Lincoln Electric IM761 User Manual

POWER FEED 15M

R

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For use with machines having Code Number : 10940

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.

IM761

September, 2005

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

NRTL/C

OPERATOR’S MANUAL

Copyright © 2005 Lincoln Global Inc.

• 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.

vapors

Mar ‘95

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 suiv­antes:

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.

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.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
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’opérations 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.

PRÉCAUTIONS DE SÛRETÉ POUR

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.

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 branché à 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 sûreté à leur
place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank 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 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_________________________________________________________________________

vv

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.

vi

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ...............................................................................................................A-2

Location................................................................................................................................A-2

High Frequency Protection...................................................................................................A-2

Digital Welding System Components ...................................................................................A-2

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

Weld Cable Size and Table..................................................................................................A-3

Coaxial Weld Cable..............................................................................................................A-4

Electrode Polarity .................................................................................................................A-4

Shielding Gas Connection....................................................................................................A-4

Changing The Drive Motor Gears ........................................................................................A-5

Wire Drive Configuration ......................................................................................................A-6

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

Remote Sense Lead Specification .......................................................................................A-7

________________________________________________________________________________

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

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

Graphic Symbols that appear on this Machine or in this Manual .........................................B-1

Definition of Welding Terms .................................................................................................B-2

General Description..............................................................................................................B-3

Duty Cycle ............................................................................................................................B-3

Recommended Processes ...................................................................................................B-3

Processes Limitations ..........................................................................................................B-3

Equipment Limitations ..........................................................................................................B-3

Making a Weld with Waveform Technology Power Sources................................................B-4

General Welding Adjustments..............................................................................................B-4

1. WFS/AMPS ...............................................................................................................B-4

2. Volts/Trim ..................................................................................................................B-4

3. Welding Mode ...........................................................................................................B-4

4. Arc Control ................................................................................................................B-4

Constant Voltage (CV) Welding ...........................................................................................B-5

Pulse Welding ......................................................................................................................B-5

STT Synergic Welding..........................................................................................................B-6

Case Front Controls .............................................................................................B-7 thru B-10

Extended Features Menu ...................................................................................................B-11

Internal Controls .................................................................................................................B-12

Cold Feed/Gas Purge Switch......................................................................................B-12

Idle Roll Pressure Setting............................................................................................B-12

Flow Meter..........................................................................................................................B-13

2 Step - 4 Step Trigger Operation and Graphics ................................................B-14 thru B-18

________________________________________________________________________________

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

Factory Installed Equipment.................................................................................................C-1

Drive Roll Kits used..............................................................................................................C-1

Common Packages with Accessories Used.........................................................................C-1

________________________________________________________________________________

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

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

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

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

Calibration Specification.......................................................................................................D-1

________________________________________________________________________________

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

How to Use Troubleshooting Guide .....................................................................................E-1

Error Fault Codes ..........................................................................................................E-2,E-3

Troubleshooting Guide ...........................................................................................E-4 thru E-5

________________________________________________________________________________

vi

Wiring Diagram & Dimension Prints .............................................................................Section F

________________________________________________________________________________

Parts Pages .............................................................................................................................P484

_______________________________________________________________________

________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS –

INPUT VOLTAGE and CURRENT

MODEL

K2196-1

Domestic

DUTY CYCLE

35% rating
60% rating

100% rating

ELECTRODE DIAMETERS and SPEED RANGE

PROCESS

GMAW

GMAW-Pulsed

GMAW-STT

FCAW

FCAW- Gas Shielded

ELECTRODE DIAMETER RANGE

.023 - .052"

(0.6 -1.3 mm)

.023 - .052"

(0.6 -1.3 mm)

.023 - .052"

(0.6 -1.3 mm)

0.035 - 5/64"

(0.9mm - 2.0 mm)

0.035 - 5/64"

(0.9mm - 2.0 mm)

POWER FEED 15M K2196-1

INPUT VOLTAGE ± 10%

40 VDC

OUTPUT RANGE (AMPERES)

up to 500 Amps

INPUT AMPERES

5A

WIRE FEED SPEED RANGE

50 - 700 ipm (1.3 - 17.8

m/min)

PHYSICAL DIMENSIONS

MODEL

K2196-1

Domestic

HEIGHT WIDTH DEPTH WEIGHT

12 Inches 9 Inches 23.3 Inches 34 lbs
(305 mm) ( 229 mm) (590 mm) (15.5 kg)

TEMPERATURE RANGE

OPERATION: -14° F to 140° F (- 10° C to 60oC)
STORAGE: - 40° F to 185° F (- 40° C to 85oC)

POWER FEED 15M

A-2

Digital Control Cable

Work
Cable

Electrode Cable

Power Sou rc e

Wire Feeder

+

-

Welding Gun

Shielding
Gas Hose

Shielding
Gas Hose

Digital Control Cable

Work
Connection

Coaxial Weld Cable

Power Sourc e

Wire Feeder

+

-

Welding Gun

SAFETY PRECAUTIONS

INSTALLATION

HIGH FREQUENCY PROTECTION

A-2

WARNING

ELECTRIC SHOCK CAN KILL.

• ONLY QUALIFIED PERSONNEL
SHOULD PERFORM THIS
INSTALLATION.

• Turn off 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 the equipment.

• Do not touch electrically hot parts.

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

LOCATION

The Power Feed 15M has an IP23 rating, suitable for
outdoor use.

The Power Feed 15M should be positioned upright on
a horizontal surface. Do not submerge the Power
Feed 15M in water. The best practice is to keep the
wire feeder in a dry environment. When working
outdoors in severe wet weather, place the Power Feed
15M with the door facing up.

CAUTION

Locate the Power Feed 15M away from radio con­trolled machinery. The normal operation of the
Power Feed 15M may adversely affect the operation
of RF controlled equipment, which may result in
bodily injury or damage to the equipment.

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

CONNECTION DIAGRAMS

CV Welding: Figure A.1

Pulse Welding or STT Welding: Figure A.2

POWER FEED 15M

A-3

Po

wer

Source

A

B

C

D

E

W

ireFeeder

A

B

C

D

E

A

B

C

D

E

CONTROL CABLE CONNECTION:

INSTALLATION

WELD CABLE SIZE

A-3

Digital Control Cable: Figure A.3

Power Source

Pin Function

A Digital I/O
B Digital I/O
C "67" voltage sense
D 40 VDC
E 40 VDC

Wire Feeder

Pin Function

A Digital I/O
B Digital I/O
C "67" voltage sense
D 40 VDC
E 40 VDC

Welding Gun/Wire Feeder Trigger Connector
Wire Feeder: Figure A.4

Wire Feede r

n

i

g Gun

Weld

Table A.1 located below are copper cable sizes rec­ommended for 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.

WIRE FEEDER

Pin Function

A Gun Trigger
B ­C Common
D Dual Procedure
E Common

TABLE A.1

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

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

AMPRERES

200
200
225
225
250
250
250
250
300
325
350
400
400
500

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

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

PERCENT

DUTY

CYCLE

60

100

20

40 & 30

30
40
60

100

60

100

60
60

100

60

0 to 50Ft.
(0 to15M)

2
2

4 or 5

3
3
2
1
1

1
2/0
1/0
2/0
3/0
2/0

50 to 100Ft.

(15 to 30M)

2
2
3
3
3
2
1
1

1
2/0
1/0
2/0
3/0
2/0

POWER FEED 15M

100 to 150 Ft.

(30 to 46M)

2
2
2
2
2
1
1
1

1
2/0
2/0
2/0
3/0
3/0

150 to 200 Ft.

(46 to 61M)

1
1
1
1
1
1
1

1
1/0
2/0
2/0
3/0
3/0
3/0

200 to 250 Ft.

(61 to 76M)

1/0
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A-4

Electrode

Work

Work

ElectrodeElectrode

WWorkork

ElectrodeElectrode

W

Workork

Power SourcePower Source

Coaxial WCoaxial Weld Cableeld Cable

Wire FeederWire Feeder

INSTALLATION

COAXIAL WELD CABLE

Coaxial welding cables are specially designed welding
cables for pulse welding or STT welding. Coaxial weld
cables feature low inductance, allowing fast changes in the
weld current. Regular cables have a higher inductance
which may distort the pulse or STT waveshape. Inductance
becomes more severe as the weld cables become longer.

A-4

SHIELDING GAS CONNECTION

WARNING

CYLINDER may explode if

damaged.

• Keep cylinder upright and
chained to support.

Coaxial weld cables are recommended for all pulse and STT
welding, especially when the total weld cable length (elec­trode cable + work cable) exceeds 50 feet (7.6m)

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

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

A coaxial weld cable is constructed by 8 small leads
wrapped around one large lead. The large inner lead con­nects to the electrode stud on the power source and the
electrode connection on the wire feeder. The small leads
combine together to form the work lead, one end attached to
the power source and the other end to the work piece. See
Figure A.5

FIGURE A.5

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

• BUILD UP OF SHIELDING GAS MAY HARM

HEALTH OR KILL.

• Shut off shielding gas supply when not in use.

• See American National Standard Z-49.1, "Safety

in Welding and Cutting” Published by the
American Welding Society.

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

Install the shielding gas supply as follows:

1. Secure the cylinder to prevent it from falling.

2. Remove the cylinder cap. Inspect the cylinder valves and
regulator for damaged threads, dirt, dust, oil or grease.
Remove dust and dirt with a clean cloth. DO NOT

ATTACH THE REGULATOR IF OIL, GREASE OR DAM­AGE IS PRESENT! Inform your gas supplier of this con-

dition. Oil or grease in the presence of high pressure oxy­gen is explosive.

3. Stand to one side away from the outlet and open the
cylinder valve for an instant. This blows away any dust or
dirt which may have accumulated in the valve outlet.

ELECTRODE POLARITY

CAUTION

When changing the electrode polarity, the weld cables must be
changed at the power source studs and the DIP switch inside the
Power Feed 15M must be properly set. Operation with the DIP

switch in the wrong position will cause erratic arc performance.

The Power Feed 15M is factory set for Electrode Positive weld­ing. Most welding procedures use Electrode Positive welding.
Some Innershield procedures may use Electrode Negative
welding.

To change the DIP switch iside the Power Feed 15M electrode
polarity:

1. Turn off power at the welding power source.

2. Remove the rear access panel on the wire drive.

3. Locate DIP switches on the Wire Drive Board.

4. Set DIP switch #7 to the desired polarity.
DIP Switch #7 Position Polarity

4. Attach the flow regulator to the cylinder valve and tighten
the union nut(s) securely with a wrench. Note: if connect­ing to 100% CO2 cylinder, insert regulator adapter
between regulator and cylinder valve. If adapter is
equipped with a plastic washer, be sure it is seated for
connection to the CO2 cylinder.

5. Attach one end of the inlet hose to the outlet fitting of the
flow regulator. Attach the other end to the welding system
shielding gas inlet. Tighten the union nuts with a wrench.

6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting spring
pressure is released.

7. Standing to one side, open the cylinder valve slowly a
fraction of a turn. When the cylinder pressure gage stops
moving, open the valve fully.

8. The flow regulator is adjustable. Adjust it to the flow rate
recommended for the procedure and process being used
before making a weld.

ON (Up) - (negative) polarity
OFF (Down) + (positive) polarity

5. Assemble the rear access panel to the wire drive.

6. Restore power.

POWER FEED 15M

A-5

Low Speed
High T orque
Gear

High Speed
Low T orque
Gear

INSTALLATION

CHANGING THE DRIVE MOTOR GEAR RATIO

WARNING

A-5

11. Use a 5/16" nut driver to remove the four screws

and washers holding the insulated panel to the
sheet metal bracket.

• Turn off input power at the weld­ing power source before installa­tion or changing drive roll and/or
wire guides.

• Do not touch electrically live parts
such as the wire drive or internal
wiring.

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

• Only qualified personnel should perform this
operation.

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

Tools required:

• 1/4" hex key wrench

• 3/4" socket and ratchet wrench

• 9/16" socket and ratchet wrench

• 7/16" nut driver

• 5/16" nut driver

• Phillips screw driver

1. Remove the spool of electrode from the wire feeder.

2. Loosen the thumb screw at the wire drive and remove the

welding gun. Take the tension off the drive rollers and
open the tension handle.

12. Lift the wire drive assembly partially out of the wire
feeder. With a Phillips screw driver, remove the
three screws and lock washers securing the
motor. Remove the motor.

13. Place the motor in the new position.

14. Assemble the three screws and lock washers
holding the wire drive motor.

15. Place the wire drive assembly inside the wire
feeder. With a 5/16" nut driver, assemble the four
screws and lock washers to hold the insulating
panel to the sheet metal bracket.

16. With a 7/16" nut driver, replace the bolt at the top
securing the wire drive insulated panel to the
sheet metal case.

17) Move DIP switch #8 on the Feed head board to
the appropriate position.

Gear Select DIP Switch #8 Setting Range

High Speed ON 50 – 700 ipm
Low Speed OFF 50 – 400 ipm

18. Reassemble the cover assembly protecting the
display board with a 5/16" nut driver.

3. Remove the outer wire guide, drive rolls and inner wire
guide.

4. Use a 7/16" nut driver to remove the gear cover.

5. Use 9/16" socket and ratchet wrench to remove the lower
drive roll hub retainer. Remove the lower drive roll hub.

6. With a Phillips screwdriver, remove the screw, washer
and collar holding the pinion gear. Remove the pinion
gear.

7. Remove the electrode lead by unscrewing the bolt using
a 3/4" socket and ratchet wrench.

8. With a 1/4" hex key wrench, loosen the socket head cap
screw securing the gun bushing. Remove the gun bush­ing from the wire drive.

9. With a 5/16" nut driver remove the screws securing the
cover assembly protecting the display board. Lift out the
cover assembly enough so it does not overlap the wire
drive.

10. Use a 7/16" nut driver to remove the bolt at the top

securing the wire drive insulated panel to the sheet
metal case.

POWER FEED 15M

19. Place the gun bushing in the wire drive and align
the threaded hole in the gun bushing with the hole
in the feed plate. With a 1/4" hex key, tighten the
socket head cap screw to secure the bushing in
the wire drive.

20. Reassemble the electrode and tighten the mount­ing hardware with a 3/4" socket and ratchet
wrench.

21. Place the new gear on the motor shaft. Secure the
gear to the motor shaft with the collar, washer and
screw.

22. Reassemble the lower drive roll hub and lower
drive roll hub retainer.

23. Reassemble the gear cover.

24. Reassemble the inner wire guide, drive rolls and
outer wire guide.

25. Place the welding gun into the gun bushing and
secure with the thumb screw.

A-6

G

E

WIRE DRIVE CONFIGURATION

(See Figure A-6)

Changing the Gun Receiver Bushing

INSTALLATION

10. Tighten the socket head cap screw.

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

A-6

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.

• Only qualified personnel should perform mainte­nance work.

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

Tools required:

• 1/4" hex key wrench.
Note: Some gun bushings do not require the use of

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.

Important: Do not attempt to completely
remove the socket head cap screw.

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

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

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

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

FIGURE A-6

THUMB SCREW

UN RECEIVER BUSHING

OUTER WIRE GUID

PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES

WARNING

• Turn off input power at the welding power source
before installation or changing drive roll and/or
wire guides.

• Do not touch electrically live parts such as the
wire drive or internal wiring.

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

• Only qualified personnel should perform this
operation.

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

1. Release the idle roll pressure arm.

2. Remove the outer wire guide by turning the knurled

thumbscrews counter-clockwise to unscrew them
from the feed plate.

3. Rotate the triangular shaped drive roll retaining

mechanism to unlock the drive rolls and remove the
drive rolls.

4. Remove the inner wire guide.

5. Insert the new inner wire guide, groove side out,

over the two locating pins in the feed plate.

6. Install a drive roll on each hub assembly and lock

by rotating the triangular drive roll retaining mecha­nism.

7. Install the outer wire guide by aligning it with the

pins and tightening the knurled thumbscrews.

8. Close the idle arm and engage the idle roll pressure

arm. Adjust the pressure appropriately.

CONNECTOR BLOCK

SOCKET HEAD
CAP SCREW

LOOSEN TIGHTEN

POWER FEED 15M

A-7

CONNECT A LL SENSE
LEADS AT THE END
OF THE WELD

CONNECT A

LL

WORK LEAD

S AT

THE BEGINN

ING

OF

THE WELD

DIRE

CTION

OF

TRAVEL

INSTALLATION

REMOTE SENSE LEAD SPECIFICATIONS

Welding with Multiple Arcs:
( See Figure A.7)

Special care must be taken when more than one arc
is welding simultaneously on a single part. Arc blow
and arc interference may occur or be magnified. Each
power source requires a work lead from the work stud
to the welding fixture. Do not combine all of the work
leads into one lead. Performing welding in the direc­tion away from the work leads. Connect all of the work
sense leads from each power source to the work
piece at the end of the weld, such that they are out of
the path of the weld current. See Figure A.7

For the best results when pulse welding, set the wire
size and wire feed speed the same for all the arcs.
When these parameters are identical, the pulsing fre­quency will be the same, helping to stabilize the arcs.

FIGURE A.7

A-7

POWER FEED 15M

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.

WARNING

• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED fea­ture, when feeding with gun trig­ger, the electrode and drive
mechanism are always electri­cally energized and could
remain energized several sec­onds after the welding ceases..

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

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

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

• FUMES AND GASSES can be
dangerous.

• Keep your head out of fumes.

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

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

• WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

INPUT POWER

ON

OFF

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

---------------------------------------------------------------------­ARC RAYS can burn.

• Wear eye, ear and body protec­tion.

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

SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MAN­UAL.

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

U

U

U

I

I

0

1

2

1

2

OPEN CIRCUIT
VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

POWER FEED 15M