Lincoln Electric CrossLinc K4345-1 Operator's Manual

Operator’s Manual

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CrossLinc

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Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10369 | Issue D ate Nov-16

Need Help? Call 1.888.935.3877

to talk to a Service Representative

Hours of Operation:

8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours?

Use “Ask the Experts” at lincolnelectric.com A Lincoln Service Representative will contact you no later than the following business day.

For Service outside the USA:

Email: globalservice@lincolnelectric.com

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

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

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

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

CROSSLINC™ REMOTE

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2

CROSSLINC™ REMOTE

ESCRIPTION

D

General Physical DescriPtion

The CrossLinc Remote is a portable unit which is connected at the

elding arc and allows the user to remotely control the welding

w output without the use of control cables. The remote is small and lightweight. It has LC-40HD style connections to the welding cables for easy connection and disconnection. The CrossLinc remote also has rubber corner caps and the controls themselves

re protected for extra durability. When the remote is connected

a to any CrossLinc compatible power source

1)

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, the output can be

adjusted in constant current or constant voltage modes.

General Functional DescriPtion

To use the CrossLinc Remote, connect the LC-40HD connectors to the electrode cable and connect the work clip to the workpiece. Once connected, the remote will power up immediately and automatically pair with the power source. Once the remote is paired, the power source preset can be adjusted with no additional control cable. The display on the front of the remote will show the preset value of current or voltage when not welding. The remote will show actual voltage or current while welding, and hold the last known current or voltage for 10 seconds after welding is finished so that the user can verify his process settings.

recoMMenDeD Processes

• GTAW

• SMAW

• GMAW (with an across-the-arc wire feeder)

• FCAW-G (with an across-the-arc wire feeder)

• FCAW-S (with an across-the-arc wire feeder)

DesiGn Features

• CrossLinc Technology

- Allows for the adjustment of preset without cumbersome ontrol cables

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Allows the welder to get the right settings every time

-

without having to return to the power source

- No more control cables to carry, repair or trip over

• Digital display with 4 digits shows workpoint

• Encoder for full range workpoint adjustment

• LC-40HD connectors standard for easy setup

• Digital meters show actual voltage or current during welding

Process liMitations

Not compatible with high frequency GTAW

eQuiPMent liMitations

• The CrossLinc Remote can only be used with CrossLinc compatible power sources

• CrossLinc can not change preset while welding

recoMMenDeD PoWer sources

• Flextec 350X

• Flextec 650X

(1) The CrossLinc Remote is not compatible with Flextec 350 Power Sources

with code numbers below 12600.

3

CROSSLINC™ REMOTE

INSTALLATION

TECHNICAL SPECIFICATIONS -

K4345-1 - CrossLinc Remote

NSTALLATION

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Input Amperes

RATED OUTPUT

Duty Cycle Amperes

14-110 VDC

60% 550

100% 425

PHYSICAL DIMENSIONS

Model

Height

Width

Depth

Weight

Operating

Temperature

Storage

Temperature

TEMPERATURE RANGES

-40°F TO 104°F (-40°C TO 40°C)

-40°F TO 122°F (-40°C TO 50°C)

K4345-1

7.75”

10.0”

4.5”

10 LB

1

Thermal tests have been performed at ambient temperature. The duty cycle (duty factor) at 40°C has been determined by simulation.

4

CROSSLINC™ REMOTE

Read this entire installation section before you start installation.

Safety Precautions

Do not attempt to use this equipment until you have thoroughly read all installation, operating and maintenance information supplied with your equipment. They include important safety precautions and detailed operating and maintenance instructions.

WARNING

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 CrossLinc Remote work clip when the welding power source is on.

• Do not attach the work clip to the remote.

• 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 90 VDC.

NSTALLATION

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select suitable location

Do not submerge the CrossLinc Remote.

The CrossLinc Remote is suitable for outdoor use.

hiGh FreQuency Protection

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

5

CROSSLINC™ REMOTE

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NSTALLATION

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CROSSLINC™ REMOTE

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CROSSLINC™ REMOTE

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The CrossLinc Remote can be connected in series with some across-the-arc wire feeders to allow for remote output control without a CrossLinc capable wire feeder. The compatible feeders are listed below:

• LN-25

• LN-25 Pro Analog

• Activ8

• LN-15

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PRO

or

8

CROSSLINC™ REMOTE

recoMMenDeD electroDe anD WorK cable

iZes For arc WelDinG

s

abulated below are copper cable sizes recommended for

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

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

NSTALLATION

I

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

0 TO 50 FT. 50 TO 100 FT. 100 TO 150 FT. 150 TO 200 FT. 200 TO 250 FT.

AMPERES

PERCENT DUTY

CYCLE

200 60 2 2 2 1 1/0

200 100 2 2 2 1 1/0

225 20 4 OR 5 3 2 1 1/0

225 40 & 30 3 3 2 1 1/0

250 30 3 3 2 1 1/0

250 40 2 2 1 1 1/0

250 60 1 1 1 1 1/0

250 100 1 1 1 1 1/0

300 60 1 1 1 1/0 2/0

325 100 2/0 2/0 2/0 2/0 3/0

350 60 1/0 1/0 2/0 2/0 3/0

400 60 2/0 2/0 2/0 3/0 4/0

400 100 3/0 3/0 3/0 3/0 4/0

500 60 2/0 2/0 3/0 3/0 4/0

** Tabled values are for operation at ambient temperatures of 40°C and

below. Applications above 40°C may require cables larger than recommended, or cables rated higher than 75°C

9

CROSSLINC™ REMOTE

OPERATION

Read and understand this entire section before operating your CrossLinc Remote.

Safety Precautions

Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your equipment and any related welding

achine it will be used with. They include important safety

m precautions, operating and maintenance instructions and parts lists.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as

output terminals or internal wiring.

• Insulate yourself from the work and

ground.

• Always wear dry insulating gloves.

nly qualified personnel should operate this equipment.

O

PERATION

O

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld upon containers which have

held combustibles.

ARC RAYS can burn.

• Wear eye, ear and body protection.

FUMES AND GASES can be dangerous.

Although the removal of the particulate matter from welding smoke may reduce the ventilation requirement, concentrations of the clear exhausted fumes and gases may still be hazardous to health. Avoid breathing concentrations of these fumes and gases. Use adequate ventilation when welding. See ANSI Z49.1, "Safety in Welding and Cutting", published by the American Welding Society.

10

CROSSLINC™ REMOTE















ase Front controls

c

Refer to Figure A.1:

1) Digital Display - The CrossLinc™ Remote has a digital display that shows the preset. This display shows actual amps or volts during welding. After welding, the digital display will flash and display the last known voltage or

mperage.

a

2) Amperage LED - This LED indicates whether amps is being displayed on the digital display.

3) Output Control Knob - This knob is used to adjust the preset amps or volts depending on the mode selected at the power source. The preset value will be displayed on the digital display.

4) Volts LED - This LED indicates whether volts is being displayed on the digital display.

5) CrossLinc™ Communication LED - The CrossLinc™ Communication LED displays whether the feeder is connected to the power source. When the power feeder is searching for a connection, or is connected to a power source that does not support CrossLinc™, the LED will not illuminate. When the feeder has successfully connected to the power source, the LED will be illuminated.

PERATION

O

6) Setup Button (hidden) - The setup button is located to the right of the digital display. It is accessed by using a paperclip to press it through a pinhole in the nameplate. This button enters the setup menu to change optional settings.

7) Input Cable (from Power Source) - The remote is equipped

ith a 4/0 input cable with an LC40HD male style connector.

w Connect this cable to the power source output.

8) Output Cable (to Electrode) Output Cable - The remote is equipped with a 4/0 output cable with an LC40HD female style connector. Connect this cable to the electrode holder, torch, or across-the-arc wire feeder.

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

FIGURE B.1

11

1

2

.

3

2

4

0

CROSSLINC™ REMOTE

PERATION

O

VerVieW oF oPeration

o

The CrossLinc Remote will power up when the work clip is connected to the workpiece and the output studs of the welding power source are ON. Once it is powered up, the remote will establish a CrossLinc connection with the power source. When

he connection is established, the CrossLinc LED will light green

t and workpoint will be displayed on the remote. Now the remote is ready for use and the power source output can be adjusted using the control knob.

An example of the display when ready for use is shown below:

FIGURE B.2

In this case the current is set for 240 amps.

If the remote displays a negative sign before the setpoint, it indicates that the remote is connected for negative polarity.

Once a CrossLinc connection is established, the remote overrides the Local setting of the power source, even if is set in “Local” control mode. Then, when the remote is disconnected, the power source will return to the local setting after 15 seconds.

If Arc Hours display is enabled (see setup menu for instructions on how to enable), then the accumulated arc hours will be displayed for 5 seconds after startup. The time will be in the format HH.MM as shown in the example below. In the example, the accumulated arc time is 12 hours and 33 minutes.

FIGURE B.3

arbon arc GouGinG

c

CrossLinc technology allows the user to switch between welding and gouging easily, without returning to the power source. In order to gouge, use the following setup instructions:

1. Set the Local/Remote output switch on the power source to “Local”, with the CrossLinc Remote disconnected.

2. Adjust the output control knob on the power source to the desired gouging output level. (Example: 700A)

3. Connect the CrossLinc Remote with stick electrode holder and turn the weld terminals ON. At this point, the CrossLinc Remote will take over output control.

4. Adjust the CrossLinc Remote to the desired welding output level. (Example: 125A for 1/8” E7018 stick welding).

5. Continue to weld with the CrossLinc Remote connected, adjusting the output on the remote as required.

6. When gouging is required, disconnect the CrossLinc Remote and replace it with an arc gouging torch.

7. Once the CrossLinc Remote is disconnected, the power source will return to the output setting from the output control knob on the power source. In this example, 700A.

8. Gouge at 700A for as long as is desired.

9. When gouging is complete, reconnect the CrossLinc Remote, and it will take over output control again.

NOTE: The same weld mode must be used for both gouging and

welding with this procedure. For example, if stick welding is being done, gouging must be performed in SMAW mode.

FIGURE B.4

al

oc

L

:

ch

Swit

trol

Con

t

u

p

t

Ou

AW

SM

:

Switch

e

Mod

Amps

ng

Gougi

:

g

tin

Set

t

u

tp

Ou

Local

t

Presen

(If

Switch

als

ermin

T

Weld

Disconnect for

Gouging

ON

):

When the arc time reaches 99.59, it will roll over to 00.00 and start counting again.

Electrode Holder

Arc Gouging Torch

12

h

r

5

8

h

o

l

d

c

u

f

b

CROSSLINC™ REMOTE

PERATION

O

et-uP Menu

s

To enter the set-up menu:

To enter the set-up menu, use paper clip to press the small button located below the Display on the case front.

FIGURE B.4

arc hours

The first option in the setup menu will be for Arc Hours. If this option is turned “ON”, accumulated arc hours will be displayed on power up. When in the setup option for Arc Hours the display will show the following:

FIGURE B.5

etup Button

S

oltMeter/aMMeter holD tiMe

V

The CrossLinc Remote will display the actual amperage or voltage after welding has stopped. The hold time option will hold these values for either 10 seconds or 300 seconds. When in the setup option for hold time, the display will show the following:

FIGURE B.6

To set the hold time to 10 seconds, turn the output control knob to the left. To set the hold time to 300 seconds, turn the output control knob to the right.

The factory default is 10 seconds.

cV FeeDbacK

When being used in a constant voltage mode, the CrossLinc Remote can be set to display either actual voltage or actual current during welding and during the hold time. When in the setup menu for CV Feedback, the display will show the following:

FIGURE B.7

To enable Arc Hours display, turn the control knob to the right while in this menu. To disable Arc Hours display, turn the control knob left.

The factory default for Arc Hours is “OFF”.

The feedback type is indicated by which LED is lit, either “A” or “V”. If the “A” LED is lit while in this menu, the CrossLinc Remote will display actual current while welding in a CV mode. If the “V” LED is lit, the CrossLinc Remote will display actual voltage while welding in a CV mode.

To choose current, turn the output control knob to the left. To choose voltage, turn the output control knob to the right.

The factory default is voltage.

13

v

o

L

C

U

r

S

t

3

CROSSLINC™ REMOTE

PERATION

O

utoMatic tiG

a

The CrossLinc Remote can automatically optimize the power source settings for scratch start TIG operation when it is connected for electrode negative polarity and the power source is in the SMAW mode. This must be disabled if stick welding with

egative polarity. When in the setup menu for Automatic TIG, the

n display will show the following:

IGURE B.8

F

Turn the knob to the right to select “Auto” TIG.

Turn the knob to the left to select “off”. This setting must be turned “off” to stick weld with negative polarity.

The factory default is “Auto”.

VoltaGe calibration

To calibrate the arc voltage display, before entering the setup menu:

• Determine the ratio of the actual arc voltage and the arc voltage displayed by the CrossLinc Remote.

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)

The calibration factor is factory set as 1.00

When in the setup menu for voltage calibration the display will show the following:

FIGURE B.9

urrent calibration

c

To calibrate the arc current display, before entering the setup menu:

• Determine the ratio of the actual arc current and the arc current displayed by the CrossLinc Remote.

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

Actual arc current / displayed arc current = calibration factor (Example: 200 / 205 = 0.97)

The calibration factor is factory set as 1.00

When in the setup menu for current calibration the display will show the following:

FIGURE B.10

Turn the knob to the right to increase the calibration factor, and to the left to decrease the calibration factor.

The factory default is 1.00.

Factory reset

In order to reset your setup parameters to the factory default, hold the setup button for 5 seconds while the remote is in an idle state. While resetting, the displays will show the following. The last digit is the seconds to reset. At the end of the countdown, the reset will take place and the display will return to its idle state. If the setup button is released before the countdown is complete, the reset will not take place.

FIGURE B.11

Turn the knob to the right to increase the calibration factor, and to the left to decrease the calibration factor.

The factory default is 1.00

14

CROSSLINC™ REMOTE

OPTIONAL KITS AND

ACCESSORIES

CCESSORIES

A

Product Number

K2483-2

K2483-3

K2484-2

K2484-3

K2485-2

K2485-3

K2487-10

K3416-70

K3416-90

K3417-70

K3417-90

DESCRIPTION

2/0 WELD CABLE WITH LC40 MALE CONNECTOR AND BARE END - 10 FT

3/0 WELD CABLE WITH LC40HD MALE CONNECTOR AND BARE END - 10 FT

2/0 WELD CABLE WITH LC40 MALE CONNECTOR AND 0.53" LUG - 50 FT

3/0 WELD CABLE WITH LC40HD MALE CONNECTOR AND 0.53" LUG - 50 FT

2/0 WELD CABLE WITH LC40 MALE AND FEMALE CONNECTOR - 50 FT

3/0 WELD CABLE WITH LC40HD MALE AND FEMALE CONNECTOR - 50 FT

INSULATED ADAPTER FOR OUTPUT STUD TO FEMALE LC40HD

LC40 FEMALE CONNECTOR (1/0 THRU 2/0)

LC-40HD FEMALE CONNECTOR (3/0 THRU 4/0)

LC40 MALE CONNECTOR (1/0 THRU 2/0)

LC-40HDMALE CONNECTOR (3/0 THRU 4/0)

15

CROSSLINC™ REMOTE

AINTENANCE

M

MAINTENANCE

WARNING

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.

Clean and tighten all welding cable connections.

PerioDic Maintenance

Blow out or vacuum the inside of the remote.

TROUBLESHOOTING

hoW to use troubleshootinG GuiDe

WARNING

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

etailed throughout this manual.

d

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the threestep 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 you 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.

E

WARNING

ELECTRIC SHOCK can kill.

• Turn off machine at the disconnect switch on the rear of the machine and remove main power supply connections before doing any troubleshooting.

16

ROSSLINC REMOTE

C

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

PROBLEM

(SYMPTOMS)

The remote does power up. No LEDs or displays are lit.

The display shows “---“ constantly at idle. The green CrossLinc light is not lit.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

1. The work sense lead is disconnected or is a poor electrical connection. (Across the arc models)

. The power source output is OFF.

2

1. The remote is not connected to a CrossLinc compatible power source.

2. Voltage feedback is not working in the remote.

3. Current feedback is not working in the power source.

4. No current pulses are present in work sense lead at idle.

RECOMMENDED COURSE OF ACTION

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

. Turn ON the power source output.

2

1. Connect to a CrossLinc compatible power source. Compatible power sources must have an “X” at the end of the name. (i.e. Flextec 350X)

2. Strike an arc and determine that the displayed voltage on the remote matches the actual arc voltage. If it does not, verify lead connections in the remote. If all lead connections are good, replace User Interface PC Board.

3. Strike an arc and verify that the current displayed on the power source matches the actual arc current. If it does not match, inspect current transducer in power source, and replace if faulty.

4. Verify that the OCV is 65V or less. If it is, replace User Interface PC Board.

The CrossLinc LED is Orange and the remote is not communicating with a power source

1. The remote is overheated. 1. Move to a cooler location

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

17

CROSSLINC™ REMOTE

CLEVELAND, OHIO U.S.A .

R

R - RED

B - BLACK

U - BLUE

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537.

W - WHITE

GENERAL INFORMATION

INPUT ELECTRODE

CABLE CONNECTION

Y -YELLOW

J11

CAVITY NUMBERING SEQUENCE

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

J31

9

8

16

1

4

6

1

3

J32, J42

J41

3

4

1

2

J33, J34

5

4

8

1

M26034PRINT

A.03

UI / DISPLAY

P.C. BOARD

123456789

10111213141516

J31

12345

6

J42

1234567

8

J33

(VIEWED FROM

INSIDE FEEDER)

859

8510

857

333

334

338

336

332

67

332

333

WORK A

336

338

123

4

J41

J34

J32

123456

334

801

802

806804

PANEL ENCODER

WFS/AMPS

857

859

8510



   

802

804

801

806

CURRENT

TRANSDUCER

(LEM)

POWER SUPPLY

P.C. BOARD

1234567

8

(VIEWED FROM

INSIDE FEEDER)

67A

67

67A





J11

TO TORCH

TO WORK CLIP

WORK C

WORK B

WORK A

337

J50

337

CROSSLINC REMOTE WIRING DIAGRAM

IAGRAMS

D

18

CrossLinc Remote -

12605

General Assembly

KEY PART NUMBER DESCRIPTION QTY

1 9SG8711 BASE 1

2 9SS32149 ANGLED PCB BRACKET 1

3A 9SM25777 CORNER CAP 8

3B 9SS9225-100 SELF TAPPING SCREW 8

3C 9SS9262-182 PLAIN WASHER 8

4A 9SS18170 HANDLE ASBLY 1

9SS9262-113 PLAIN WASHER 2

9SS9262-98 PLAIN WASHER 2

9SCF000170 1/4-20X.375HHB 2

5A 9SG8696-1 POWER SUPPLY PC BD 1

5B 9SS9225-76 SELF TAPPING SCREW 2

9SM26153 WELD CABLE ASSEMBLY 1

9SS32142 LEAD COVER PLATE 2

6B 9SS19999-4 CORD GRIP CONNECTOR 2

9SS31643-3 NYLON LOCKNUT 1" NPT 2

6D 9SS18504-6 CURRENT TRANSDUCER 1

6E 9SM26151 iNSULATION PIERCING CONNECTOR 1

6F K3416-90 TWECO STYLE PLUG FOR 3/0-4/0 CABLE 1

6G K3417-90 TWECO STYLE RECEPTACLE FOR 3/0-4/0 CABLE 1

9SS9225-100 SELF TAPPING SCREW 4

9SL17127 HARNESS 1

8A 9ST9274-1 GROMMET 1

9SS32141 GROUND LEAD CONNECTER PLATE 1

9SS9225-100 SELF TAPPING SCREW 4

9SS17211-7 GROUND LEAD ASBLY 1

9SM22861 WORK CLAMP LIGHT DUTY 1

10 9SG8710 ROOF 1

11 9SG6529 UI TRIM 1

9SG8748 USER INTERFACE ASBLY 1

12A 9SL17048 UI CASE FRONT 1

12B 9SG8747 NAMEPLATE 1

12C 9SG8651-1 UI PC BD 1

12D 9ST10082-12 SEMS SCREW 4

12E 9SM17789-6 ENCODER 1

Printed 11/04/2016 at 07:12:15. Produced by Enigma.

CrossLinc Remote - 12605 3

General Assembly

KEY PART NUMBER DESCRIPTION QTY

12F 9ST7028-241 INSULATION TUBE 1

12G 9ST14034 SEAL 1

12H 9SM22778-2 KNOB 1.5" 1

12J 9SM25778 KNOB GUARD 1

12K 9SS9225-99 SELF TAPPING SCREW 2

12L 9SS9225-99 SELF TAPPING SCREW 4

13 9SS20601-5 WARNING DECAL 1

14 9SM26268 DECAL 1

15 9SM26268 DECAL 1

16 9SM26268 DECAL 1

17 9SM26268 DECAL 1

18 9SM26268 DECAL 1

4 CrossLinc Remote - 12605

Printed 11/04/2016 at 07:12:15. Produced by Enigma.

General Assembly

P-1081-C.jpg

Printed 11/04/2016 at 07:12:15. Produced by Enigma.

CrossLinc Remote - 12605 5

WARNING

panish

S

AVISO DE

PRECAUCION

French

ATTENTION

erman

G

WARNUNG

ortuguese

P

ATENÇÃO

Japanese

Chinese

l Do not touch electrically live parts or

electrode with skin or wet clothing.

l Insulate yourself from work and

ground.

l

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.

l

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.

l

Isole-se da peça e terra.

l Keep flammable materials away.

l

Mantenga el material combustible fuera del área de trabajo.

l

Gardez à l’écart de tout matériel inflammable.

l Entfernen Sie brennbarres Material!

l

Mantenha inflamáveis bem guardados.

l Wear eye, ear and body protection.

l

Protéjase los ojos, los oídos y el cuerpo.

l

Protégez vos yeux, vos oreilles et votre corps.

l Tragen Sie Augen-, Ohren- und Kör-

perschutz!

l

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.

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.

l

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.

l

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

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

serviço.

l

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.

l

Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in Betrieb setzen!

l

Mantenha-se afastado das partes moventes.

l Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

rench

F

ATTENTION

German

WARNUNG

ortuguese

P

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.

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

o exceed their expectations. On occasion, purchasers may ask

t 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.

Lincoln Electric CrossLinc K4345-1 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual