Lincoln Electric IM613 User Manual
Power Feed 11 SemiAutomatic
RETURN TO MAIN MENU
For use with: Power Feed 11 K1635-1 (World Model) Code 10529; 10777
Power Feed 11 K1636-1 (European Model) Code 10531; 10778
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.
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
importantly, think before you act
and be careful.
And, most
DO
Cabinet Wire Feeder
IM613-B
October, 2000
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2000 Lincoln Global Inc.
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.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.
___________________________________________________
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.
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.
Mar ‘95
ii
SAFETY
ii
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.
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 with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
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 Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. 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.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
vapors
to
iii
SAFETY
iii
WELDING 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.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
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
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
Mar ‘95
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opé rations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branchéà une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûretéà leur
place.
Mar. ‘93
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediatel
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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
y
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Wire Feeder to Power Source Configurations......................................................................A-2
Mounting on Top of the Power Source..........................................................................A-2
Hanging.........................................................................................................................A-2
On the Floor ..................................................................................................................A-2
Control Box Orientation.................................................................................................A-2
Cable Connections ...............................................................................................................A-3
Control Cable Connections ...........................................................................................A-3
Control Cable Specifications .........................................................................................A-3
Typical Cabinet Feeder Connection..............................................................................A-3
Control Cable Installation ..............................................................................................A-3
Electrode Cable Connections........................................................................................A-3
Electrode Cable Installation ..........................................................................................A-3
Work Cable Connections ..............................................................................................A-4
Wire Drive Gear Ratio (High or Low Speed) ........................................................................A-4
Selecting the Proper Gear Ratio ...................................................................................A-4
Changing the Wire Drive Ratio......................................................................................A-4
DIP Switch Setup .................................................................................................................A-6
Setting DIP Switches in the Control Box .......................................................................A-6
Setting DIP Switches in the Wire Drive .........................................................................A-7
Wire Feed Drive Roll Kits .....................................................................................................A-8
Procedure to Install Drive Rolls and Wire Guides ................................................................A-8
Gun and Cable Assemblies..................................................................................................A-9
Gun Connection Guidelines .................................................................................................A-9
GMAW Shielding Gas ........................................................................................................A-10
Lifting Handle .....................................................................................................................A-10
Optional Features Installation.............................................................................................A-11
Optional Panels for Control Box .........................................................................................A-11
General Panel Installation Guidelines ................................................................................A-11
vi
Operation ............................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
Product Description ..............................................................................................................B-1
Recommended Processes and Equipment ..........................................................................B-1
Duty Cycle ............................................................................................................................B-1
Control Box Operation..........................................................................................................B-1
Control Box Panels - Upper Panel ................................................................................B-1
Control Box Panels - Set Up Controls Description........................................................B-4
Control Box - P.C. Board Adjustments..........................................................................B-4
Control Box - Setting Operating Limits..........................................................................B-5
Control Box - Using Operating Limits............................................................................B-5
Wire Drive Operation............................................................................................................B-6
Wire Drive Settings - External ..............................................................................................B-6
Wire Drive - P.C. Board Adjustments ...................................................................................B-7
Wire Reel Loading................................................................................................................B-7
Feeding Electrode and Brake Adjustment............................................................................B-8
Drive Roll Pressure Setting ..................................................................................................B-8
Gas Guard Regulator Setting ...............................................................................................B-8
Making a Weld......................................................................................................................B-9
Wire Reel Changing .............................................................................................................B-9
Wire Feed Overload Protection ............................................................................................B-9
Component Status Lights ...................................................................................................B-10
Status Light States ......................................................................................................B-10
Accessories .....................................................................................................Section C
Drive Roll and Guide Tube Kits............................................................................................C-1
Other Accessories................................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Avoiding Wire Feeding Problems.........................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Procedure for Removing Feedplate from Wire Feeder ........................................................D-1
vii
TABLE OF CONTENTS
Page
Troubleshooting ..............................................................................................Section E
Safety Precautions ...............................................................................................................E-1
Troubleshooting Guide .........................................................................................................E-2
Diagrams .............................................................................................................Section F
Wiring (Power Feed 11 Wire Feeder) ....................................................................F-1
Wiring (Power Feed 11 Control Box) .....................................................................F-2
Dimension Print......................................................................................................F-3
Parts Lists .......................................................................................................P315 Series
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – Power Feed 11
COMPLETE UNITS
SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO
Speed Solid Cored Speed Solid Cored
Wire Size Wire Size
A-1
K1635-1
K1636-1
Power Feed 11
Cabinet (1.27-15.9 m/m) (0.6 - 1.6 mm) (0.8 - 2.0 mm) (2.03 - 27.9 m/m) (0.6 - 1.2 mm) (0.8 - 1.2 mm)
Wire
Feeder
(World Model)
Power Feed 11
Cabinet (1.27-15.9 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm) (2.03 - 27.9 m/m) (0.6 - 1.2 mm) (0.9 - 1.2 mm)
Wire
Feeder
(European
Model)
50-625 IPM .025 - 1/16 in. .030 - 5/64 in 75 - 1100 IPM .025 - .045 in. .030 - .045 in.
50-625 IPM .025 - 1/16 in. .035 - 5/64 in 75 - 1100 IPM .025 - .045 in. .035 - .045 in.
COMPLETE UNITS
SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING
K1635-1 Power 40 VDC 20.0 “ 9.0 “ 28.7 “ 61 Lbs
Height Width Depth Weight Operating Storage
Feed 11 (508 mm) ( 230 mm) (729 mm) (27.7 Kg)
(World
Model)
Dimensions
+40°C +40°C
K1636-1 Power 40 VDC 20.0 “ 9.0 “ 28.7 “ 61 Lbs -20°C -40°C
Feed 11 (508 mm) ( 230 mm) (729 mm) (27.7 Kg)
(European
Model)
to to
The PF-11 is environmentally rated IP21S per IEC60529
POWER FEED 11
A-2
INSTALLATION
A-2
SAFETY PRECAUTION
ELECTRIC SHOCK can
kill.
• Only qualified personnel should perform this installation.
• Turn off the input power to the power source at the
disconnect switch or fuse box before working on
this equipment. Turn off the input power to any
other equipment connected to the welding system
at the disconnect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door) to
a proper safety (Earth) ground.
----------------------------------------------------------------------------------------
WIRE FEEDER TO POWER SOURCE
CONFIGURATIONS
The Wire Feeder is equipped to operate in the vertical
or horizontal position. It is shipped ready for use in the
in the vertical position.
MOUNTING ON TOP OF THE POWER SOURCE
The Wire Feeder is shipped with the vertical mounting
bracket installed on the bottom of the Feeder. The
Feeder must be placed on top (right side) of the
Power Source such that the bolt on the mounting
bracket goes thru the hole in the Power Source’s Lift
Bail and the front hole on the right front foot of the
mounting bracket is placed over the weld stud on the
roof of the Power Source. Use the Wing Nut/washer
assembly provided to secure the Feeder to the Power
Source.
Note: A longer or additional Control Cable may be
required when hanging the Feeder. See ACCESSORIES section for information on optional Control
Cables.
ON THE FLOOR
The Wire Feeder is equipped with aluminum skids
which protect the enclosure when the Feeder is
placed on the floor in either the horizontal or vertical
position.
CONTROL BOX ORIENTATION
The Control Box is designed to be easily rotated to
accommodate horizontal or vertical positions. The procedure to change the Control Box Orientation is as follows:
1. Open the Wire Drive compartment door.
2. Locate the Retaining Collar(just above the Wire
Drive unit) and depress the Release Bar and
remove the Retaining Collar from the Control Box
mounting shaft.
3. Pull the Control Box out just enough to allow the
Control Box to be rotated to the desired position
and then re-install. ( Be sure no leads are pinched)
Note: For the Horizontal position the right side of
the Control Box must be next to the front panel
components.
4. Re-install the Retaining Collar. Some light pressure
on the Control Box may be necessary to get the
release bar to “click” into the mounting shaft
groove.
Note: The Wire Feeder can also be mounted horizontally. See ACCESSORIES section for information on
the Optional Horizontal Mounting Bracket.
HANGING
The Wire Feeder is equipped with 2 insulated Lifting
Eyes for hanging the Feeder. It is recommended that
the Lifting Eyes always be used when hanging the
Feeder. The Lifting Handles should be used for short
term carrying of the Feeder
POWER FEED 11
A-3
INSTALLATION
A-3
CABLE CONNECTIONS
CONTROL CABLE CONNECTIONS
• All system control cables are the same.
• All control cables can be connected end to end to
extend their length.
• All system equipment must be connected to a control cable.
Welding systems using the Power Feed 11 offer previously unprecedented flexibility in the connection of
system components. This system uses the same type
of control cable between each of the system components. Connections can be “daisy chained” from one
system component to another. Since communication
over the control cables is done by a robust communications network, the order of connection of the components makes no difference. The cables can be connected anywhere that there is a mating connector.
CONTROL CABLE SPECIFICATIONS
aligning the pins and key, plug it into the back of
the wire feeder head, rotate the threaded locking
ring until the connector is completely fastened
Note: Depending on the location of the of the Wire
Feeder relative to the Power Source a longer
Control Cable or additional Control Cable(s) may be
required.See section 2.0 “Optional Features” for
information on optional Control Cables.
ELECTRODE CABLE CONNECTIONS
Most welding applications run with the electrode being
positive (+). For those applications, connect the electrode cable between the wire feeder and the positive
(+) output stud on the power source (located beneath
the spring loaded output cover near the bottom of the
case front).
A work lead must be run from the negative (-) power
source output stud to the work piece. The work piece
connection must be firm and secure, especially if
pulse welding is planned. Excessive voltage drops at
the work piece connection often result in unsatisfactory pulse welding performance.
The cable is a 5 copper conductor cable in a SO-type
rubber jacket. There is one 20 gauge twisted pair for
network communications. This pair has an impedance
of approximately 120 ohms and a propagation delay
per foot of < 2.1 ns. There are two 12 gauge conductors that are used to supply the 40 VDC to the network. The fifth wire is 18 gauge and is used as an
electrode sense lead. It is typically connected to the
feed plate on the feed head when that feed head is
active.
NOTE: Maximum cable length between any two
nodes is 250'.
TYPICAL CABINET FEEDER CONNECTION
The Control cable is connected from the Power
Source to the Wire Feeder. The Power Feed 11
comes standard with an 8 ft. Control Cable.
CONTROL CABLE INSTALLATION:
1. Connect the end of the control cable with the 5-pin
cable plug to the mating receptacle on the power
source. With the pins and key aligned, plug it into
the power source, rotate the threaded locking ring
until the connector is completely fastened
When negative electrode polarity is required, such as
in some Innershield™ applications, install as above,
except reverse the output connections at the power
source (electrode cable to the negative (-) stud, and
work cable to the positive (+) stud).
ELECTRODE CABLE INSTALLATION:
The Power Feed 11 comes with an installed electrode
cable. Connect the power source end of the cable to
the power source output terminal of the desired polarity.
The K1636-1 Power Feed 11 (Europe) electrode cable
is equipped with a Twist-Mate™ connector while the
K1635-1 Power Feed 11 (World) is equipped with a
lug connector. Also for both models open the Wire
Drive compartment door and check that the electrode
cable lug is against the Feedplate and that the connection is tight. Any electrode cable replacement or
extension should be sized according to the specifications given in the work cable connections section .
2. Connect the end of control cable with the 5-socket
end to the mating receptacle on the back of the
wire feeder. To connect the cable to the feeder,
POWER FEED 11
A-4
INSTALLATION
A-4
WORK CABLE CONNECTIONS
Connect a work lead of sufficient size and length (per
the following table) between the proper output terminal on the power source and the work. Be sure the
connection to the work makes tight metal-to-metal
electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid
excessive lengths, bundle the electrode and ground
cables together where practical, and do not coil
excess cable.
Minimum work and electrode cables sizes are as follows:
Current
60% Duty
Cycle
500 Amps
600 Amps
Minimum Copper Work Cable Size, AWG
Up to 100 ft Length (30m)
3/0 (85 mm2)
3/0 (85 mm2)
SELECTING THE PROPER GEAR RATIO
See the Technical Specifications at the front of this
section for feed speed and wire size capabilities with
high and low speed gear ratios. To determine whether
you should be using the high or low speed ratio use
the following guidelines:
- When operating at wire feed speeds
(15.9 m/m), you must have the high speed gear
(large 30 tooth, 1.6 inch diameter gear) installed.
- When operating at wire feed speeds below 625 IPM
(15.9 m/m), you must have the low speed gear
(small 17 tooth, .95 inch diameter gear) installed for
all wire sizes because using the low speed ratio provides the maximum available wire feeding force.
Note:
If you are feeding only .045” (1.2 mm) diameter and smaller wires you may, at your option, use
the factory installed high speed ratio.
above 625 IPM
CHANGING THE WIRE DRIVE RATIO
When using an inverter type power source, Use the
largest welding (electrode and ground) cables that are
practical. At least 3/0 (85 mm
the average output current would not normally require
it. When pulsing, the pulse current can reach very
high levels. Voltage drops can become excessive,
leading to poor welding characteristics, if undersized
welding cables are used.
2
) copper wire — even if
WIRE DRIVE GEAR RATIO (HIGH
OR LOW SPEED)
The speed range capability and drive torque of the
Power Feed 11 wire drive can be easily and quickly
changed by changing the external drive gear. The
Power Feed 11 is shipped with both a high speed and
a low speed gear. As shipped from the factory, the
high speed (low torque) gear is installed on the feeder. If this is the desired gear ratio, no changes need
to be made.
Changing the ratio requires a gear change and a PC
board switch change. The Power Feed 11 is shipped
with both a high speed and a low speed gear. As
shipped from the factory, the high speed (low torque)
gear is installed on the feeder. For identification purposes, the low speed (high torque) gear has 17 teeth
and is .95 inches in diameter. The high speed gear
has 30 teeth and is 1.6 inches in diameter. See
Figure A.2.
WIRE
FEEDER
FIGURE A.2 — CHANGING WIRE DRIVE RATIO.
POWER FEED 11
PHILLIPS
HEAD SCREW
DRIVE
GEAR
A-5
INSTALLATION
A-5
RATIO CHANGE PROCEDURE:
1) Power down the Power Feed by turning OFF its
companion PowerWave power source. For maximum safety, disconnect the control cable from the
Power Feed.
2) Pull open the Wire Feeder’s Compartment Door.
3) Remove the Feedplate per the following:
a) Disconnected the Electrode from the Feedplate
b) Pull open the Wire Drive Pressure Door.
c) Using a 3/16" Hex Key Wrench remove the two
screws that secure the Feedplate to the
Interface Plate. These screws are located just
below and to the right and just below and to left
of the lower drive gears.
d) Swing the rear of the Feedplate out towards
the front of the machine which will allow it to be
pulled back and out of the machine.
Note: The shielding gas hose and gun leads are still
attached to the Feedplate. This is OK provided that
the Feedplate is setting on a suitable surface such
that no excess tension is being place on the gas hose
and gun leads. If necessary remove the gas hose and
disconnect the leads.
4) Remove the pinion gear as follows:
a) Using a phillips head screwdriver remove the
screw that secures the gear to the output shaft
of the gearbox and remove the gear.
b) Lightly cover the output shaft with engine oil or
equivalent. Install appropriate size gear(small
gear for low speed and a large gear for high
speed) onto output shaft and secure with flat
washer, lock washer, and Phillips head screw
which were previously removed.
Note: Be sure that the woodruff key remains secured
to the output shaft during the gear change.
6) Re-attach Feedplate (and gas hose and gun leads
if they were removed) that was removed in Step 3
and reconnect the Electrode Cable.
Note: The screws that secure the Feedplate to the
Interface Plate must go thru the insulator bushings in
the Feedplate.
7) Close the Wire Drive Pressure Door and Wire
Feeder’s Compartment Door.
8) Set the High/Low Dip Switch on Feed Head PC
board as follows:
a) Remove the left case side as follows:
- Remove 4 screws that directly secure the
case side
- Loosen the 3 screws that secure the lower
skid rail. This will free the case side edge
and allow it to be lifted up and removed.
Note: PF-11's that have been installed horizontally on
top of the Power Source will need to remove the
Mounting Bracket in order to access the the left case
side.
b) Locate the 8-position DIP switch (S1) on the
Feed Head PC board. The setting will be made
on the bottom most switch, DIP switch #8.
c) Using a pencil or other small object, to slide the
switch left, to the “OFF" position, when the low
speed gear is installed. Conversely, slide the
switch right, to the “ON" position, when the high
speed gear is installed. Refer to the diagrams
below.
Setting for Low Speed Setting for High Speed
O
N
12 3456 78
N
O
12 3456 78
5) Position the Motor/Gearbox as follows:
a) There are 4 screws that secure the
Motor/Gearbox to the Interface Plate. Using a
3/16" Hex Key Wrench remove the 2 upper
screws and loosen (but don’t remove) the 2
lower screws.
b) Slide the Motor/Gearbox to the
UPPER SET OF HOLES FOR LOW SPEED
LOWER SET OF HOLES FOR HIGH SPEED.
c) Secure in position with flat washers, lock wash-
ers, and socket head screws that were previously removed and loosened.
S1
d) Replace the left case side and screws(and
POWER FEED 11
S1
Mounting Bracket if required). The PC board
will “read” the switch at power up, automatically
adjusting all control parameters for the speed
range selected.
A-6
INSTALLATION
A-6
DIP SWITCH SETUP
ON
12 3456 78
S1
SETTING DIP SWITCHES IN THE
CONTROL BOX
There are two DIP switch banks on the mother board
of the Control Box. They are labeled S1 and S2 and
are located and oriented as shown in Figure A.3.
ON
12 3456 78
FIGURE A.3
S2
S1 DIP Switch Bank on Control Box Motherboard (For Software version S24456-1)
Switch Off On
1 Standard speed limits adjustable High speed gearbox limits adjustable
2 WFS Display = inches/minute WFS Display = meters/minute
3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing
Left Display is actual weld current when weld current is flowing
CC modes override this switch regardless of position. Left Display is always preset weld current when weld current is not flowing and actual weld current when weld current is flowing
4 Run-in = Minimum Speed Available Run-in = weld WFS
If any option containing a Run-in setting is connected to the motherboard, it automatically
overrides this switch regardless of position.
5 Memory change with trigger disabled Memory change with trigger enabled
6 Acceleration, MSB (Sets acceleration rate for wire drive) see below
7 Acceleration (Sets acceleration rate for wire drive) see below
8 Acceleration, LSB (Sets acceleration rate for wire drive) see below
DIP SWITCH 6 DIP SWITCH 7 DIP SWITCH 8
Acceleration 1 (slow) Off Off On
Acceleration 2 Off On Off
Acceleration 3 Off On On
Acceleration 4 On Off Off
Acceleration 5 (fast ) (factory setting) Off Off Off
Note: the factory shipped settings for Switch S1 are as follows:
PF-11 European - Switches 1-2 “ON”; Switches 3-8 “OFF”
PF-11 World - Switch 1 “ON”; Switches 2-8 “OFF”
POWER FEED 11
A-7
INSTALLATION
S2 DIP Switch Bank on Control Box Motherboard (For software version S24456-1)
Switch Off On
1 Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting)
2 Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting)
3 4-Step Domestic Configuration 4-Step European Configuration
4 Power Feed 10 / Dual Power Feed 11
5 Procedure change with trigger “OFF” Procedure change with trigger “ON”
6 Must be off for normal operation Adjust lower limits
7 Must be off for normal operation Adjust upper limits
8 Must be on for all units (Permits selection of extended modes)
Note: the factory shipped settings for Switch S2 are as follows:
PF-11 European - Switches 1,2 & 5-7 “OFF”; Switches 3,4,8 “ON”
PF-11 World - Switches 1-3 & 5-7 “OFF”; Switches 4, 8 “ON”
N
O
12 3456 78
A-7
SETTING DIP SWITCHES IN THE WIRE
DRIVE
There is one DIP switch bank on the control board of
the wire drive. It’s labeled S1 and is located and oriented as shown in Figure A.4.
FIGURE A.4
S1
S1 DIP Switch Bank on Wire Drive Control Board (For software version S24468-1)
Switch Off On
1 Network Group ID, MSB (Assigns Wire Drive to a specific group)
2 Network Group ID, LSB (Assigns Wire Drive to a specific group )
3 Network Feed Head ID, MSB (Assigns feed head number to wire drive)
4 Network Feed Head ID (Assigns feed head number to wire drive)
5 Network Feed Head ID, LSB (Assigns feed head number to wire drive)
6 Spare
7 Electrode Sense Polarity = Positive Electrode Sense Polarity = Negative
Switch position must match polarity of weld cable attached to feed plate.
8 Gear Box Ratio = Low Gear Box Ratio = High
Switch position must match actual gear box ratio of wire drive.
Note: the factory shipped settings for Switches 1-7 is “OFF”, Switch 8 is “ON”.
POWER FEED 11
A-8
INSTALLATION
A-8
WIRE FEED DRIVE ROLL KITS AND
FAST-MATE™ GUN ADAPTER
GUIDE TUBES
NOTE: The maximum rated solid and cored wire
sizes and selected drive ratios are shown on the
SPECIFICATIONS in the front of this section. The
electrode sizes that can be fed with each drive roll and
wire guide are stenciled on each part. Check the kit
for proper components. Kit specifications can be
found in the ACCESSORIES section.
FAST-MATE™ GUN ADAPTER GUIDE
TUBES
Guide Tubes for Steel Wire:
The Power Feed 11 is supplied with 4 wire guide
tubes which allow the I.D. of the Fast-Mate™ gun
adapter to be optimized for every wire size. The various size wire guide tubes are identified by the number
of rings scribed toward one end of the tube and
should be selected per the table below.
PROCEDURE TO INSTALL DRIVE
ROLLS AND GUIDE TUBES
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
When feeding without Power Feed 11 “Cold
•
Feed” feature, electrode and drive mechanism
are “hot” to work and ground and could remain
energized several seconds after the gun trigger
is released.
• Turn OFF input power at welding power
source before installation or changing drive
roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National Electrical
Code or any applicable local codes.
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed
throughout this manual.
DRIVE ROLL KIT AND GUIDE TUBE
INSTALLATION
Wire Size Number
of Rings
.023"-.045" (0.6-1.2mm) 1
.045"-1/16" (1.2-1.6mm) 2
1/16"-5/64" (1.6-2.0mm) 3
5/64"-7/64" (2.0-2.8mm) 4
Guide Tubes for Aluminum Wire:
For optimum aluminum wire feeding the appropriate
plastic lined guide tube should be used per the table
below. These must be ordered.
Part Wire Size Tube
Number Color
S24129-1 .030"-.035" (0.8-0.9mm) Black
S24129-2 .035"-3/64" (0.9-1.2mm) Blue
S24129-3 1/16" (1.6mm) Red
1) Turn OFF Welding Power Source.
2) Pull open Pressure Door to expose rolls and wire
guides.
3) Remove Outer Wire Guide by turning knurled
thumb screws counter-clock-wise to unscrew them
from Feed plate.
4) Remove drive rolls, if any are installed, by pulling
straight off shaft. Remove inner guide.
Note: Not all Drive Roll and Wire Guide changes
require changing the Gun Adapter Guide
Tubes. See FAST-MATE™ GUN ADAPTER
GUIDE TUBES in this section for the proper
size guide tube required for the wire size to be
used. If a guide tube change is NOT required
skip Steps 5 & 6 And go to Step 7.
5) Loosen the small Knurled Knob on the Feedhead.
This the Knurled Knob that is closest to the Gun
Adapter and is used to secure the wire guide tube
into the Gun Adapter.
6) Insert the new wire guide tube (either end, tube is
symmetric) into the incoming end of the Gun
Adapter (This will remove an existing tube if present) until it flush with the incoming end and retighten the small Knurled Knob.
POWER FEED 11
A-9
INSTALLATION
A-9
7) Insert inner Wire Guide, groove side out, over the
two locating pins in the feed plate.
8) Install each drive roll by pushing over shaft until it
butts up against locating shoulder on the drive roll
shaft. (Do Not exceed maximum wire size rating of
the wire drive).
9) Install Outer Wire Guide by sliding over locating
pins and tightening in place.
10) Engage upper drive rolls if they are in the “open”
position and close Pressure Door.
NOTE: To set drive roll pressure, see DRIVE ROLL
PRESSURE SETTING in the OPERATION section.
GUN AND CABLE ASSEMBLIES
The Power Feed 11 wire feeder is equipped with a
Fast-Mate™ Gun Adapter that provides for the use of
guns with Fast-Mate™ or European style gun connections and will handle both standard Fast-Mate™and
Dual Schedule Fast-Mate™ guns.
The Fast-Mate™ Gun Adapter requires the use of
wire guide tubes. The Power Feed 11 is supplied with
4 wire guide tubes. See FAST-MATE™ GUN
ADAPTER GUIDE TUBES and DRIVE ROLL KIT
AND GUIDE TUBE INSTALLATION sections for proper selection and installation of Fast-Mate™ Gun
Adapter wire guide tubes.
MAGNUM GUNS
Magnum Fast-Mate™ air cooled and water cooled
gun and cable assemblies are available to allow welding with solid and cored wire electrodes. See the
appropriate Magnum Literature for descriptions of the
200 to 400 ampere air cooled gun and cables that are
available, as well as the Magnum 450 ampere water
cooled gun and cable.
Magnum X-Tractor gun and cable assemblies provide
fume extraction capability for welding with solid and
cored wire electrodes. See the appropriate Magnum
Literature for descriptions of the 250 to 400 ampere
air cooled gun and cable assemblies that are available.
GUN CONNECTION GUIDELINES
General Guidelines
The instructions supplied with the gun should be followed when installing and configuring a gun. What follows are some general guidelines that are not intended to cover all guns.
a. Check that the drive rolls, wire guide and gun
adapter wire guide tube are proper for the electrode size and type being used. If not, change
them.
b. Connect gun to gun connector making sure all pins
and gas tube line up with appropriate holes in connector. Tighten gun by turning large nut on gun
clockwise.
WATER COOLED GUIDELINES
The Power Feed 11 comes equipped with coolant inlet
and outlet connections on the front and back of the
feeder. The maximum water pressure permitted for
use with the PF-11 is 100 psi.
a. Using male quick connect fittings, connect appro-
priate water hoses to the coolant inlet and outlet on
the back of the feeder. Connect the other ends of
these hoses to the appropriate ports on your water
cooling unit.
b. Connect the gun hoses to the coolant inlet and out-
let on the front of the feeder. In the event the
water line fittings on your water cooled gun are
incompatible with the female quick connects on the
front of the Power Feed 11, male quick connects
are provided for installation on 3/16" (5mm) hose
(Customer to provide appropriate clamps). The
feeder connectors self seal when disconnected.
c. Water cooled guns can be damaged very quickly if
they are used even momentarily without water
flowing. To protect the gun, we recommended that
a K1536-1 Magnum Flow Sensor kit be installed.
This will prevent wire feeding if no water flow is
present. See ACCESSORIES Section for more
information regarding this kit
Note:Most Non-Lincoln Guns can be connected to the
Power Feed 11 provided the gun has a European
Style Gun Connector.
POWER FEED 11
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