wo r k Power Source Work Electrode Wire Feeder [...]

  • Page 12

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-6 A-6 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C W elding Gun/W ire Feeder T rigger Connector Wire Feeder Pin Functio[...]

  • Page 13

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-7 A-7 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C CHANGING DRIVE ROLLS AND WIRE GUIDES FIGURE A.4 ITEM DESCRIPTION 1 I[...]

  • Page 14

    POWER FEED 10M SINGLE/DUAL NOTES A-8 A-8 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C T o change the gun bushing: 1. T urn off power at the welding power source. 2[...]

  • Page 15

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-9 A-9 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELDING GUNS, T ORCHES AND A CCES- SORIES GUN RECEIVER BUSHING The P ower F eed 10M Single Wire Feeder comes with a K1500-2 gun [...]

  • Page 16

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-10 A-10 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C WIRE FEED SHUT DOWN CIRCUIT The wire feed shut down circuit is use[...]

  • Page 17

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-11 A-11 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C WIRE REEL LOADING S pindle Placement The wire reel stand provides [...]

  • Page 18

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-12 A-12 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C U sing K1504-1 Coil Reel 50-60 lb. (22.7 - 27.2 kg) Coil Mounting [...]

  • Page 19

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-13 A-13 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C Loading 30 lb. (13.6 kg) Readi-Reels ( See Figure A.1 1 ) A K363-P[...]

  • Page 20

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-14 A-14 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C SHIELDING GAS CONNECTION NOTE: Gas supply pressure must be regulat[...]

  • Page 21

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-15 A-15 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C R obotic/Semi-Automatic System • Use the bench feeder for offlin[...]

  • Page 22

    POWER FEED 10M SINGLE/DUAL INST ALLA TION A-16 A-16 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C CONTROL BOX ROLL BAR REEL ST AND AND BASE ASSEMBL Y WIRE DRIVE SPI[...]

  • Page 23

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section B-1 Section B-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ................................................................................................................Section B Safety Precau[...]

  • Page 24

    SAFETY PRECAUTIONS Read this entire section of operating instructions b efore 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. • Do not use AC welder if your cloth- ing, glove[...]

  • Page 25

    POWER FEED 10M SINGLE/DUAL OPERA TION B-3 B-3 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C DEFINITIONS OF WELDING MODES N ON-SYNERGIC WELDING MODES • A Non-syner[...]

  • Page 26

    OPERA TION POWER FEED 10M SINGLE/DUAL B-4 B-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C PROCESS LIMIT A TIONS The Power Feed 10M Single Wire Feeder is not suit-[...]

  • Page 27

    Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C OPERA TION B-5 B-5 POWER FEED 10M SINGLE/DUAL ITEM DESCRIPTION 1 Status LED indicates system status. 2 Digital Meter D[...]

  • Page 28

    POWER FEED 10M SINGLE/DUAL OPERA TION B-6 B-6 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 1. ST A TUS LED T he status LED indicates system status. Normal oper- at[...]

  • Page 29

    POWER FEED 10M SINGLE/DUAL OPERA TION B-7 B-7 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C AFTER WELDING Weld Process V olt/T rim Display All Processes After weldi[...]

  • Page 30

    POWER FEED 10M SINGLE/DUAL OPERA TION B-8 B-8 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C • Limit setting for restricting the operators range of control. • Lo[...]

  • Page 31

    POWER FEED 10M SINGLE/DUAL OPERA TION B-9 B-9 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C CHANGING ARC W A VE CONTROL If the selected weld mode uses any of the fo[...]

  • Page 32

    POWER FEED 10M SINGLE/DUAL OPERA TION B-10 B-10 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C SETUP FEA TURES MENU The Setup Menu gives access to the set-up configu[...]

  • Page 33

    POWER FEED 10M SINGLE/DUAL OPERA TION B-11 B-11 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C the machine will always operate in 2-step if a weld is made exclusivel[...]

  • Page 34

    POWER FEED 10M SINGLE/DUAL NOTES B-12 B-12 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C P .8 TIG Gas Control (T wo Settings) 1. "V alve (manual)" , the i[...]

  • Page 35

    POWER FEED 10M SINGLE/DUAL OPERA TION B-13 B-13 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 4. COLD FEED / GAS PURGE SWITCH Cold Feed and Gas Purge are combined i[...]

  • Page 36

    POWER FEED 10M SINGLE/DUAL OPERA TION B-14 B-14 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Head / Pr ocedu re Sel e c t • Pr es s to se le ct head or change ac ti ve procedu re . • Ch an ges to we ld settings affe c [...]

  • Page 37

    POWER FEED 10M SINGLE/DUAL OPERA TION B-15 B-15 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 4 STEP TRIGGER OPERA TION ( See Figure B.5 ) The 4 step trigger sequen[...]

  • Page 38

    POWER FEED 10M SINGLE/DUAL OPERA TION B-16 B-16 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C PROCESS SETUP AND OPERA TION The Power Feed/Power W ave system deliver[...]

  • Page 39

    POWER FEED 10M SINGLE/DUAL OPERA TION B-17 B-17 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C STEEL AND ST AINLESS SYNERGIC GMA W-P (PULSED MIG) WELDING Synergic GM[...]

  • Page 40

    POWER FEED 10M SINGLE/DUAL OPERA TION B-18 B-18 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C ALUMINUM SYNERGIC GMA W-P (PULSED MIG)AND GMA W-PP (PULSE ON PULSE) WE[...]

  • Page 41

    POWER FEED 10M SINGLE/DUAL OPERA TION B-19 B-19 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C ARC FORCE (Soft)-10.0 to (Crisp)+10.0 DESCRIPTION Arc Force adjusts th[...]

  • Page 42

    POWER FEED 10M SINGLE/DUAL OPERA TION B-20 B-20 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C EFFECT / RANGE Postflow T ime 0 to 10 seconds Crater Procedure (0 T O [...]

  • Page 43

    POWER FEED 10M SINGLE/DUAL OPERA TION B-21 B-21 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C MACHINE FUNCTIONALITY BY WELD PROCESS G MA W (SYNERGIC) Use the follow[...]

  • Page 44

    POWER FEED 10M SINGLE/DUAL OPERA TION B-22 B-22 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C ARC CONTROL PULSE FREQUENCY : (Low)-10.0 to (High)+10.0 DESCRIPTION Fo[...]

  • Page 45

    POWER FEED 10M SINGLE/DUAL OPERA TION B-23 B-23 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 200 ---- WFS AMPS V OL TS TRIM LESS D EPOSITION MORE D EPOSITION EFFEC[...]

  • Page 46

    POWER FEED 10M SINGLE/DUAL OPERA TION B-24 B-24 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C MACHINE FUNCTIONALITY BY WELD PROCESS G T A W (T ouch Start TIG) Weldi[...]

  • Page 47

    POWER FEED 10M SINGLE/DUAL OPERA TION B-25 B-25 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C USER MEMORIES Recall a memory with memory buttons T o recall a user a [...]

  • Page 48

    POWER FEED 10M SINGLE/DUAL OPERA TION B-26 B-26 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C LIMIT SETTING E ach user memory can be optionally configured to limit [...]

  • Page 49

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section C-1 Section C-1 T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ............................................................................................................Section C General Option[...]

  • Page 50

    POWER FEED 10M SINGLE/DUAL ACCESSORIES C-2 C-2 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C OPTIONAL: K2339-1 K2429-1 K2360-1 K1543-xx K1796-xx K1842-xx K1500-1 K1[...]

  • Page 51

    POWER FEED 10M SINGLE/DUAL ACCESSORIES C-3 C-3 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C K 1500-4 K1500-5 K489-7 K466-2 K613-7 K1546-1 K1546-2 K1733-1 K870-1 K9[...]

  • Page 52

    POWER FEED 10M SINGLE/DUAL ACCESSORIES C-4 C-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C K162-1 K435 K468 K363P K438 K1504-1 K1634-1 K1634-2 K590-6 Spindle Adap[...]

  • Page 53

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section D-1 Section D-1 T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ...........................................................................................................Section D Routine Mainten[...]

  • Page 54

    D-2 D-2 POWER FEED 10M SINGLE/DUAL Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C MAINTENANCE SAFETY PRECAUTIONS W ARNING Observe all additional Safety Guidelines de[...]

  • Page 55

    POWER FEED 10M SINGLE/DUAL MAINTENANCE D-3 D-3 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 1. CONTROL BOX ASSEMBL Y 2. WIRE DRIVE ASSEMBL Y 3. MOTOR ASSEMBL Y 4. [...]

  • Page 56

    POWER FEED 10M SINGLE/DUAL NOTES D-4 D-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C[...]

  • Page 57

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section AA-1 Section AA-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ............................................................................................................Section AA T echni[...]

  • Page 58

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-2 AA-2 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TECHNICAL SPECIFICA TIONS – Power Feed 10M Dual Wire Feeder WIRE[...]

  • Page 59

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-3 AA-3 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C SAFETY PRECAUTION ELECTRODE ROUTING The electrode supply may be ei[...]

  • Page 60

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-4 AA-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C NEGA TIVE ELECTRODE POLARITY When negative electrode polarity is r[...]

  • Page 61

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-5 AA-5 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C VOL T AGE SENSING The best arc performance occurs when the P owerW[...]

  • Page 62

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-6 AA-6 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C WIRE DRIVE GEAR RA TIO (HIGH OR LOW SPEED) The speed range capabil[...]

  • Page 63

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-7 AA-7 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C GEAR RA TIO RECOGNITION: 1. Remove the rear access door from the w[...]

  • Page 64

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-8 AA-8 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C PROCEDURE T O INST ALL DRIVE ROLLS AND WIRE GUIDES Drive Roll Kit [...]

  • Page 65

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-9 AA-9 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C Magnum 550 Guns The easiest and least expensive way to use the Mag[...]

  • Page 66

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-10 AA-10 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C Flow Sensor Kit installation is as follows: 1. Remove rear acces[...]

  • Page 67

    POWER FEED 10M SINGLE/DUAL INST ALLA TION AA-11 AA-11 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C S hown with • K2230-1 Power Feed 10M Single Wire Feeder • K1[...]

  • Page 68

    POWER FEED 10M SINGLE/DUAL NOTES AA-12 AA-12 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C[...]

  • Page 69

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section BB-1 Section BB-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ..............................................................................................................Section BB Safety Preca[...]

  • Page 70

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-2 BB-2 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C COMMON WELDING ABBREVIA TIONS W FS • Wire Feed Speed CC • C onstan[...]

  • Page 71

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-3 BB-3 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C PRODUCT DESCRIPTION The Power Feed 10M Dual Wire Feeder unit consists [...]

  • Page 72

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-4 BB-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C FIGURE BB.1 OPERA TIONAL FEA TURES AND CONTROLS POWER FEED-10M SERIES [...]

  • Page 73

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-5 BB-5 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 3. OUTPUT CONTROLS • The Power Feed 10M Dual Wire Feeder has 2 e nco[...]

  • Page 74

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-6 BB-6 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C LA YOUT -CONTROLS ( SEE FIGURE B.3 ) The MSP4 panel controls (Items 7 [...]

  • Page 75

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-7 BB-7 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C CHANGING ARC W A VE CONTROL If the selected weld mode uses any of the [...]

  • Page 76

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-8 BB-8 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C LIMIT SETTING The MSP4 can be optionally configured to limit the opera[...]

  • Page 77

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-9 BB-9 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C P .0 Press the right button to exit the setup menu. P .1 WFS units M e[...]

  • Page 78

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-10 BB-10 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C P .8 TIG Gas Control (T wo Settings) 1. "V alve (manual)" [...]

  • Page 79

    POWER FEED 10M SINGLE/DUAL OPERA TION P .99 Show T est Modes Many weld tables include special modes for testing a nd servicing the welding system. Set this parameter to YES to show all test modes. When the power source is turned off, the Show T est Modes parameter automatically reverts back to "NO". P .100 V iew Diagnostics D iagnostics a[...]

  • Page 80

    FIGURE BB.3 POWER FEED 10M SINGLE/DUAL OPERA TION BB-12 BB-12 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C[...]

  • Page 81

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-13 BB-13 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C E ach procedure contains/stores the following information: • Basic[...]

  • Page 82

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-14 BB-14 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C Recalling from Memory T o recall the contents of a memory into the a[...]

  • Page 83

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-15 BB-15 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 4 Step Synergic Operation: Without Start/Crater/Burnback functions a[...]

  • Page 84

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-16 BB-16 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C WIRE REEL LOADING - READI-REELS, SPOOLS OR COILS T o Mount a 30 Lb. [...]

  • Page 85

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-17 BB-17 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C FIGURE BB.4 T o Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 [...]

  • Page 86

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-18 BB-18 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C FEEDING ELECTRODE AND BRAKE ADJUSTMENT 1) Turn the Reel or spool unt[...]

  • Page 87

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-19 BB-19 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C MAKING A WELD 1) Use only a network compatible power source. 2) Prop[...]

  • Page 88

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-20 BB-20 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C COMPONENT ST A TUS LIGHTS Each network component has a single status[...]

  • Page 89

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-21 BB-21 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C ST A TUS LIGHT ST A TES (CON’T) LED State Red LED blinking at a fa[...]

  • Page 90

    POWER FEED 10M SINGLE/DUAL OPERA TION BB-22 BB-22 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C LIMIT SETTING E ach user memory can be optionally configured to limi[...]

  • Page 91

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section CC-1 Section CC-1 T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories .........................................................................................................Section CC Drive Roll and[...]

  • Page 92

    POWER FEED 10M SINGLE/DUAL ACCESSORIES CC-2 CC-2 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C T ABLE CC.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll DH Dr[...]

  • Page 93

    POWER FEED 10M SINGLE/DUAL ACCESSORIES CC-3 CC-3 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C • Readi-Reel Adapters - Adapts 22-30 lb. Readi-Reels to a 2" S[...]

  • Page 94

    POWER FEED 10M SINGLE/DUAL ACCESSORIES CC-4 CC-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C K435 - COIL ADAPTER P ermits 14 lb. (6 kg) Innershield coils to be mo[...]

  • Page 95

    POWER FEED 10M SINGLE/DUAL ACCESSORIES CC-5 CC-5 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C K1500-4 (MILLER CONNECTION) For any gun having a newer style Miller c[...]

  • Page 96

    POWER FEED 10M SINGLE/DUAL ACCESSORIES CC-6 CC-6 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C K1733-1 WIRE STRAIGHTENER Install per the Instructions shipped with t[...]

  • Page 97

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section DD-1 Section DD-1 T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ........................................................................................................Section DD Safety Precauti[...]

  • Page 98

    POWER FEED 10M SINGLE/DUAL MAINTENANCE DD-2 DD-2 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C MAINTENANCE Safety Precautions A voiding Wire Feeding Problems Wire f[...]

  • Page 99

    POWER FEED 10M SINGLE/DUAL MAINTENANCE DD-3 DD-3 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C 1. CONTROL BOX ASSEMBL Y 2. WIRE DRIVE ASSEMBL Y 3. MOTORS ASSEMBL Y [...]

  • Page 100

    POWER FEED 10M SINGLE/DUAL NOTES DD-4 DD-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C[...]

  • Page 101

    FIGURE E.2 – GENERAL DESCRIPTION CONTROL BO ARD SHUTD OW N TO P O WER SOURCE OR CONTROL BO X IN PUT NETW ORK RECE PT A CL NETW ORK CONNEC T OR COLD INCH/ G AS P URGE G AS SOLENOID NETW ORK OUT PUT RECE PT A CL 2-S TEP/ 4-S TEP G UN TRIGGER AND DU AL PROCEDURE RECE PT A CLE S T A TUS LED FEED BA C K T AC H GEAR B OX AND CONDUC T OR BL OCK DRIVE M [...]

  • Page 102

    POWER FEED 10M SINGLE/DUAL THEOR Y OF OPERA TION POWER FEED 10M FEED HEAD The Power Feed 10M is a four roll, high performance, digitally controlled, modular wir e feeder that operates on 40 VDC input power . It is designed to be a part of a modular , multi-process welding system. Refer to Figur e E.2. Network communications, intelligence, PC board [...]

  • Page 103

    POWER FEED 10M SINGLE/DUAL .THEOR Y OF OPERA TION E-3 E-3 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C FIGURE E.3 – CONTROL BOX (User Interface) DISPLA Y AND ENC[...]

  • Page 104

    POWER FEED 10M SINGLE/DUAL NOTES E-4 E-4 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C[...]

  • Page 105

    Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL Section F-1 Section F-1 T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR SECTION - T roubleshooting & Repair Section ........................................................................Section F How to[...]

  • Page 106

    HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician and machine operator and will invalidate your factory warranty . For your safety and to avoid Electrical Shock, please observe all safet[...]

  • Page 107

    POWER FEED 10M SINGLE/DUAL Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC boa[...]

  • Page 108

    Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TROUBLESHOOTING & REP AIR F-4 F-4 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACT[...]

  • Page 109

    The voltmeter on the Control Box does not function properly even though the ST A TUS LEDS are steady green. 1. Make sure the DIP switches are configured correctly for the weld- ing polarity being used. See Setting Dip Switches in the Wire Drive in the Installation section of this manual. 2. Check the #67 lead on the wire drive unit. Make sure it is[...]

  • Page 110

    Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-6 F-6 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S[...]

  • Page 111

    Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-7 F-7 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S[...]

  • Page 112

    POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-8 F-8 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S[...]

  • Page 113

    Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-9 F-9 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S[...]

  • Page 114

    POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-10 F-10 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT[...]

  • Page 115

    POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-11 F-11 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C Observe all Safety Guidelines detailed throughout t[...]

  • Page 116

    POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-12 F-12 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C If for any reason you do not understand the test pr[...]

  • Page 117

    POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-13 F-13 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C If for any reason you do not understand the test pr[...]

  • Page 118

    POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-14 F-14 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C O bserve all Safety Guidelines detailed throughout [...]

  • Page 119

    POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-15 F-15 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C Observe all Safety Guidelines detailed throughout t[...]

  • Page 120

    POWER FEED 10M SINGLE/DUAL NOTES F-16 F-16 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C[...]

  • Page 121

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed t[...]

  • Page 122

    POWER FEED 10M SINGLE/DUAL F-18 F-18 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power from the wire [...]

  • Page 123

    POWER FEED 10M SINGLE/DUAL F-19 F-19 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TROUBLESHOOTING AND REP AIR Service and repair should be performed by only Lincol[...]

  • Page 124

    POWER FEED 10M SINGLE/DUAL F-20 F-20 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TROUBLESHOOTING AND REP AIR WIRE FEED CONTROL BD. BLUE Black RED J84 T ACH FEEDBA[...]

  • Page 125

    POWER FEED 10M SINGLE/DUAL F-21 F-21 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TROUBLESHOOTING AND REP AIR Service and repair should be performed by only Lincol[...]

  • Page 126

    POWER FEED 10M SINGLE/DUAL F-22 F-22 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TROUBLESHOOTING AND REP AIR 1 2 5 6 #550 #551 J83 #551(-) BLACK #550(+) WHITE DRI[...]

  • Page 127

    POWER FEED 10M SINGLE/DUAL F-23 F-23 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C TROUBLESHOOTING AND REP AIR Service and repair should be performed by only Lincol[...]

  • Page 128

    POWER FEED 10M SINGLE/DUAL F-24 F-24 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C D RIVE MOTOR # 551 (BLACK) #550 ( WHITE) G EAR BOX GAS FITTING WIRE DRIVE A SSEMB[...]

  • Page 129

    POWER FEED 10M SINGLE/DUAL TROUBLESHOOTING & REP AIR F-25 F-25 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C GEAR BOX AND DRIVE MOTOR REMOV AL AND REPLACEMENT T[...]

  • Page 130

    TROUBLESHOOTING AND REP AIR F-26 F-26 Re t ur n to Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re tur n t o Se ct io n T O C Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any [...]

  • Page 131

    POWER FEED 10M SINGLE/DUAL Re t ur n to Ma st e r T OC Re tu r n to Ma st e r T OC Re tur n to Ma st e r T O C Re tur n t o Ma ste r T O C Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams.....................................................................................................................[...]

  • Page 132

    ELECTRICAL DIAGRAMS G-2 POWER FEED 10M SINGLE/DUAL WIRING DIAGRAM - ENTIRE MACHINE - CODE 10962, 1 1194 (G4319-1) WIRING DI AGRAM - POWER FEED 10 M DUAL A G4319-1 MOTOR/GEARBOX J1 2 3 613 4 67D T ACH R CONNECTION W 651 2 J2 I NPUT ELECTRODE CABLE 5 650 B U B 67D VOLTAGE SENSING 6 614 SELECT P.C. BOARD 67C VOLTAGE SENSE 637 1 631 2 634 3 B U R 1 1 L[...]

  • Page 133

    ELECTRICAL DIAGRAMS G-3 POWER FEED 10M SINGLE/DUAL WIRING DIAGRAM - ENTIRE MACHINE - CODE 1 1086, 11216 (G4439) WIRING DI AGRAM - POWER FEED 10M SINGL E FEED HEAD G4439 D MOTOR/GEARBOX J1 2 3 513 4 67A T ACH R CONNECTION W 550 N.D. 5 79A 532 N.C. STATUS LED 2 578 553 550 2 1 2 1 5 4 3 2 8 CO N T R O L P C B O A R D 5 4 2 5 4 1 9 10 12 548 J85 570D [...]

  • Page 134

    ELECTRICAL DIAGRAMS G-4 POWER FEED 10M SINGLE/DUAL WIRING DIAGRAM - ENTIRE MACHINE - CODE 1 1193 (G4439-1) WIRING DI AGRAM - POWER FEED 10 M SINGLE BOOM FEEDER G4439-1 B MOTOR/GEARBOX J1 2 3 513 4 67A T ACH R CONNECTION W 550 N.D. 579A 5 32 N.C. S TATUS LED 2 578 553 550 2 1 2 1 5 4 3 2 8 C O N T R O L P C B O A R D 5 42 5 4 1 9 10 12 5 70D 543 AC [...]

  • Page 135

    Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Ma st e r T O C Re tur n to Ma ste r T OC Re tur n to Ma ste r T OC Re tur n to Ma ste r T OC ELECTRICAL DIAGRAMS G-5 POWER FEED 10M SINGLE/DUAL SCHEMA TIC - ENTIRE MACHINE - CODE 10962 (G4320-1) E N-170 S O L I D E D G E G432[...]

  • Page 136

    ELECTRICAL DIAGRAMS G-6 POWER FEED 10M SINGLE/DUAL SCHEMA TIC - ENTIRE MACHINE - CODE 11086, 1 1216 (G4440) G 4 440 ENGINEERING CONTROLLED MANUFACTURER: No C O M P L E T E L Y R E V I S E D E THE INFORM ATION ON THIS PRINT ISFOR REFERENC E ONLY. COM PONENTSAND CIRCUITRYMAY BE DIFFERENT FROM ANACTUAL MACHINE . G444 0 POWER FEED 10M SINGL E (BENCH) M[...]

  • Page 137

    ELECTRICAL DIAGRAMS G-7 POWER FEED 10M SINGLE/DUAL SCHEMA TIC - ENTIRE MACHINE - CODE 11 193 (G5002) G 5 002 ENGINEERING CONTROLLED MANUFACTURER: No C H A N G E D E T A I L : A D D E D C A P A C I T O R W I T H N O T E N . E . , T O R O I D A N D J 8 3 J U M P E R B THE INFORM ATION ON THIS PRINT ISFOR REFERENC E ONLY. COM PONENTSAND CIRCUITRYMAY B[...]

  • Page 138

    ELECTRICAL DIAGRAMS G-8 POWER FEED 10M SINGLE/DUAL SCHEMA TIC - ENTIRE MACHINE - CODE 11 194 (G5003) S O L I D E D G E G 5003 ENGINEERING CONTROLLED MANUFACTURER: No CHA NGE DETAIL: A DDED C APACIT OR WITHNOTE N.E., TOR OID AN D J83 JUM PER B THE INFORM ATION ON THIS PRINT ISFOR REFERENC E ONLY. COM PONENTSAND CIRCUITRYMAY BE DIFFERENT FROM ANACTUA[...]

  • Page 139

    ELECTRICAL DIAGRAMS G-9 POWER FEED 10M SINGLE/DUAL SCHEMA TIC - WIRE DRIVE PC BOARD - (G3883 SHEET 1) G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Ma st e r T O[...]

  • Page 140

    ELECTRICAL DIAGRAMS G-10 POWER FEED 10M SINGLE/DUAL SCHEMA TIC - WIRE DRIVE PC BOARD - ALL CODES - (G3883 SHEET 2) G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to[...]

  • Page 141

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 142

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 143

    ELECTRICAL DIAGRAMS G-13 POWER FEED 10M SINGLE/DUAL PC BOARD ASSEMBL Y - VOL T AGE SENSE - ALL CODES - (M19540-3) G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to [...]

  • Page 144

    ELECTRICAL DIAGRAMS G-14 POWER FEED 10M SINGLE/DUAL SCHEMA TIC - MSP4 DISPLA Y PC BOARD - ALL CODES - (G4456) G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Ma s[...]

  • Page 145

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 146

    ELECTRICAL DIAGRAMS G-16 POWER FEED 10M SINGLE/DUAL SCHEMA TIC - DISPLA Y PC BOARD - ALL CODES - (L1 1756) G-16 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Ma st e[...]

  • Page 147

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 148

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 149

    ELECTRICAL DIAGRAMS G-19 POWER FEED 10M SINGLE/DUAL PC BOARD ASSEMBL Y - SPOOL GUN - ALL CODES - (M20159-3) G-19 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Ma st [...]

  • Page 150

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 151

    ELECTRICAL DIAGRAMS G-21 POWER FEED 10M SINGLE/DUAL PC BOARD ASSEMBL Y - FIL TER - ALL CODES - (M19488-2) G-21 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Ma st e [...]