Lincoln Electric IM613-B manual

Po wer F eed 11 SemiAutomatic Cabinet W ire Feeder OPERA TOR’S MANUAL IM613-B October, 2000 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR T[...]

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. ________________________________________________[...]

ii SAFETY ii 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. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

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[...]

iv SAFETY iv PR É CA UTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: S û ret é Pour Soudage A L ’ Arc 1. Protegez-vous contre la secousse é le[...]

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 par[...]

vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ..............................................[...]

Page Troubleshooting ..............................................................................................Section E Safety Precautions ............................................................................................................. ..E-1 Troubleshooting Guide ....................................................................[...]

A-1 INST ALLA TION POWER FEED 11 A-1 TECHNICAL SPECIFICA TIONS – P o wer Feed 11 COMPLETE UNITS SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO The PF-11 is environmentally rated IP21S per IEC60529 Wire Size Wire Size Speed Solid Cored Speed Solid Cored K1635-1 Power Feed 11 50-625 IPM .025 - 1/16 in. .030 - 5/64 in 75 - 1100 IPM .025 - .045 in. .03[...]

A-2 INST ALLA TION POWER FEED 11 A-2 SAFETY PRECA UTION WIRE FEEDER T O PO WER SOURCE CONFIGURA TIONS The Wire Feeder is equipped to operate in the vertical or horizontal position. It is shipped ready for use in the in the vertical position. MOUNTING ON T OP OF THE PO WER SOURCE The Wire Feeder is shipped with the vertical mounting bracket installe[...]

A-3 INST ALLA TION POWER FEED 11 A-3 CABLE CONNECTIONS CONTROL CABLE CONNECTIONS • All system control cables are the same. • All control cables can be connected end to end to extend their length. • All system equipment must be connected to a con- trol cable. Welding systems using the Power Feed 11 offer previ- ously unprecedented flexibility [...]

A-4 INST ALLA TION POWER FEED 11 A-4 WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length (per the following table) between the proper output termi- nal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to ac[...]

A-5 INST ALLA TION POWER FEED 11 A-5 RATIO CHANGE PROCEDURE: 1) Power down the Power Feed by turning OFF its companion PowerWave power source. For maxi- mum safety, disconnect the control cable from the Power Feed. 2) Pull open the Wire Feeder ’ s Compartment Door. 3) Remove the Feedplate per the following: a) Disconnected the Electrode from the [...]

A-6 INST ALLA TION POWER FEED 11 A-6 FIGURE A.3 DIP SWITCH SETUP SETTING DIP SWITCHES IN THE CONTROL BO X There are two DIP switch banks on the mother board of the Control Box. They are labeled S1 and S2 and are located and oriented as shown in Figure A.3. S1 ON 1 2 3 456 7 8 S2 ON 1 2 3 456 7 8 S1 DIP Switch Bank on Contr ol Bo x Motherboard (For [...]

A-7 INST ALLA TION POWER FEED 11 A-7 SETTING DIP SWITCHES IN THE WIRE DRIVE There is one DIP switch bank on the control board of the wire drive. It ’ s labeled S1 and is located and ori- ented as shown in Figure A.4. FIGURE A.4 S2 DIP Switch Bank on Contr ol Bo x Motherboard (For software ver sion S24456-1) Switch Off On 1 Network Group ID, MSB ([...]

A-8 INST ALLA TION POWER FEED 11 A-8 WIRE FEED DRIVE R OLL KITS AND F AST -MA TE ™ GUN AD APTER GUIDE TUBES NOTE: The maximum rated solid and cored wire sizes and selected drive ratios are shown on the SPECIFICATIONS in the front of this section. The electrode sizes that can be fed with each drive roll and wire guide are stenciled on each part. C[...]

A-9 INST ALLA TION POWER FEED 11 A-9 7) Insert inner Wire Guide, groove side out, over the two locating pins in the feed plate. 8) Install each drive roll by pushing over shaft until it butts up against locating shoulder on the drive roll shaft. (Do Not exceed maximum wire size rating of the wire drive). 9) Install Outer Wire Guide by sliding over [...]

A-10 INST ALLA TION POWER FEED 11 A-10 LIFTING HANDLE The Power Feed 11 is shipped with a insulated Lifting Handle which can be mounted on the top or back of the Wire Feeder. This handle is intended to be primar- ily used for short term carrying of the Feeder. While this handle is suitable for hanging the Feeder it is rec- ommended that the Lifting[...]

A-11 INST ALLA TION POWER FEED 11 A-11 OPTIONAL FEA TURES INST ALLA TION A number of Optional Features are available for use with Power Feed 11. Some Installation informa- tion is provided in this section, REFER TO THE INSTRUCTIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLA- TION. OPTIONAL P ANELS FOR CONTROL BO X All optio[...]

B-1 OPERA TION POWER FEED 11 B-1 SAFETY PRECA UTIONS PR ODUCT DESCRIPTION The Power Feed 11 is a high performance, digitally controlled, modular cabinet style wire feeder. Properly equipped, it can support the GMAW, GMAW- P, FCAW, and SMAW processes. The Power Feed wire feeders are designed to be a part of a modular, multi process welding system. T[...]

B-2 OPERA TION B-2 The user adjusts WFS according to factors such as weld size, penetration requirements, heat input, etc. The power source then uses the WFS setting to adjust its output char- acteristics (output voltage, output current) according to pre- programmed settings contained in the power source. In constant current modes (arc gouging, sti[...]

B-3 OPERA TION B-3 K1542-12 MSP2 Panel: (Optional) This panel provides a selection of over 25 weld modes, including CV, pulse, FCAW and CC, through a toggle switch and indicator lights (LEDs). It allows for adjustment of all set up parameters, Preflow, Run In, Arc Control, Burnback, Postflow, and Crater, through an up/down toggle switch, indicator [...]

B-4 OPERA TION B-4 To recall a memory setting, simply push that memory button. That memory ’ s contents will be immediately recalled to the Control box. If the ‘ Memory Change with Trigger Pull ’ DIP switch is on (see “ Setting DIP Switches in the Control Box ” sec- tion) it is possible to recall a given memory by quickly pulling and rele[...]

B-5 OPERA TION B-5 CONTROL BO X -- SETTING OPERA TING LIMITS Upper and lower operating limits can be set for the WFS/Amps setting and the Volts/Trim setting. Doing so requires knowledge of how to set the limits, and access to the PC board in the Control Box. There are two independent sets of limits, Procedure A limits and Procedure B limits. If a D[...]

B-6 OPERA TION B-6 WIRE DRIVE OPERA TION The most frequently used Wire Drive settings are external; some features are accessed by internal set- tings. WIRE DRIVE SETTINGS -- EXTERNAL 2 STEP/4 STEP SWITCH: The Wire Drive has a 2 Step/ 4 Step switch located near the gun connector. This switch has no effect in CC modes of operation, such as stick weld[...]

B-7 OPERA TION B-7 WIRE DRIVE -- PC BO ARD ADJUSTMENTS ELECTRODE POLARITY: The system needs to be aware of the electrode polari- ty. A DIP switch setting on the Wire Drive PC board is used for this purpose. See INSTALLATION Section “ Setting DIP Switches in the Wire Drive ” . GEAR BOX RATIO: The systems needs to know which gear has been install[...]

B-8 OPERA TION B-8 FEEDING ELECTR ODE AND BRAKE ADJUSTMENT 1) Turn the Reel or spool until the free end of the electrode is accessible. 2) While tightly holding the electrode, cut off the bent end and straighten the first 6" (150 mm). Cut off the first 1" (25 mm). (If the electrode is not proper- ly straightened, it may not feed or may ja[...]

B-9 OPERA TION B-9 MAKING A WELD 1. Use only a network compatible power source. 2. Properly connect the electrode and work leads for the correct electrode polarity. 3. Set all desired parameters such as trigger logic, Run-in Speed, Acceleration, Electrode polarity, etc. per “ DIP SWITCH SETUP ” in the INSTALLATION section. 4. Set 2-step, 4-step[...]

B-10 OPERA TION B-10 COMPONENT ST A TUS LIGHTS Each network component has a single status light. The light is a bicolor, Green/Red, LED. The purpose of the status light is to allow the operator to quickly identify that the system is working properly or, if not, which component is causing the problem. By using the status lights the operator can quic[...]

B-11 OPERA TION B-11 POWER FEED 11 ST A TUS LIGHT ST A TES (CON ’ T) LED State Red LED blinking at a fast rate Red LED ON and steady Green LED ON and steady Power Source LED Power source needs to be reprogrammed. Contact your Local Authorized Lincoln Field Service Facility. Power source has a non-recoverable hard- ware fault. Contact your Local A[...]

TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll Drive (4-Driven) Solid Steel Electrode 0.023 ” - 0.025 ” (0.6 mm) KP1505 - 030S 0.030 ” (0.8 mm) KP1505 - 030S 0.035 ” (0.9 mm) KP1505 - 035S 0.040 ” (1.0 mm) KP1505 - 045S* 0.045 ” (1.2 mm) KP1505 - 045S* 0.052 ” (1.4 mm) KP1505 - 052S 1/16 ” (1.6 mm) KP1505 - 1/16S 5/64[...]

C-2 A CCESSORIES C-2 DESCRIPTION OF OPTIONAL CON- TR OL BO X P ANELS A number of Optional Features are available for use with Power Feed 11. Some Installation information is provided in this section, REFER TO THE INSTRUC- TIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLATION. OPTIONAL P ANELS FOR CONTROL BO X The PF-11 Contr[...]

C-3 A CCESSORIES C-3 WIRE SPINDLE AD APTERS K435 - Permits 14 lb. (6 kg) Innershield coils to be mounted on 2" (51 mm) O.D. spindles. K363P - Adapts Lincoln Readi-Reel coils of electrode 30 lb. (14 kg) and 22 lb. (10 kg) to a 2" (51 mm) spin- dle. Durable molded plastic one piece construction. Designed for easy loading; adapter remains on[...]

D-1 MAINTENANCE D-1 POWER FEED 11 A v oiding Wire Feeding Prob lems Wire feeding problems can be avoided by observing the following gun handling and feeder set up proce- dures: a) Do not kink or pull cable around sharp corners. b) Keep the electrode cable as straight as possible when welding or loading electrode through cable. c ) Do not allow doll[...]

E-1 TR OUBLESHOO TING E-1 POWER FEED 11 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 UTION This Troubleshooting Guide is provided to help you locate and repair[...]

E-2 TR OUBLESHOO TING E-2 POWER FEED 11 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 UTION PROBLE[...]

E-3 TR OUBLESHOO TING E-3 POWER FEED 11 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 UTION PROBLE[...]

E-4 TR OUBLESHOO TING E-4 POWER FEED 11 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 UTION PROBLE[...]

E-5 TR OUBLESHOO TING E-5 POWER FEED 11 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 UTION PROBLE[...]

E-6 TR OUBLESHOO TING E-6 POWER FEED 11 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 UTION PROBLE[...]

E-7 TR OUBLESHOO TING E-7 POWER FEED 11 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 UTION PROBLE[...]

E-8 TR OUBLESHOO TING E-8 POWER FEED 11 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 UTION PROBLE[...]

E-9 TR OUBLESHOO TING E-9 POWER FEED 11 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 UTION PROBLE[...]

E-10 TR OUBLESHOO TING E-10 POWER FEED 11 Observe all Safety Guidelines detailed throughout this manual Note: For any Err # listed below write down the error number for reference and try cycling power to see if the error clears itself. If not, refer to the What to Do column for the given Err. If for any reason you do not understand the test procedu[...]

E-11 TR OUBLESHOO TING E-11 POWER FEED 11 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 UTION Observe all Safety Guidelines detailed throughout this manual Note[...]

E-12 TR OUBLESHOO TING E-12 POWER FEED 11 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 UTION Observe all Safety Guidelines detailed throughout this manual Note[...]

F-1 DIA GRAMS F-1 POWER FEED 11 45 6 559 512A 512 558 56 4 1 2 512 557 512 557 558 556 558 556 559 6 P11 P13 1 3 A 3 4 A 12 5 1 6 4 CAVITY NUMBERING SEQUENCE (AS VIEW ED FROM LEAD SIDE OF CONNECTOR) B 2 STEP/ 4 STEP 7-2 0 00 512 B 67A 550 542D 500D 540D 67A 511 400 (J2) 67 A B 67 = CHAS SIS CO NNEC TI ON 553 550 552 551 REC TIFIER BRIDGE 553 540B 5[...]

F-2 DIA GRAMS F-2 POWER FEED 11 6 3 1 2 3 4 500 7 P.C. BOARD ENCODER DUAL LOWER 1 2 1 4 3 4 3 2 43 34 2 1 540A 500A 542A 541A 12 6 2 1 1 512C 2 500C 555 1 556 553 3 2 554 4 1 1 5 6 3 (J1) N.F. (J1) N.F. N.C. STATUS LED RED/GREEN W B 7 8 511 560 561 559 562 563 500D 557 500E 558 512A 555 556 553 (J1) 554 N.A. (J2) 500C 551 512 512C 4 N.B. N.A. CABIN[...]

F-3 DIA GRAMS F-3 POWER FEED 11 1.29 2.01 8.66 2.13 (MOUNTING HOLES ON BRACKET) 7.34 .38 3.90 3.10 15.71 17.96 .68 1.18 19.59 16.84 28.69 18.02 18.52 .44 20.01 .50 21.00 (MOUNTING HOLES ON BRACKET) 24.96 26.64 L10834 B-UF[...]

NO TES POWER FEED 11[...]

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W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fume[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O 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 A[...]

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