Lincoln Electric IM689 User Manual

For use with machines having code numbers: 10729,10801

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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 O R
REP A I R THI S EQUIP M E NT
WIT H O UT REA D I NG THI S
MAN U A L AND T HE SAF E TY
PRE CAUT IONS CON T AIN E D
THR O U GHOU T . And , most

importantly, think before you act
and be careful.

Power Feed 10 Robotic

K1780-1

IM689-A

May, 2007

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © 2007 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

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

i

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 th e fuel near an open fl ame
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 conta ct 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. I n some cases it may be neces sa ry to rem ove sa fe ty

gu a rds to p erf o rm r equ i red mai n ten a nce . Rem ove
guards only when necessary and replace them when the
ma i nte n anc e re q uir i ng the i r r emo v al is comp let e .
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. Electri c cur rent flowing through any c onductor cause s
local ized Elect ric and Magne tic Fields (EMF). Weldi ng
curre nt creates EM F fields around we lding c ables and
welding machines

2.b. E MF fields may interfere wi th some p ac em ak ers, a nd
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. Nev er coil the electrode lead ar ou nd your b od y.

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.

POWER FEED 10 / R

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 ʻ95

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 . Wea r dry , hol e-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
mu st be pe rfor med un der el ectr ical ly haz ardo us
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,
elect rode reel, w elding hea d, no zzle or semiaut omatic
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 ga ses. Wh en we ld ing, ke ep
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

we ldin g with elec trod es which re quir e special
ve ntil ati on such as stain less or hard fac ing (see
instructions on con tai ner or MSDS) or on lea d 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)
us ing l oca l exhaus t or mechanical ventilation . In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
al so req uire d when w eldi ng on ga lvan ized s teel .

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. N ever simultaneo us ly tou ch ele ct rically “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. 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
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.d. Shielding gases used for arc welding can displace air and

cause inj ur y or de ath. Always u se enough ven tilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
ma t eri a l s afe t y d ata she et (MS D S) and fol low you r
employerʼs safety practices. MSDS forms are available from
yo u r weld ing di s tri b uto r o r fro m t he man ufac ture r.

5.f. Also see item 1.b.

vapors

AUG 06

to

POWER FEED 10 / R

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 wel di ng sparks from sta rting a f ir e.

materials from welding can easily go through small cracks
an d op eni ngs to adja cent area s. Avoi d we ldi ng n ear
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
Standar d Z49 .1) and the operating infor mation 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
Co n tai n ers a n d Pip i ng T h at H a ve H e ld Ha z ard o us
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
incre ase the possibility of the w elding 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 folllow 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.

Remem ber that weldin g sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Us e o n ly com p res s ed gas cyl i nde r s
containing the correct shielding gas for the
pr o ces s use d an d pro perl y o p era t ing
re g ula t ors des igne d f or the g a s and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. A lw ay s keep cylinders in an upr ig ht position sec ur el y
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. R ead and follo w th e inst ructi on s on com press ed g as
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. I nstall equi pment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.

Jan 07

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

POWER FEED 10 / R

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 suiv­antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse . Un court-ci rcuit accide ntal peut pro voquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼo pérations d e dégraissage, nettoyag e ou pistolage. La
chaleur ou les rayons de lʼarc 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 nʼimporte quelle partie
du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Pr otéger lʼautre personnel travaillant à proximité a u

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gou ttes de lai tier en fus ion s ont é mises de lʼ arc d e
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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
zones où lʼon pique le laitier.

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
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ʻ93

POWER FEED 10 / R

TThhaannkk YYoouu

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!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs 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.

CUSTOMER ASSISTANCE POLICY

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.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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

Mounting the Wire Drive Unit ........................................................................................A-2

Electrode Routing..........................................................................................................A-2

Electrode and Work Cable Connections .......................................................................A-2

Negative Electrode Polarity...........................................................................................A-3

Shielding Gas Connection.............................................................................................A-3

Control Cable .......................................................................................................................A-3

Control Cable Connections ...........................................................................................A-3

Control Cable Specifications .........................................................................................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-5

Wire Feed Drive Roll Kits ..............................................................................................A-6

Procedure to Install Drive Rolls and Wire Guides .........................................................A-6

Drive Roll Kit Installation (KP1505-[ ]),(KP1507-[ ]) .................................................A-6

General Gun Connection Guidelines ............................................................................A-6

Gun Receiver Bushings and Adapters ..........................................................................A-7

Conduit Adapters ..........................................................................................................A-7

Remote Sense Lead Specifications ..............................................................................A-7

Installation of Field Installed Options ............................................................................A-7

Feeding Electrode and Brake Adjustment.....................................................................A-8

Drive Roll Pressure Setting ...........................................................................................A-8

Operation .........................................................................................................Section B

Safety Precautions ..............................................................................................................B-1

Duty Cycle.....................................................................................................................B-1

General Description ......................................................................................................B-1

Recommended Processes ............................................................................................B-1

Process Limitations .......................................................................................................B-1

Recommended Equipment / Interface...........................................................................B-1

vi

Accessories.....................................................................................................Section C

Optional Equipment..............................................................................................................C-1

Drive Roll and Guide Tube Kits............................................................................................C-1

Maintenance ....................................................................................................Section D

Safety Precautions ...............................................................................................................D-1

Routine Maintenance ....................................................................................................D-1

Drive Rolls and Guide Tubes.............................................................................D-1

Avoiding Wire Feeding Problems..................................................................................D-1

Periodic Maintenance ...................................................................................................D-1

Procedure for Removing Feedplate from Wire Feeder ...........................................D-1

Troubleshooting..............................................................................................Section E

Safety Precautions ...............................................................................................................E-1

Troubleshooting Guide ...........................................................................................E-2 thru E-4

Diagrams ..........................................................................................................Section F

Wiring Diagram ......................................................................................................F-1

Dimension Print......................................................................................................F-2

Parts Lists...................................................................................................P-381 Series

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – Power Feed 10 Robotic-K1780-1

WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER

SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO

Speed Solid Cored Speed Solid Cored

Wire Size Wire Size

A-1

K1780-1

Power Feed 10

50-800 IPM .025 - 3/32 in. .035 - .120 in 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in.
(1.27-20.3 m/m) (0.6 - 2.4 mm) (0.9 - 3.2 mm) (2.03 - 30.5 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm

CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS

SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING

Dimensions

K1780-1

Power 40 VDC 13.5 “ 10.3 “ 12.0 “ 23.5 Lbs -20° to +40° C -40° to +40° C

Height Width Depth Weight Operating Storage

Feed 10 (340 mm) ( 261 mm) (304 mm) (10.7 Kg)
Wire
Feeder

POWER FEED 10 / R

A-2

SAFETY PRECAUTIONS

INSTALLATION

ELECTRODE ROUTING

A-2

WARNING

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.

----------------------------------------------------------------------------------------

MOUNTING OF THE PF10/R

Mount the wire drive unit by means of the 4 holes in
the bottom of the wire drive base. Note that the gear­box assembly is electrically “hot” when wel ding.
Therefore, make certain the gearbox does not come in
contact with the structure on which the unit is mount­ed. The wire feed unit should be mounted so that the
drive rolls are in a vertical plane to prevent the accu­mulation of dirt in the drive roll area. Do not bend the
conduit more than 45°.

The electrode supply may be either from reels, Readi­Reels, spools, or bulk packaged drums or reels.
Observe the following precautions:

• Do not bend the conduit more than 45°, and to use
the minimum amount of conduit necessary for the
wire reel to connect to the wire feeder.

• The electrode is "hot" while welding and must be
insulated from the boom, conduit and wire payoff
structure.

• If more than one wire feed unit shares the same
boom and are not sharing the some power source
output stud, their wire and reels must be insulated
from each other as well as insulated from their
mounting structure.

ELECTRODE AND WORK 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.

1.97

1.77

.25 DIA.
(4 Places)

FIGURE A.1

7.11

1.77

.22 DIA.
(2 Places)

Connect a work lead of sufficient size and length (per
TABLE 1) 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. Do not
bundle the electrode and work leads tightly together.
Avoid excessive lengths and do not coil excess cable.

Use K1796 Coaxial welding cables wherever possible.

Minimum work and electrode cables sizes are as follows:

TABLE 1

MINIMUM COPPER WORK

3.05

Current (60% Duty Cycle)
400 Amps
500 Amps
600 Amps

CABLE SIZE, AWG
Up To-100 Ft. Length (30 m)
2/0 (67 mm2)
3/0 (85 mm2)
3/0 (85 mm2)

POWER FEED 10 / R