Lincoln Electric IM658-A manual

Po wer F eed 10 Dual W ire Drives & Control Bo x es Boom Mount or Bench M odel OPERA TOR’S MANUAL IM658-A August, 2007 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 N[...]

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 sk[...]

iii SAFETY iii 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 manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

iv SAFETY iv Mar. ʻ93 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les c[...]

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[...]

vi 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 ...................................................................[...]

POWER FEED 10 DUAL A-1 INST ALLA TION A-1 TECHNICAL SPECIFICA TIONS – Power Feed 10 Dual Wire Drives & Control Boxes WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO * Also part of K1683-[ ] Boom package and K1686-[ ] Bench Feeder. ∆ Dimensions do not include wire reel. # For Control Box and wire drive[...]

A-2 INST ALLA TION POWER FEED 10 DUAL A-2 SAFETY PRECAUTIONS MOUNTING THE WIRE DRIVE UNIT BOOM MOUNTING OF WIRE DRIVE UNIT Mount the wire drive unit by means of the 4 holes in t h e b o t t o m o f t h e w i r e d r i v e case. (See Figure A.1) The gearbox assembly is electrically “hot” when the gun trigger is pressed. Therefore, make certain t[...]

A-3 INST ALLA TION POWER FEED 10 DUAL A-3 5. Remove plug button taped to inside of Control Box and insert it into hole on front panel of the Wire Drive. MOUNTING THE CONTROL BOX (BOOM OR SEP ARA TED BENCH MODELS) The back plate of the Control Box has four keyhole slots for mounting. See Figure A.2 for the size and location of these slots. #10 screw[...]

A-4 INST ALLA TION POWER FEED 10 DUAL A-4 Typical Bench Feeder Connection: Control cable is connected from the Power Wave 455 output receptacle to the input receptacle on the back of the Wire Drive. Typical Boom Feeder Connection: One control cable is connected from the Power Wave 455 output receptacle to the Control Box input recep- tacle. A secon[...]

A-5 INST ALLA TION POWER FEED 10 DUAL A-5 Connect the one end of the electrode cable, to the power source output terminal of the desired polarity. Connect the other end of the electrode cable to the connection bar at the front of the wire drive feed plate using the provided bolt and lockwasher. The elec- trode cable lug must be against the feed pla[...]

A-6 INST ALLA TION POWER FEED 10 DUAL A-6 RATIO CHANGE PROCEDURE: 1) Pull open the Pressure Door. 2) Remove the Phillips head screw retaining the pin- ion gear to be changed and remove the gear. If the gear is not easily accessible or difficult to remove, remove the feed plate from the gearbox. To remove feed plate: a) Loosen the clamping collar sc[...]

FIGURE A.3 A-7 INST ALLA TION POWER FEED 10 DUAL A-7 DIP SWITCH SETUP SETTING DIP SWITCHES IN THE CONTROL BOX 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 Control Box Motherboard (Fo[...]

A-8 INST ALLA TION POWER FEED 10 DUAL A-8 MSB - Most Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the left. LSB - Least Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the right. S2 DIP Switch Bank on Control Box Motherboard (For software versio[...]

A-9 INST ALLA TION POWER FEED 10 DUAL A-9 SETTING DIP SWITCHES IN THE WIRE DRIVE There is one DIP switch bank on each Control PC board for the wire drives. They are labeled S1 and are located and oriented as shown in Figure A.4. The PC board for the left feed head (facing forward) is located on the rear access panel. The PC board for the right feed[...]

A-10 INST ALLA TION POWER FEED 10 DUAL A-10 WIRE FEED DRIVE ROLL KITS N O T E : The maximum rated solid and cored wire sizes and selected drive ratios are shown on the SPECIFICATIONS in the front of this sec- tion. The electrode sizes that can be fed with each roll and guide tube are stenciled on each part. Check the kit for proper components. Kit [...]

A-11 INST ALLA TION POWER FEED 10 DUAL A-11 Magnum 200 / 300 / 400 Guns The easiest and least expensive way to use Magnum 200/300/400 guns with the Power Feed 10 Dual wire feeder is to order them with the K466-10 connector kit, or to buy a completely assembled Magnum gun hav- ing the K466-10 connector (such as the K497-21 dedi- cated Magnum 400). M[...]

A-12 INST ALLA TION POWER FEED 10 DUAL A-12 The upper location must be used for 50-60 lb. Readi- Reels, Spools and Coils. For smaller coils (44lb, 30lb, 10lb, etc.), the spindle can be placed in either the upper or lower location. The goal is to make the wire path from the coil to the wire drive an entry into the incoming guide tube that is as stra[...]

A-13 INST ALLA TION POWER FEED 10 DUAL A-13 OPTIONAL FEA TURES INST ALLA TION A number of Optional Features are available for use with Power Feed 10 Dual. 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 BOX [...]

B-1 OPERA TION POWER FEED 10 DUAL B-1 SAFETY PRECAUTIONS PRODUCT DESCRIPTION The Power Feed Wire Feeders are high performance, digitally controlled, modular wire feeders. Properly equipped, they 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 characteristics (output voltage, output cur- rent) according to pre-programmed settings contained in the power source. In constant current modes (arc gouging, stic[...]

B-3 OPERA TION B-3 Memory has an advanced feature called ʻmemory reminderʼ. When the Save key is hit, the memory reminder function flashes the LED of the most recently used memory, so the operator can save procedures in the most recently used memory if desired. It is not necessary to save to the most recently used memory; the memory reminder func[...]

B-4 OPERA TION B-4 POWER FEED 10 DUAL The value of the active Set Up parameter, as defined by the Set Up LED, is displayed on the MX2 panel Set Up display. The value can be modified with the Set switch. The Set switch is an up/down center-off momentary toggle switch. Moving the switch bat up or down adjusts the displayed value in the correspond- in[...]

B-5 OPERA TION B-5 Crater - Used only when welding with the 4-Step trig- ger mode. Can be set to Off or On. When On, Adjustments can be made to WFS and Volts/Trim on the Control/Display panel. These settings are then used for ʻcrateringʼ when in the 4-Step trigger mode (see explanation of 2 Step and 4 Step operation below). When Off, ʻcratering?[...]

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 on the gun side of the Status LED. This switch has no effect in CC modes of operation, such[...]

B-7 OPERA TION B-7 WIRE DRIVE -- PC BOARD 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 RA TIO: The systems needs to know which gear has been installed[...]

B-8 OPERA TION B-8 FIGURE B.1 T o Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 mm Diameter) or 14Lb.(6 Kg) Innershield Coils: The Spindle should be located in the LOWER mounting hole. (For 8" (200 mm) spools, a K468 spindle adapter must first be slipped onto spindle.) (For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil Adapter must be [...]

B-9 OPERA TION B-9 FEEDING ELECTRODE 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 jam[...]

B-10 OPERA TION B-10 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-11 OPERA TION B-11 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-12 OPERA TION B-12 POWER FEED 10 DUAL ST A TUS LIGHT ST A TES (CONʼT) 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[...]

C-1 ACCESSORIES C-1 POWER FEED 10 DUAL TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll DH 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 - 040S 0.040” (1.0 mm) KP1505 - 045S 0.045” (1.2 mm) KP1505 - 045S 0.05[...]

C-2 ACCESSORIES C-2 DESCRIPTION AND INST ALLA TION OF OPTIONAL CONTROL BOX P ANELS A number of Optional Features are available for use with Power Feed 10 Dual. 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[...]

C-3 ACCESSORIES C-3 K1542-6 “M” P ANEL The M Panel provides a fixed large bat toggle switch selection of three Power Source modes. The upper position selects the generic CV/MIG mode from the power source, the middle position selects the CV/FLUX CORED mode, and the lower position selects the CC/STICK/GOUGE mode. Arc control is accomplished throu[...]

C-4 ACCESSORIES C-4 K1542-1 1 MX2 P ANEL (LARGE P ANEL) The MX2 Panel provides a selection of four Power Source modes. In addition, it provides for the adjustment of the following parameters: preflow, run in, arc control, Burn back, postflow, and spot time. Descriptions Indicator Lights - Extra bright red LEDʼs for viewing at almost any angle. Alw[...]

C-5 ACCESSORIES C-5 K1542-12 MSP2 P ANEL AND K1542- 10 MS/STT P ANEL (LARGE P ANEL) The MSP2 or MS/STT Panel provides a selection of numerous process specific and generic Power Source modes. In addition, it provides for the adjustment of the following parameters: preflow, run in, arc control, Burn back, postflow, and spot time. Only one parame- ter[...]

C-6 ACCESSORIES C-6 tings of the procedure by 10 percent. Lincoln Power Wave power sources utilizes a control scheme known as adaptive control in all pulse modes. Because the Power Wave utilizes adaptive control, it can adjust the pulsing parameters based on changes in the arc due to changes in the electrical sitckout of the electrode. (Electrical [...]

C-7 ACCESSORIES C-7 which procedure the gun switch is requesting. Memory Selection RECALL - When a memory key is depressed its indi- cator comes on, and its contents are copied to the active procedure. As long as no changes are made to the contents of that procedure, the memory indicator will be on anytime that procedure is active. This indi- cates[...]

C-8 ACCESSORIES C-8 K1548-1 LINC NET RECEPT ACLE KIT (INPUT AND OUTPUT) LINC NET RECEPTACLE (OUTPUT) Optional Output Connector Installation into the Control Box Cabinet and/or into the Feeder Head Enclosure. Control Box Cabinet Procedure 1. Turn off power. 2. Remove the screws from the front of the lower and middle option panels of the User Interfa[...]

C-9 ACCESSORIES C-9 LINC NET RECEPTACLE (INPUT) Power Feed Wire Feeder Optional Input Connector Installation into the Control Box Cabinet and Conversion to Fixture Wire Feeder 1. Turn off power. 2. Remove the screws from the front of the lower and middle option panels of the Control Box cabi- net. 3. Tilt the option panels away from the front openi[...]

C-10 ACCESSORIES C-10 GUNS AND GUN ADAPTERS The Power Feed 10 Dual wire feeder is equipped with a factory installed K1500-2 gun connection Kit. This kit is for guns having a Tweco™ #2-#4 connector. The Power Feed 10 Dual has been designed to make con- necting a variety of guns easy and inexpensive with the K1500 series of gun connection kits. Gun[...]

C-11 ACCESSORIES C-11 CONDUIT ADAPTERS K1546-2 ADAPTER for use with Lincoln Magnum conduit and E-Beam conduit (wire sizes 1/16 - .120) For Magnum conduit: Install the K1546-2 gun adapter at the incoming end of the feed plate, secure with the set screw located at the back of the feed plate. If a brass fitting is supplied with the conduit, remove it [...]

C-12 ACCESSORIES C-12 K590-6 W A TER CONNECTION KIT (FOR DRIVE ONL Y) Install per the instructions shipped with the kit. K1536-1 W A TER FLOW SENSOR KIT Install per the instructions shipped with the kit K659-1 GAS GUARD REGULA TOR Adjustable flow regulator with removable adjuster key for CO2 and Argon blend gases. Mounts onto feeder inlet, and redu[...]

D-1 MAINTENANCE D-1 POWER FEED 10 DUAL A voiding Wire Feeding Problems 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 d[...]

E-1 TROUBLESHOOTING E-1 POWER FEED 10 DUAL 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[...]

E-2 TROUBLESHOOTING E-2 POWER FEED 10 DUAL 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[...]

E-3 TROUBLESHOOTING E-3 POWER FEED 10 DUAL 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[...]

E-4 TROUBLESHOOTING E-4 POWER FEED 10 DUAL 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[...]

E-5 TROUBLESHOOTING E-5 POWER FEED 10 DUAL 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[...]

E-6 TROUBLESHOOTING E-6 POWER FEED 10 DUAL 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[...]

E-7 TROUBLESHOOTING E-7 POWER FEED 10 DUAL 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[...]

E-8 TROUBLESHOOTING E-8 POWER FEED 10 DUAL 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[...]

E-9 TROUBLESHOOTING E-9 POWER FEED 10 DUAL 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[...]

E-10 TROUBLESHOOTING E-10 POWER FEED 10 DUAL 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 proc[...]

E-11 TROUBLESHOOTING E-11 POWER FEED 10 DUAL 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 No[...]

E-12 TROUBLESHOOTING E-12 POWER FEED 10 DUAL 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 No[...]

F-1 DIAGRAMS F-1 POWER FEED 10 DUAL B G3582 WIRING DIAGRAM - POWER FEED 10 DUAL FEED HEAD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service [...]

F-2 DIAGRAMS F-2 POWER FEED 10 DUAL 6.88 .218 4.25 .75 .75 .81 .90 12.07 12.96 18963 3.06 8.50 M 4.08 3.86 (4 KEYHOLE SLOTS) 10-17-97 CONTR OL BO X DIMENSION PRINT[...]

F-3 DIAGRAMS F-3 POWER FEED 10 DUAL 19.89 A A 19. 9 A A 15.41 A A 30.61 A A L 11044 7- 21- 200 0C WIRE FEEDER (BENCH MODEL) DIMENSION PRINT[...]

F-4 DIAGRAMS F-4 POWER FEED 10 DUAL 8. 56 A A 14. 1 0 A A 15. 5 5 A A 6. 00 A A D O O R O PEN TY P . 5. 25 A A 19. 4 3 A A 11. 1 2 A A 2. 54 T Y P . A A 4. 43 A A 2. 25 A A 2. 93 A A 4. 25 T Y P . A A WIRE DRIVE DIMENSION PRINT 7-2000 M19304 •[...]

NOTES POWER FEED 10 DUAL[...]

W ARNING AV I S O D E 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 E[...]

W ARNING AV I S O D E 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 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[...]

• 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 •[...]