Lincoln Electric Activ8X Operator's Manual

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Page 1

Operator’s Manual

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IM10458-A | Issue D ate Apr-19

For use with machines having Code Numbers:

12759, 12877

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Activ8X

™

Page 2

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

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 thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

Page 3

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

Page 4

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if

welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS 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 and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer’s safety practices. SDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

Page 5

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151.

FOR ELECTRICALLY 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 Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

Page 6

ACTIV8X™

TABLE OF CONTENTS

GENERAL DESCRIPTION........................................................................................................................................3

RECOMMENDED PROCESSES ...............................................................................................................................3

PROCESS LIMITATIONS.........................................................................................................................................3

EQUIPMENT LIMITATIONS .....................................................................................................................................3

RECOMMENDED POWER SOURCES.......................................................................................................................3

OTHER POWER SOURCES......................................................................................................................................3

DESIGN FEATURES................................................................................................................................................3

INSTALLATION .............................................................................................................................................SECTION A

TECHNICAL SPECIFICATIONS ............................................................................................................................A-1

LOCATION .........................................................................................................................................................A-2

ACROSS THE ARC SET-UP WITH CROSSLINC™ (RECOMMENDED).....................................................................A-3

ACROSS THE ARC SET-UPS WITHOUT CROSSLINC™ ........................................................................................A-3

RECOMMENDED ELECTRODE AND WORK CABLE SIZES FOR ARC WELDING ......................................................A-5

TRIGGER CONNECTOR.......................................................................................................................................A-5

CHANGING THE GUN ADAPTER BUSHING ...........................................................................................................A-6

PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES................................................................................A-7

PRESSURE ARM ADJUSTMENT..........................................................................................................................A-7

GUN CONNECTION.............................................................................................................................................A-8

SHIELDING GAS CONNECTION ...........................................................................................................................A-8

OPERATION ................................................................................................................................................SECTION B

POWER-UP SEQUENCE......................................................................................................................................B-1

CASE FRONT CONTROLS...................................................................................................................................B-2

INTERNAL CONTROLS .......................................................................................................................................B-3

REAR CONTROLS ..............................................................................................................................................B-4

DIGITAL METER OPERATION..............................................................................................................................B-5

SET-UP MENU OPERATION................................................................................................................................B-6

CONSTANT CURRENT OPERATION.....................................................................................................................B-9

OPTIONS/ACCESSORIES...............................................................................................................................SECTION C

MAINTENANCE .............................................................................................................................................SECTION D

ROUTINE MAINTENANCE ...................................................................................................................................D-1

PERIODIC MAINTENANCE ..................................................................................................................................D-1

TROUBLESHOOTING .....................................................................................................................................SECTION E

DIAGRAMS .................................................................................................................................................SECTION F

PARTS LIST ...............................................................................................................PARTS.LINCOLNELECTRIC.COM

CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION MANUALS, GO TO PARTS.LINCOLNELECTRIC.COM.

Page 7

ACTIV8X™

General Description

The Activ8X™ is a rugged, portable, across-the-arc wire feeder with CrossLinc™ and True Voltage Technology™. With its 8 in. spool, the Activ8X is specifically designed for shipyards or field construction where a smaller, portable wire feeder is needed. When used with a CrossLinc equipped power source, this Activ8X allows the user to adjust the welding voltage at the wire feeder front panel without the need for a control cable. As a result, setup and changeover time s reduced while productivity is increased. True Voltage Technology™ (TVT™) does the thinking so you don’t have to. TVT learns. In as little as one weld, TVT begins to make the necessary power source adjustments to ensure that the voltage you set at the feeder will be the same voltage delivered to the arc. TVT remembers. Set point adjustments remain – even after the power to the Activ8X has been removed.

The Activ8X comes factory equipped with a K1500-2 Magnum

Tweco-compatible style #2-#4 gun adapter. Other K1500 series gun adapters are available as field installed options.

In addition to CrossLinc, the Activ8X wire feeder has the following features:

• Rating- 330 amp, 60% duty cycle rating.

• Gas apparatus – can be used for FCAW-G and GMAW processes.

• The plastic case is molded from a high impact, flame retardant plastic for high durability and low weight.

• The heart of the Activ8X is the 2 roll MAXTRAC®drive. The patented features on the wire drive offer tool-less changing of the drive rolls and wire guides for quick spool changes. A tachometer controlled motor powers the patented drive rolls for smooth, steady feeding without slippage.

recoMMenDeD processes

• GMAW

• FCAW

process liMitations

• Not recommended for stitch or spot welding.

eQUipMent liMitations

• The duty cycle of the wire feeder is 330A, 60%. Duty cycle is based upon the amount of welding performed in a 10 minute period.

• The maximum spool size diameter is 8”.

• Maximum recommended FCAW gun length is 15 ft.

• Maximum recommended GMAW gun length is 15 ft.

• Push-pull guns do not work with the Activ8X™.

recoMMenDeD poWer soUrces

• Flextec 350X

™

• Flextec 500X

™

• Flextec 650X

™

otHer poWer soUrces

• CV-250, 300, 305, 400, 655

• DC-400, 600, 655

• Invertec V-350 Pro, V-450

• Multi-Weld 350

• Ranger 10,000, 3 Phase, 225, 250, 250 GXT

• Ranger 250 LPG, 305

• Cross Country 300

• Vantage 322, 435, 549, 565

• Air Vantage 566

• Dual Vantage 700

• Flextec 450, 500, 500P, 650

• Engine Drive Welder with a wire feed module

DesiGn FeatUres

Loaded with Standard Features Controls

• Digital Displays with large voltage and wire feed speed knobs.

• Trigger interlock for comfort when making long welds.

• Cold-feed switch for wire feeding without activating welding output.

• Gas Purge switch for purging the gas path without activating welding output.

• True Voltage Technology™ (TVT™) automatically compensates for voltage drop between the power source and the Activ8X. This ensures that the actual welding voltage matches the preset voltage.

• The following options are available from the setup menu:

- CC/CV operation for accommodating constant current power sources.

- Variable run-in for smoother arc starting.

- Burnback time provides adjustable power source output shutoff to prevent the electrode from sticking in the crater.

- Preflow and Postflow ensures proper gas shielding coverage before and after each weld.

Page 8

A-1

INSTALLATIONACTIV8X™

tecHnical speciFications -

INPUT - SINGLE PHASE

Input Voltage +/- 10%

Input Amperes @ Rated

Output

15 - 110V DC

MODEL SUMMARY

K# Description Meters

Drive Roll Kit

Included

Feed Plate Gun Adapter

Installed

K3519-1 ACTIV8X™ DIGITAL ---- K1500-2

K3519-2 ACTIV8X™ DIGITAL ---- K1500-2

RATED OUTPUT (ALL MODELS)

Duty Cycle Amperes

60% 330A

PHYSICAL DIMENSIONS

Model Height Width Depth Weight

K3519-1

11.75 in

(298 mm)

7.4 in

(188 mm)

18.7 in

(475 mm)

27.5 lbs

(12.4 kg)

K3519-2

11.75 in

(298 mm)

7.4 in

(188 mm)

18.7 in

(475 mm)

27.5 lbs

(12.4 kg)

TEMPERATURE RANGES

OPERATING TEMPERATURE

RANGE

STORAGE TEMPERATURE

RANGE

-14°F to 104°F (-10°C to 40°C) -40°F to 122°F (-40°C to 50°C)

Thermal tests have been performed at ambient temperature. The duty cycle

(duty factor) at 40°C has been determined by simulation.

Process Wire Diameter Range Wire Feed Speed Range

GMAW 0.023 - 0.052” (0.6 - 1.3mm)

50 - 700 IPM (1.3 - 20.3 m/minute)

FCAW 0.035 - 5/64” (0.9 - 2.0mm)

Page 9

A-2

INSTALLATIONACTIV8X™

READ ENTIRE INSTALLATION SECTION BEFORE INSTALLING THE ACTIV8X™ .

INSTALLATION

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the disconnect switch or fuse box before attempting to connect or disconnect input power lines, output cables or control cables.

• Only qualified personnel should perform this installation.

• Do not touch metal portions of the Activ8X™ work clip when the welding power source is on.

• Do not attach the work clip to the wire feeder.

• Connect the work clip directly to the work, as close as possible to the welding arc.

• Turn power off at the welding power source before disconnecting the work clip from the work.

• Only use on power sources with open circuit voltages less than 110 VDC.

select sUitable location

For best wire feeding performance, place the Activ8X™ on a stable and dry surface. Keep the wire feeder in a vertical position. Do not operate the wire feeder on an angled surface of more than 15 degrees.

Do not submerge the Activ8X™. The Activ8X™ is rated IP23 and is suitable for outdoor use. The handle of the Activ8X™ is intended for moving the wire

feeder about the work place only. When suspending a wire feeder, insulate the hanging device from

the wire feeder enclosure.

High Frequency Interference Protection

Locate the Activ8X™ away from radio controlled machinery. The normal operation of the Activ8X™ may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

CAUTION

WARNING

Page 10

A-3

INSTALLATIONACTIV8X™

across tHe arc set-Up WitH crosslinc™ (recoMMenDeD)

Place the power source Local/Remote switch in the Remote position. In many newer models of CrossLinc compatible power sources, the Local/Remote switch is automatically overridden by CrossLinc and there is no need to set it.

across tHe arc set-Ups WitHoUt crosslinc™

CV Power Sources with Stud Connectors with Local/Remote Switch

Place the power source Remote/Local switch in the Local position.

Item

Description

K3519-1

Activ8X™ (Tweco)

K3519-2

Activ8X™ CE (Twistmate/Dinse)

- Drive Roll Kit

- Welding Gun

Flextec 350X

™

- Work Cable

- Work Clamp

- Weld Power Cable

Item

Description

K3519-1

Activ8X™ (Tweco)

K3519-2

Activ8X™ CE (Twistmate/Dinse)

- Drive Roll Kit

- Welding Gun

- CV power source

- Weld Power Cable

- Work Cable / w/ Clamp

- Lug to Tweco Adapter

CV-400

CV-600

DC-400

DC-600

DC-655

V450-PRO

SAE-400

w/ CV Adapter

Engine Drive Welder

w/ Wire Feed Module

Ranger 250 GXT

Vantage 520SD

Vantage 600

Air Vantage 600

Flextec 450

Flextec 500P

Page 11

CV Power Sources with Stud Connectors and no Remote/Local Switch

CV Power Source with Twist-Mate Connectors and no Remote/Local Switch

A-4

INSTALLATIONACTIV8X™

Ranger 250

Ranger 250 LPG

Ranger 305G

Ranger 305D

Ranger 10,000

Ranger 3 Phase

Ranger 225

Ranger 225 GXT

Commander 300

Vantage 300

Vantage 400

Vantage 500

Air Vantage 500

Air Vantage 650

SAE 300

Dual Vantage 700

Classic 300

Item

Description

K3519-1

Activ8X™ (Tweco)

K3519-2

Activ8X™ CE (Twistmate/Dinse)

- Drive Roll Kit

- Welding Gun

- CV power source

- Weld Power Cable

- Work Cable w/Clamp

- Lug to Tweco Adapter

Item

Description

K3519-1

Activ8X™ (Tweco)

K3519-2

Activ8X™ CE (Twistmate/Dinse)

- Drive Roll Kit

- Welding Gun

- CV power source

Page 12

A-5

INSTALLATIONACTIV8X™

recoMMenDeD electroDe anD WorK cable siZes For arc WelDinG

(See Table A.1) Tabulated below are copper cable sizes recommended for

different currents and duty cycles. Lengths stipulated are the distance from the welder through work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop.

triGGer connector

There is one circular connector for the gun trigger on the front of the Activ8X™

ELECTRIC SHOCK CAN KILL.

• Do not touch electrically live parts.

WARNING

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F OR 75°C)**

Amperes

PERCENT

DUTY CYCLE

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

0 to 50Ft. (0 to15m)

50 to 100Ft. (15 to 30m)

100 to 150 Ft.

(30 to 46m)

150 to 200 Ft.

(46 to 61m)

200 to 250 Ft.

(61 to 76m)

200

1 1/0

200

100

2 2

1 1/0

225

4 or 5

1/0

225

40 & 30

1/0

250

1 1/0

250

1/0

250

1 1

1/0

250

100

1 1

1 1/0

300

1 1

1/0 1/0

350

100

2/0

2/0 2/0

350

1/0 1/0

1/0

2/0 3/0

400

2/0 2/0

2/0

3/0 4/0

400

100

3/0 3/0

3/0

4/0

500

2/0

3/0 4/0

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables

larger than recommended, or cables rated higher than 167°F(75°C).

TABLE A.1

Picture Function Pin Wiring

5 PIN TRIGGER

CONNECTOR FOR

PUSH-ONLY GUNS.

A 15 VOLT SUPPLY B NOT USED C TRIGGER D 83% WFS SWITCH E 15 VOLT SUPPLY

Page 13

A-6

INSTALLATIONACTIV8X™

cHanGinG tHe GUn aDapter bUsHinG

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Do not operate with covers, panels or guards removed or open.

• Only qualified personnel should perform maintenance work.

Tools required:

• ¼" hex key wrench

Note: Some gun adapters do not require the use of the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

5. Loosen the socket head cap screw that holds the connector bar against the gun adapter. Important: Do not attempt to completely

remove the socket head cap screw.

6. Remove the outer wire guide, and push the gun adapter out of the wire drive. Because of the precision fit, light tapping may be required to remove the gun bushing.

7. Disconnect the shielding gas hose from the gun bushing, if required.

8. Connect the shielding gas hose to the new gun adapter, if required.

9. Rotate the gun adapter until the thumb screw hole aligns with the thumb screw hole in the feedplate. Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun adapter and tighten the thumb screw.

WARNING

FIGURE A.2

Thumb Screw

Gun Adapter

Outer Wire Guide

TIGHTEN

¼" Hex Key Wrench

LOOSEN

Page 14

A-7

INSTALLATIONACTIV8X™

proceDUre to install Drive rolls anD Wire GUiDes

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Do not operate with covers, panels or guards removed or open.

• Only qualified personnel should perform maintenance work.

1. Turn power off at the welding power source.

2. Release the idle roll pressure arm.

3. Remove the outer wire guide by turning the knurled thumbscrews counter-clockwise to unscrew them from the feedplate.

4. Rotate the locking hub lock and remove the drive rolls.

5. Remove the inner wire guide.

6. Insert the new inner wire guide, groove side out, over the two locating pins in the feedplate.

7. Install a drive roll on each hub assembly secure with the locking hub.

8. Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews.

9. Close the idle arm and engage the idle roll pressure arm. Adjust the pressure appropriately.

pressUre arM aDjUstMent

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Do not operate with covers, panels or guards removed or open.

• Only qualified personnel should perform maintenance work.

The pressure arm controls the amount of force the drive rolls exert on the wire. Proper adjustment of the pressure arm gives the best welding performance.

Set the pressure arm as follows:

WARNING

FIGURE A.3

Aluminum wires between 1 and 3

Cored wires between 3 and 4

Steel, Stainless wires between 4 and 6

UNLOCKED POSITION

LOCKED POSITION

Aluminum

FCAW

GMAW

Page 15

A-8

INSTALLATIONACTIV8X™

GUn connection

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Do not operate with covers, panels or guards removed or open.

• Only qualified personnel should perform maintenance work.

The Activ8X™ comes with a K1500-2 gun adapter installed, this accepts #2 - #4 guns. To install a gun,

1. Turn power OFF at the welding power source.

2. Remove the thumb screw.

3. Push the gun the completely into the gun bushing.

4. Secure the gun in place with the thumb screw.

5. Connect the trigger cable from the gun to the trigger connector on the front of the feeder.

Note: Not all gun bushings require the use of the thumb screw.

sHielDinG Gas connection

CYLINDER may explode if damaged.

• Keep cylinder upright and chained to support.

• Keep cylinder away from areas where it may be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live electrical circuits.

Build up of shielding gas may

harm health or kill.

• Shut off shielding gas supply when not in use.

• See American National Standard Z-49.1, "Safety in Welding and Cutting” Published by the American Welding Society.

Maximum inlet pressure is 100 psi. (6.9 bar.)

Install the shielding gas supply as follows:

1. Secure the cylinder to prevent it from falling.

2. Remove the cylinder cap. Inspect the cylinder valves and

regulator for damaged threads, dirt, dust, oil or grease. Remove dust and dirt with a clean cloth. DO NOT ATTACH THE

REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT!

Inform your gas supplier of this condition. Oil or grease in the presence of high pressure oxygen is explosive.

3. Stand to one side away from the outlet and open the cylinder

valve for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet.

4. Attach the flow regulator to the cylinder valve and tighten the

union nut(s) securely with a wrench. Note: if connecting to 100% CO2cylinder, insert regulator adapter between regulator and cylinder valve. If adapter is equipped with a plastic washer, be sure it is seated for connection to the CO2cylinder.

5. Attach one end of the inlet hose to the outlet fitting of the flow

regulator. Attach the other end to the welding system shielding gas inlet. Tighten the union nuts with a wrench.

6. Before opening the cylinder valve, turn the regulator adjusting

knob counterclockwise until the adjusting spring pressure is released.

7. Standing to one side, open the cylinder valve slowly a fraction

of a turn. When the cylinder pressure gage stops moving, open the valve fully.

8. The flow regulator is adjustable. Adjust it to the flow rate

recommended for the procedure and process being used before making a weld.

WARNING WARNING

Thumb screw

Page 16

B-1

OPERATION

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

ARC RAYS can burn.

• Wear eye, ear and body protection.

Observe additional Safety Guidelines detailed in the beginning of this manual.

The serviceability of a product or structure utilizing the Activ8X™ wirefeeder is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the Activ8X™ wirefeeder. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of the Activ8X™ wirefeeder may not be suitable for all applications, and the builder/user is and must be solely responsible for welding settings.

poWer-Up seQUence

If the gun trigger is activated during power up, the feeder will not operate until the gun trigger is released.

GrapHic sYMbols tHat appear on tHis MacHine or in tHis ManUal

WARNING

ACTIV8X™

INPUT VOLTAGE

WARNING OR CAUTION

HIGH TEMPERATURE

READ INSTRUCTION MANUAL

GAS INPUT

SINGLE PHASE

PROTECTIVE GROUND

OUTPUT ON

GAS PURGE

Page 17

B-2

OPERATION

case Front controls

1. Wire Feed Speed Digital Display

- The Activ8X™ has a digital display that shows the wire feed speed. This display is also capable of displaying amperage and the setup menu.

83% Wire Feed Speed The 83% wire feed speed reduces the

wire feed speed to 83% of the original set value when activated. For example, if the original wfs = 200 in/min, the feeder will regulate to 0.83 x 200 = 166 in/min.

The 83% trigger requires a gun with a dual procedure switch. This feature is often useful when welding pipe, and a “cooler”

procedure is required on the bottom portion.

2. Wire Feed Speed Knob -

Use the Wire Feed Speed Knob to set the rate of wire feed speed. The wire feed speed will be displayed on the Wire Feed Speed Digital Display. During CV operation, the wire feed speed will remain a constant value, independent of arc voltage changes, as along as the arc voltage does not drop below the values per the following table.

3. Voltage Digital Display -

The Activ8X™ has a digital display that shows the voltage between electrode and work. This display is also capable of displaying the setup menu.

4. Voltage Knob -

Use the Voltage Knob to set the voltage when connected to a CrossLinc™ Power Source. When not using a CrossLinc™ compatible power source, the Activ8X™ voltage display will show dashes. The voltage will be displayed on the Voltage Digital Display. During CV operation, the voltage will remain stable while welding.

5. Thermal LED, Motor Overload -

The thermal light illuminates when the wire drive motor draws too much current. If the thermal light illuminates, the wire drive will automatically shutdown for up to 30 seconds to allow the motor to cool. To start welding again, release the gun trigger, inspect the gun cable, liner (and conduit). Clean and make repairs as necessary. Start welding again when the problem has been safely resolved.

For best results, keep the gun cable and conduit as straight

as possible. Perform regular maintenance and cleaning on the gun liner, conduit and gun. Always use quality electrode, such as L-50 or L-56 from Lincoln Electric.

6. CrossLinc™ LED -

The CrossLinc™ LED displays whether the feeder is connected to a CrossLinc™ compatible power source. When the feeder has successfully connected to the power source, the LED will illuminate.

7. Wire Feed Speed LED -

The Wire Feed Speed and Amperage LEDs will communicate what is being displayed on the Wire Feed Speed Digital Display. When the Wire Feed Speed LED is illuminated, wire feed speed is being displayed.

8. Amperage LED -

When the Amperage LED is illuminated,

amperage is being displayed.

9. Voltage LED -

The Voltage LED will be illuminated when the Voltage Digital Display is displaying actual voltage or when its displaying with a CrossLinc™ connection.

10. Five Pin Gun Trigger Connector -

The 5 Pin Gun Trigger Connector is where the trigger that is attached to the welding gun is connected. This will actuate the welding current when the trigger is pulled.

11. Work Sense Lead -

The Work Sense Lead is used to power the feeder and communicate with the power source. Connecting the Work Sense Lead is critical for the operation of the feeder, as it will not power up if it is disconnected.

12. True Voltage Technology (TVT) -

When the TVT LED is illuminated, the CrossLinc™ enabled power source is compensating for the voltage dropped across the electrode in between the power source and Activ8X™.

Minimum Arc Volts Maximum WFS

15 V

280

17 V

340

21 V

440

24 V

520

27 V

600

ACTIV8X™

Page 18

B-3

OPERATION

internal controls

1. Pressure Arm Adjustment Knob

2. Spool Retainer

3. Spindle Brake

4. Gun Bushing

5. Thumb Screw

6. Socket Head Cap Screw for Gun Bushing

7. Drive Hubs

8. Inlet Wire Guide

9. COLD FEED / GAS PURGE SWITCH

- Place the toggle (momentary) switch in the UP position for cold feeding, or in the DOWN position for gas purge. When cold feeding, the wire drive will feed electrode but neither the feedplate nor the gas solenoid will be energized. Adjust the speed of cold feeding by rotating the WFS knob. Cold feeding, or "cold inching" the electrode is useful for threading the electrode through the gun. When gas purging, the gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on. The Gas Purge switch is useful for setting the proper flow rate of shielding gas.

10. 2 Step - Trigger Interlock Switch

- The 2 Step - Trigger Interlock switch changes the function of the gun trigger. 2 Step trigger operation turns welding on and off in direct response to the trigger. Trigger Interlock operation allows welding to continue when the trigger is released for comfort on long welds.

Place the toggle switch in the DOWN position for 2 Step

operation or in the UP position for Trigger Interlock operation.

2 Step Trigger -

2 Step trigger operation is the most common. When the gun trigger is pulled, the welding power source energizes the electrode output and the wire feeder feeds wire for welding. The power source and wire feeder continue welding until the trigger is released.

Trigger Interlock -

Trigger Interlock operation provides for operator comfort when making long welds. When the gun trigger is first pulled, the welding power source energizes the output and the wire feeder feeds wire for welding. The gun trigger is then released while the weld is made. To stop welding, the gun trigger is pulled again, and when it is released the welding power source output turns off and the wire feeder stops feeding wire.

ACTIV8X™

Page 19

B-4

OPERATION

rear controls

1. Electrode Lead

2. Shielding Gas Inlet

The serviceability of a product or structure utilizing the Activ8X™ wire feeder is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the Activ8X™ wire feeder. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of the Activ8X™ wirefeeder may not be suitable for all applications, and the builder/user is and must be solely responsible for welding settings.

CAUTION

ACTIV8X™

Page 20

B-5

OPERATION

DiGital Meter operation

CrossLinc™

When connected to a power source that supports CrossLinc™, the CrossLinc™ LED will be illuminated when a connection is made between the feeder and power source.

When connected to a power source that does not support CrossLinc™, the CrossLinc™ LED will not be illuminated.

Idle

The left display shows the preset wire feed speed. The right display shows the preset voltage when it is connected to a power source that supports CrossLinc™ and CrossLinc communication is activated.. It will display dashes when connected to a power source that does not support CrossLinc™, meaning that voltage can not be preset from the feeder and must be set at the power source.

When connected to a power source with CrossLinc

™

When connected to a power source without CrossLinc

™

During Welding

The value in the left display will be either amps or actual wire feed speed, depending upon the selection chosen in the set-up menu. The corresponding LED below the display will light. Note that actual WFS may not match preset WFS, if welding at low voltages with high wire feed speeds. The right display shows the arc voltage. If the wire feeder is connected for electrode negative welding, then the voltage display shows a minus sign.

After Welding

The display continues to hold the value of the amperage or WFS and arc voltage for ten seconds after welding stops. The amperage or WFS and voltage displays flash. For 10 sec or until the WFS or V knobs are rotated.

Wire Feed Speed Voltage Preset

200 180

Wire Feed Speed

200 ----

Actual Amperage

300 -257

Actual Voltage

ACTIV8X™

CrossLinc™

Page 21

B-6

OPERATION

setUp MenU operation

The Activ8X™ setup menu is accessed through the hidden setup menu push button that is located below a small hole just right of the right 4 digit display.

To enter the setup menu, use a paper clip to quickly press and release the small button located to the right of the voltage display on the front of the Activ8X™.

The setup menu settings (in order) are:

• Wire feed speed units (metric or English)

• Preflow time

• Run in wire feed speed

• Burnback time

• Postflow time

• Display of actual wire feed speed or arc current

• Arc hours display on/off

• After weld display hold time

• True Voltage Technology (TVT) enable/disable

• CrossLinc™ enable/disable

• CC or CV power source

• Wire feed speed calibration

• Arc voltage display calibration

• Arc current display calibration

The left display will show the menu item, and the right display will show the set value.

The left encoder is used to select the setup menu item to be changed. The right encoder will be used to change the set value.

While in the setup menu, there are 3 ways to exit the menu and return to showing preset settings on the displays.

1. A quick press and release of the setup button.

2. A quick gun trigger closure and release.

3. 30 seconds of inactivity while in the setup menu.

ACTIV8X™

Page 22

B-7

OPERATION

ACTIV8X™

Setup Menu Item

Left

Display

Right

Display

Factory Default

Description

Wire feed speed units

US / Euro

US*

Changes the display of wire feed speed between inches per minute (US) and meters per minute (Euro)

Preflow time

PrE / FLo

OFF / 0.10 -

10.0

OFF

The preflow timer range is OFF to 10 seconds. Preflow time is the time delay from when the trigger is pulled to when the wire starts to feed and is energized. Preflow is used to purge the welding gun with shielding gas and helps to minimize porosity at the start of the weld.

Run in wire feed speed

run

OFF/ 10 /

20/ 30 / 40/

OFF

"Run-in” refers to the wire feed speed during the time from when the trigger is pulled to when an arc is struck. The RunIn range is Off, 10%,20%,30%,40%,50% of the set welding wire feed speed.When a number is displayed, the Run-in wire feed speed is that percentage of the welding wire feed speed until an arc is struck. When Run-in is “OFF”, the wire feed speed is the same as the welding wire feed speed. Turn Run-In “OFF” for fast, crisp starts, especially when running with .035 or .045 (0.9 or 1.2mm) solid steel wires at high wire feed speeds.

Burnback time

burn /

bAC

OFF / 0.030

- 0.250

OFF

The burnback timer controls the additional amount of time the power source output remains ON after the wire drive has stopped feeding wire. The range for Burnback is Off, 0.1010sec. Burnback adjustment prevents the wire from sticking to the weld at the end of a weld and helps to condition the wire for the next weld.

Postflow time

POSt /

Flo

OFF / 0.10 -

10.0

OFF

Postflow is the time from when the power source output turns off until the postflow timer expires. The range for Postflow gas time is Off, .1-10sec. Use postflow to protect the weld while the weld cools.

Display of actual wire feed speed or arc current

dISP Curr / FEEd

Curr

The left display can show either amperage (CUrr) or actual WFS (FEEd) during welding.

Arc hours display on/off

hrS OFF / On

OFF

When on, the cumulative arc hours and arc minutes will be displayed at power on.

After weld display hold time

hoLd

5 or 300 /

SEC

The display of the actual wire feed speed or amperage and voltage after welding has stopped will be held for either 5 seconds or 300 seconds.

True Voltage Technology (TVT) enable/disable

tUt OFF / On

Turns TVT functionality on or off.

CrossLinc™ enable/disable

CroS /

LInC

OFF / On

Turns CrossLinc™ functionality on or off. TVT is operational only when CrossLinc™ is on.

CC or CV power source

CV / CC

By default, CrossLinc is active and it is assumed the Activ8X is being used with a CV output power source. In this case, voltage will be presettable at the feeder and WFS will be the actual WFS. When used with a CC output only power source, voltage will not be presettable at the feeder and WFS will be a function of the WFS setting and the actual welding voltage. (refer to Fig B.4)

*K3519-2 has a factory default of EURO

Page 23

B-8

OPERATION

ACTIV8X™

Setup Menu Item

Left

Display

Right

Display

Factory Default

Description

Wire feed speed calibration

SPd / CAL 0.95 - 1.05

This is used to calibrate the wfs meter to a known calibrated wfs meter. To calibrate the wire feed speed, before entering the set-up menu:

• Set the display to the desired wire feed speed (example: 400 inches per minute)

• Measure the actual wire feed speed (example: 405 inches per minute)

While in the set-up menu, adjust the calibration factor as follows:

Actual WFS / Set WFS = Calibration factor Example: 405 / 400 = 1.01

Arc voltage display calibration

UOL / CAL 0.90 - 1.10

This is used to calibrate the voltage meter. To calibrate the arc voltage display, before entering the setup menu:

• Determine the ratio of the actual arc voltage and the arc voltage displayed.

While in the setup menu, adjust the calibration factor as follows:

Actual arc voltage / displayed arc voltage = calibration factor Example: 20.0 / 20.5 = 0.97

Arc current display calibration

Cur / CAL 0.90 - 1.10

This is used to calibrate the current meter to a know calibrated voltmeter. To calibrate the arc current display, before entering the setup menu:

• Determine the ratio of the actual arc current displayed by the power source and the current displayed by the wire feeder.

While in the setup menu, adjust the calibration factor as follows:

Power source displayed arc current / Wire feeder displayed arc current = calibration factor

Example: 205 / 200 = 1.03

Page 24

B-9

OPERATION

ACTIV8X™

constant cUrrent operation

Setting Wire Feed Speed in CC mode

When Across the Arc models are operated with CC power sources, the wire feed speed changes as the arc voltage changes. When the arc voltage increases, the wire feed speed will increase; and when the arc voltage decreases, the wire feed speed will decrease. To preset the wire feed speed on CC power sources:

1. Set the Activ8X™ to "CC" in the setup menu.

2. Refer to the Figure B.4 graph to determine CC setting of the wire feed speed knob. Select the horizontal line representing the Desired Wire Feed Speed. (See Figure B.4 arrow for 375 in/min.)

3. Select the diagonal line representing the Arc Volts. (See Figure B.4 for 29 volts.)

4. Determine the vertical line representing the CC Wire Feed Speed setting where the above two lines cross. (See Figure B.4 arrow line for 450.) Set the Activ8X™ wire feed speed knob to this value.

CC WFS dial setting = desired WFS x 35

Arc Volts

Example:

375 in/min. (Horizontal Line) x 35 29 Arc Volts (Diagonal Line)

= 452.5 (Vertical Line)

(See Figure B.4)

(Actual wire feed speed)

100

150

200

250

300

350

400

450

500

550

600

650

700

50 100 150

FIGURE B.4

A constant voltage (CV) power source is recommended for flux-cored arc welding. (FCAW) and gas metal arc welding (GMAW) to obtain code quality results. However, this wire feeder may also be used with a constant current (CC) power source to obtain passable results for noncritical quality applications.

ARC VOLTS

Use 450 setting

200 250

300 350

400

450 500

550

600

650 700

Page 25

B-10

OPERATION

ACTIV8X™

constant cUrrent operation

Lincoln Electric does NOT recommend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality requirements.

Most semiautomatic welding processes perform better using constant voltage power sources.

Welding codes usually do not address the power source selection or specifically, whether the welding process is to be operated in the constant voltage or constant current mode. Instead, codes typically specify limitations on the current, voltage, heat input and preheat temperature based on the material to be welded. The intention is to assure that proper weld material properties will develop.

Welding is sometimes performed using constant current power sources. The operation can be more convenient because it may allow the use of an existing stick (SMAW) power source and the power source can be placed at a distant location without any provision for adjusting the output settings.

For constant current operation, the power source is set to deliver the specified current. The power source regulates this current regardless of changes in the welding circuit, including cable length, electrode diameter, wire feed speed, contact tip to work distance, etc.

Changes in the wire feed speed (WFS) or contact tip to work distance (CTWD) affect the arc voltage when constant current power sources are used. Lowering the wire feed speed raises the voltage, raising the wire feed speed lowers the voltage. Lengthening the contact tip to work distance raises the voltage, shortening the contact tip to work distance lowers the voltage.

If the contact tip to work distance is properly maintained, a satisfactory operating voltage range may be achieved, and a sound weld may result. However, when a welder uses a longer contact tip to work distance, an arc-sensing wire feeder compensates by increasing the wire feed speed to regulate the voltage. Even if the voltage and current remain unchanged, the increased wire feed speed may result in a deposition rate well beyond the specified range of the electrode. Under these conditions, the specified weld metal properties may not be achieved.

Constant voltage power sources deliver large current surges to stabilize the arc when the electrode is shorted or the

arc length is very short. However, a constant current power source does not provide such a response to stabilize the arc. It may be difficult to achieve required weld metal properties, or to achieve the required quality of welds needed to pass nondestructive tests, when such welds are made under constant current operation.

For these reasons, Lincoln Electric does NOT recommend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality requirements.

CAUTION

Constant Current Power Source

Current

Wire Feeder

WFS

CTWD

Welding Cable (Electrode)

Welding Cable (Work)

GUN AND CABLE ASSEMBLY

FIGURE B.5

Page 26

C-1

OPTIONS/ACCESSORIES

The following options/accessories are available for your Activ8X™ from your local Lincoln Electric Distributor.

ACTIV8X™

ACCESSORIES

DRIVE ROLL KITS, 2 ROLL DRIVE

Steel Wire Drive Roll Kits

KP1696-030S .023-.030 (0.6-0.8MM)

INCLUDES:

2 V GROOVE DRIVE ROLLS AND

INNER WIRE GUIDE.

KP1696-035S .035 (0.9MM)

KP1696-045S .045 (1.2MM)

KP1696-052S .052 (1.4MM)

KP1696-1/16S 1/16 (1.6MM)

KP1696-1 .035,.045 (0.9, 1.2MM)

KP1696-2 .040 (1.0MM)

Cored Wire Drive Roll Kits

KP1697-035C .030-.035" (0.8-0.9MM)

INCLUDES:

2 KNURLED DRIVE ROLLS AND

INNER WIRE GUIDE.

KP1697-045C .040-.045" (1.0-1.2MM)

KP1697-052C .052" (1.4MM)

KP1697-1/16C 1/16" (1.6MM)

KP1697-068 .068-.072" (1.7-1.8MM)

KP1697-5/64 5/64" (2.0MM)

Page 27

C-1

ACCESSORIES

Optional Kits & Accessories

K2485-2 Weld Cable Tweco Male to Tweco Female (2/0), 50ft.

K2485-3 Weld Cable Tweco Male to Tweco Female (3/0), 50ft.

K2487-1 Lug to Tweco Female adapter.

K489-7

Feed Plate Adapter

for Lincoln Fast-Mate guns.) Includes: Gun receiver

bushing with trigger connector.

K586-1

Deluxe Adjustable Gas Regulator

Includes: Deluxe Gas Regulator for Mixed Gases, Adapter for CO2 and 10' (3.0m) Hose.

K283

Wire Feed Speed Meter

Includes: A wire feed speed meter with digital display.

K910-1 & K910-2

Work Clamp

Jaws open full 2-1/2 inches (63 mm). Welding cable lug bolts directly to the work clamp. 60% duty cycle. Select K910-1 for 300 Amp applications. K910-2 for 500 Amp.

K1500-1

Feed Plate Adapter

(for guns with K466-1 Lincoln gun connectors; Innershield and Subarc guns)

Includes: Gun receiver bushing, set screw and hex key wrench.

ACTIV8X™

Page 28

D-1

MAINTENANCE

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Do not operate with covers, panels or guards removed or open.

• Only qualified personnel should perform maintenance work.

roUtine Maintenance

• Check weld cables and gas hoses for cuts.

• Clean and tighten all weld terminals.

perioDic Maintenance

• Clean the drive rolls and inner wire guide and replace if worn.

• Blow out or vacuum the inside of the feeder.

WARNING

ACTIV8X™

MAINTENANCE

Page 29

E-1

TROUBLESHOOTING

ACTIV8X™

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS).” This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF

ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

TROUBLESHOOTING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result 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 safety notes and precautions detailed throughout this manual.

WARNING

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

Page 30

Observe all Safety Guidelines detailed throughout this manual

E-2

TROUBLESHOOTING

ACTIV8X™

PROBLEM

POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION

Err 81 Motor overload, long term

The wire drive motor has overheated.

1. Check that the electrode slides easily through the gun and cable.

2. Remove tight bends from the gun and cable.

3. Check that the spindle brake is not too tight.

4. Verify a high quality electrode is being used.

5. Wait for the error to reset and the motor to cool (approximately 1 minute).

6. Clean/inspect/replace liner.

Err 82 Motor overload, short term

The wire drive motor current draw has exceeded limits, usually because the motor is in a locked rotor state.

1. Check that motor can turn freely when idle arm is open.

2. Verify that the gears are free of debris and dirt.

Output Problems

The feeder does power up no voltage, no cold feed.

1. The work sense lead has a poor electrical connection.

2. No output from power source.

1. Connect the work sense lead to the work in a location free of dirt, rust and paint.

2. Won’t power up if power source is off.

The wire feeder powers up but there is no output when the trigger is pulled. The shielding gas is flowing and the drive rolls turn

1. The contactor coil connections are loose.

2. The contactor has failed.

1. Verify the contactor coil connections.

2. Replace the contactor.

No shielding gas. 1. The gas supply is OFF or

empty.

2. The gas hose is cut or crushed

3. Dirt or debris is in the solenoid.

4. There is a loose solenoid connection.

5. The solenoid has failed.

1. Verify the gas supply is ON and flowing.

2. Route the gas hose so it avoids sharp corners and make sure nothing is on top of it. Repair or replace damaged hoses.

3. Open the flow meter valve.

4. Apply filtered shop at 80psi to the solenoid to remove dirt.

5. Remove the cover and check that all connections are in good condition.

Inconsistent wire feeding or wire not feeding but drive rolls turning.

1. The gun cable is kinked and/or twisted

2. The wire is jammed in the gun and cable.

3. The gun liner is dirty or worn.

4. The electrode is rusty or dirty.

5. The contact tip is partially melted or has spatter.

6. Improper gun liner, tip, drive

1. Keep the gun cable as straight as possible. Avoid sharp corners or bends in the cable.

2. Remove the gun from the wire feeder and pull the jammed wire out of the gun and cable.

3. Blow dirt out of the liner with low pressure (40psi or less). Replace the liner if worn.

4. Replace contact tip.

WWW.LINCOLNELECTRIC.COM/LOCATOR

Page 31

E-3

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING

ACTIV8X™

PROBLEM

POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION

Inconsistent wire feeding or wire not feeding but drive rolls turning.

6. Improper gun liner, tip, drive rolls and/or inner wire guide.

7. Incorrect tension arm pressure on the drive rolls.

8. The spindle brake is too tight.

9. Worn drive roll.

6. Verify the proper parts are installed.

7. Adjust the tension arm per the Instruction Manual. Most electrodes feed well at a tension arm setting of "3".

8. Verify the spool of wire moves with minimal effort.

9. Replace the drive rolls if worn or filled with dirt.

Wire feed speed consistently operates at the wrong value. The speed changes when the wire feed speed knob is adjusted.

1. The wrong gear is installed in the wire drive.

2. The brushes on the motor are worn.

1. Install the proper pinion gear in the wire drive.

2. Replace the motor/gearbox assembly.

The wire feed speed stuck at 200-300 in/min and there is no change when the wire feed speed knob is adjusted.

1. The tachometer is connected improperly.

2. The tachometer has failed.

1. Verify all of the tachometer leads are properly connected.

2. Replace the motor and tachometer assembly.

Variable or "hunting" arc. 1. Wrong size, worn and/or

melted contact tip

2. Worn work cable or poor work connection.

3. Wrong polarity.

4. The gas nozzle is extended beyond the contact tip or the wire stickout is too long.

5. Poor gas shielding on processes requiring gas.

1. Replace the contact tip.

2. Verify all work and electrode connections are tight and that the cables are in good condition. Clean/replace as necessary.

3. Adjust polarity to the recommended procedure. Verify DIP switch #7 setting matches the electrode polarity.

4. Adjust the gas nozzle and shorten the stickout to ½ to ¾ inches.

5. Check gas flow and mixture. Remove or block sources of drafts.

When the trigger is pulled, the wire feeds slowly.

The Run-In set to “ON” Use the set-up Push-button to turn Run-in OFF.

Poor arc starts with sticking or "blast-offs", weld porosity, narrow and ropy looking bead.

Improper procedures or

techniques.

See "Gas Metal Arc Welding Guide" (GS-100)

WWW.LINCOLNELECTRIC.COM/LOCATOR

Page 32

E-4

DIAGRAMS

ACTIV8X™

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 Department for a replacement. Give the equipment code number.

CONTROL P.C. BO ARD

CLEVELAND, OHIO U.S.A.

WIRING DIAGRAM- ACTIV8X

A.03

G9130PRINT

FEED

PLATE

P53/J53

MOTOR /

GEARBOX

TACH

531

TRIGGER

INTERLOCK /

2 STEP

563

1 2345678910 11 12 13 14 15 16

537

534

551

550

432

NOTES:

N.A. SWITCHES SHOWN FROM REAR CONNEC TION SIDE OF SWITCH.

587A

N.A.

1234567

10 11 12

500

622

509A

530

690

531

537

587

507

612

509

509B

2345678910

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

LEAD COLOR CODING

B - BLACK R - RED

W - WHITE U - BLUE

507 578

CONTACTOR COIL

CONTACTOR

550

667

67A

821B

(SHOWN IN 2 STEP)

J1, J2

CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)

J3, J5,

J52, J53

J32, J54

P14

J55,

J61, J62

J4, J31

555

500A

TRIGGER

CONNECTOR

622A

P14

622B

555A

COLD

FEED /

GAS

PURGE

530A

509B

612A

MOTOR FILTER P. C. BOARD

1234

J61

667D B1

667

67B

INPUT ELECTRODE

CABLE CONNECTION

821C

821B

TO WORK CLIP

661

67B

621

BRIDGE

RECTIFIER

563

N.A.

511

512

513

517

518

519

510

707

708

563

J31

J32

563

J33 FOR

PROGRAMMING

ONLY

U.I. PC BOARD

512

707

517

519

661A

821A

511

510

708

513

518

821A

661A

1234

J62

CURRENT

TRANSDUCER

805

804

801

802

805

804

FOR

PROGRAMMING

ONLY

661

BRIDGE

RECTIFIER

667D

578691

534

551

690

691

GAS

SOLENOID

821D

802

801

67A

67B

BLACK

RED

FAN

J52/P52

563

RED

BLACK

621

P55/J55

500

622

J54/P54

2 1

530

612

509

509A

587

587A

555

Page 33

E-5

DIAGRAMS

ACTIV8X™

L17408

A.01



13.00 CIRCLE

11.55

18.55

7.49

11.84

11.00 X 14.00 ELLIPSE

Page 34

WARNING

panish

AVISO DE

PRECAUCION

French

ATTENTION

erman

WARNUNG

ortuguese

ATENÇÃO

Japanese

Chinese

l Do not touch electrically live parts or

electrode with skin or wet clothing.

l Insulate yourself from work and

ground.

No toque las partes o los electrodos bajo carga con la piel o ropa mojada.

l Aislese del trabajo y de la tierra.

l Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

l Isolieren Sie sich von den

Elektroden und dem Erdboden!

l Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

Isole-se da peça e terra.

l Keep flammable materials away.

Mantenga el material combustible fuera del área de trabajo.

Gardez à l’écart de tout matériel inflammable.

l Entfernen Sie brennbarres Material!

Mantenha inflamáveis bem guardados.

l Wear eye, ear and body protection.

Protéjase los ojos, los oídos y el cuerpo.

Protégez vos yeux, vos oreilles et votre corps.

l Tragen Sie Augen-, Ohren- und Kör-

perschutz!

Use proteção para a vista, ouvido e corpo.

Korean

Arabic

READ AND UNDERSTAND 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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 35

l Keep your head out of fumes. l Use ventilation or exhaust to

remove fumes from breathing zone.

l Turn power off before servicing.

l Do not operate with panel open or

guards off.

WARNING

l Los humos fuera de la zona de res-

piración.

l Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

l Gardez la tête à l’écart des fumées. l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

Vermeiden Sie das Einatmen von Schweibrauch!

l Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça. l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

l Débranchez le courant avant l’entre-

tien.

Strom vor Wartungsarbeiten abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

l Não opere com as tampas removidas. l Desligue a corrente antes de fazer

serviço.

Não toque as partes elétricas nuas.

l No operar con panel abierto o

guardas quitadas.

l N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in Betrieb setzen!

Mantenha-se afastado das partes moventes.

l Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

rench

ATTENTION

German

WARNUNG

ortuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 36

cUstoMer assistance policY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

TABLE OF CONTENTS GENERAL DESCRIPTION INSTALLATION OPERATION ACCESSORIES MAINTENANCE TROUBLE SHOOTING DIAGRAMS