Lincoln Electric IM777 User Manual

Power Feed®10M Dual Wire Feeder: Code 10962, 11194, 11897, 11898

Copyright © Lincoln Global Inc.

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Power Feed 10M Dual Wire Feeder

IM777-C

September, 2012

For use with:

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.

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

OPERATORʼS MANUAL

• 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.

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.

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.

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 ma y 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 within applicable OSHA PEL and
ACGIH TLV limits 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.

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

vapors

to

5.e. 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.f. Also see item 1.b.

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

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

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

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use on ly com pr essed 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. Re ad and foll ow the inst ru ctions o n c ompressed 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. Ins tall 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.

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

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

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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.

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.

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.

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-circuit accidental peut provoquer 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
dʼopérations de dégraissage, nettoyage 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.

PRÉCAUTIONS DE SÛRETÉ POUR

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. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
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.

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.

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!

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

Your Product”. 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 “Support” and then “Register

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

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

Control Cable .......................................................................................................................A-2

Control Cable Connections ...........................................................................................A-2

Control Cable Specifications, avaliable Cable Assemblies ...........................................A-2

Output Cable, Connections and Limitations..................................................................A-3

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

Electrode Sense Polarity, To Set The Electrode Sense Polarity Switch .......................A-3

Voltage Sensing ............................................................................................................A-4

Wire Drive Gear Ratio (High or Low Speed) ........................................................................A-5

Selecting the Proper Gear Ratio ...................................................................................A-5

Changing the Wire Drive Ratio......................................................................................A-6

Ratio Change Procedure...............................................................................................A-6

Gear Ratio Recognition.................................................................................................A-6

Wire Feed Drive Roll Kits .....................................................................................................A-7

Procedure to Install Drive Rolls and Wire Guides ................................................................A-7

Gun and Cable Assemblies with Standard Connection........................................................A-7

Gun and Cable Assemblies with Fast-Mate Connection ......................................................A-7

General Gun Connection Guidelines....................................................................................A-8

GMAW Shielding Gas ..........................................................................................................A-8

Wire Spindle Placement .......................................................................................................A-9

Water Connections (For Water Cooled Guns) .....................................................................A-9

Wire Feed Shut Down Circuit (Optional) ............................................................................. A-9

Examples of Connecting an Arclink Power Wave System .................................................A-10

________________________________________________________________________________

vi

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

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

Definition of Welding Modes.................................................................................................B-1

Common Welding Abbreviations ..........................................................................................B-1

Product Description ..............................................................................................................B-2

Recommended Processes and Equipment ...................................................................B-2,B-3

Operation Features and Controls (Items 1 thru 5)................................................................B-3

1 Wire Feed Speed (WFS)/Amp Meter .........................................................................B-3

2 Volt / Trim Meter.........................................................................................................B-3

3 Output Controls ..........................................................................................................B-4

4 Dual Procedure / Dual Head Select W/Memory Panel...............................................B-4

5 Mode Select Panel 4 (MSP4) .......................................................................B-4 thru B-6

Set-Up Features Menu .........................................................................................B-7 thru B-14

Dual Head/Dual Procedure with Memory .................................................................B-15, B-17

2 Step / 4 Step Operation .........................................................................................B-17, B-18

Cold Feed/Gas Purge Switch .............................................................................................B-18

Hot Inch ..............................................................................................................................B-19

Foot Amptrol.......................................................................................................................B-19

Wire Drive PC board adjustments ......................................................................................B-19

Wire Reel Loading ....................................................................................................B-19, B-20

Feeding Electrode and Brake Adjustment..........................................................................B-20

Drive Roll Pressure Setting ................................................................................................B-20

Procedure for Setting Angle of Feedplate ..........................................................................B-20

Gas Guard Regulator Setting ....................................................................................................B-20

Making a Weld....................................................................................................................B-22

Wire Reel Changing ...........................................................................................................B-22

Wire Feed Overload Protection ..........................................................................................B-22

Component Status Lights ...................................................................................................B-23

Status Light States ............................................................................................B-23, B-24

________________________________________________________________________________

Limit Settings...............................................................................................................B-25

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

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

Other Accessories..................................................................................................C-2 thru C-5

________________________________________________________________________________

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 thru E-9

________________________________________________________________________________

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

Wiring (Power Feed 10 Dual Head).......................................................................F-1

Control Box Dimension Print..................................................................................F-2

Bench Model Dimension Print................................................................................F-3

Dual Wire Drive Dimension Print ...........................................................................F-4

________________________________________________________________________

Parts Lists ......................................................................................................P-468 Series

________________________________________________________________________

vii

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS – Power Feed®10M Dual Wire Feeder

WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER

SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO

Speed Solid Cored Speed Solid Cored

K2234-1 Bench Model 50-800 IPM .025 - 3/32 in. .035 - .125 in 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in.
K2316-1

Boom

Model (1.27-20.3 m/m) (0.6 - 2.4 mm) (0.9 - 3.2 mm) (2.0 - 30 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

Wire Size Wire Size

Dimensions

Height Width Depth Weight Operating Storage

K2234-1

Bench
Model
Feeder

K2316-1

Boom Box only ( 330 mm) (215 mm) (105 mm) (4.5 Kg.) (-10°C to 40°C) (-40°C to 40°C)
Model
Feeder

K2316-1

Boom only ( 228 mm) (483 mm) (394 mm) (18.1Kg.)
Model
Feeder

Wire Drive & 19.9“ 19.9“ 30.6“ 90 Lbs

Reel Stand ( 506 mm) (506 mm) (777 mm) (40.8 Kg.)

Dimensions Δ

Height Width Depth Weight

Control 40VDC 13.0“ 8.5“ 4.0“ 10.1Lbs 14°F to 140°F -40°F to 185°F

Dimensions Δ

Height Width Depth Weight

Wire Drive 9.0“ 19.0“ 15.5“ 40 Lbs

WELDING CAPACITY RATING

Amp Rating Duty Cycle

600 A 60%
500 A 100%

Δ Dimensions do not include wire reel.

POWER FEED®10M DUAL WIRE FEEDER

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.

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

ELECTRODE ROUTING

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

Typical Bench Feeder Connection:

Control cable is connected from the Power Wave 455
output receptacle to the input receptacle on the back
of the Wire Drive.

CONTROL CABLE SPECIFICATIONS

It is recommended that only genuine Lincoln control
cables be used at all times. Lincoln cables are specifi­cally designed for the communication and power
needs of the Power Wave
The use of non-standard cables, especially in lengths
greater than 25Ft. (7.6m), can lead to communication
problems (system shutdowns), poor motor accelera­tion (poor arc starting) and low wire driving force (wire
feeding problems).

Lincoln control cables are copper 5 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 less than 2.1 nanoseconds.
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.

®

/ Power Feed®system.

a) The electrode must be routed to the wire drive

unit so that the bends in the wire are at a mini­mum, and also that the force required to pull the
wire from the reel into the wire drive unit is kept at
a minimum.

b) The electrode is “hot” when the gun trigger is

pressed and must be insulated from the boom
and structure.

c) 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.

CONTROL CABLE

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.

AVAILABLE CABLE ASSEMBLIES

K1543 Control cable only. Available in lengths of 8Ft.

(2.4m), 16Ft. '(4.9m), 25Ft.(7.6m), 50Ft.
(15.2m) and 100Ft. (30.5m).

NOTE: The maximum cable length between Power
Source and Power Feed

®

is 100'(30.5m).

POWER FEED®10M DUAL WIRE FEEDER

A-3

INSTALLATION

A-3

OUTPUT CABLES, CONNECTIONS
AND LIMITATIONS

Connect a work lead of sufficient size and length (Per
Table A.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. Avoid
excessive lengths and do not coil excess cable.

Minimum work and electrode cables sizes are as follows:

TABLE A.1

(Current (60% Duty Cycle)

400 Amps 2/0 (67 mm2)
500 Amps 3/0 (85 mm2)
600 Amps 3/0 (85 mm2)

NOTE: K1796 coaxial welding cable is recommended
to reduce the cable inductance in long distance Pulse
applications up to 300 amps.

MINIMUM COPPER

WORK CABLE SIZE AWG

Up To-100 Ft. Length (30 m)

For additional Safety information regarding the elec­trode and work cable set-up, See the standard "SAFE­TY INFORMATION" located in the front of the
Instruction Manuals.

CAUTION

Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.

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

NEGATIVE ELECTRODE POLARITY

When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) stud, and work cable to the positive
(+) stud).

ELECTRODE SENSE POLARITY

This options allows for the setting of negative polarity
sensing when a negative polarity welding process is
performed.

CAUTION

When using an inverter type power source like the
power waves, use the largest welding (electrode
and work) cables that are practical. At least 2/0
copper wire - even if 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.

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

Output connections on some Power Waves are made
via 1/2-13 threaded output studs located beneath the
spring loaded output cover at the bottom of the case
front.

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). Connect the other end of the electrode
cable to the wire drive feed plate. The electrode cable
lug must be against the feed plate. Be sure the con­nection to the feed plate makes tight metal-to-metal
electrical contact. The electrode cable should be sized
according to the specifications given in the work cable
connections section. Connect a work lead 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.

When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) stud, and work cable to the positive
(+) stud).

When operating with electrode polarity negative the
Wire Feeder must be set to recognize this option.

To Set the Electrode Sense Polarity Switch

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the dis­connect switch before working on
this equipment.

• Do not touch electrically hot parts.

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
10M Dual must be properly set. Operation with the
DIP switch in the wrong position will cause erratic
arc performance.

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

POWER FEED®10M DUAL WIRE FEEDER

A-4

INSTALLATION

A-4

The Power Feed®10M Dual Wire Feeder is factory set
for Electrode Positive welding.

Most welding procedures use Electrode Positive weld­ing. Some Innershield procedures may use Electrode
Negative welding. For most applications, the Power

®

Feed
the Wire Drive set to the same polarity. To weld with
opposite polarities, each head would have to be weld­ing on isolated work pieces and the weld cable attach­ing the two feed heads would have to be removed.

To change the DIP switch inside the Power Feed
10M Dual Wire Feeder for 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 BOTH Wire Drive Boards.

4. Set DIP switch #7 on BOTH Wire Drive Boards to
the desired polarity.

10M Dual Wire Feeder will have both sides of

VOLTAGE SENSING

The best arc performance occurs when the power
waves have accurate data about the arc conditions.
Depending upon the process, inductance within the
electrode and work lead cables can influence the volt­age apparent at the studs of the welder. Voltage
sense leads improve the accuracy of the arc condi­tions and can have a dramatic effect on performance.
Sense Lead Kits (K940-xx) are available for this pur­pose.

®

If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
extremely high welding outputs may occur.

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

The ELECTRODE sense lead (67) is built into the
control cable, and is automatically enabled for all
semi-automatic processes. The WORK sense lead
(21) connects to the Power Wave at the four pin con­nector located underneath the output stud cover. By
default the WORK voltage is monitored at the output
stud in the Power Wave 455. For more information on
the WORK sense lead (21), see"Work Voltage

Sensing” in the following paragraph.

CAUTION

DIP Switch #7 Position
Polarity

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

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

6. Restore power.

}

Enable the voltage sense leads as follows:

TABLE A.2

Process

GMAW
GMAW-P
FCAW
SAW
GTAW
GMAW
CAC-C

* The electrode voltage 67 sense lead is integral to

the control cable to the wire feeder.

Electrode Voltage Work Voltage
Sensing 67 lead * Sensing 21 lead

67 lead required 21 lead optional

Voltage sense at studs Voltage sense at studs

POWER FEED®10M DUAL WIRE FEEDER

A-5

INSTALLATION

A-5

Work Voltage Sensing

The standard Power Wave 455ʼs default to the work
stud (work sense lead disabled)

For processes requiring work voltage sensing, con­nect the (21) work voltage sense lead (K940) from the
Power Wave work sense lead receptacle to the work
piece. Attach the sense lead to the work piece as
close to the weld as practical, but not in the return cur­rent path. Enable the work voltage sensing in the
Power Wave as follows:

WARNING

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

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

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

1. Turn off power to the power source at the discon­nect switch.

2. Remove the front cover from the power source.

WIRE DRIVE GEAR RATIO (HIGH
OR LOW SPEED)

The speed range capability and drive torque of the
Power Feed®wire drives can be easily and quickly
changed by changing the external drive gear. The
Power Feed®Wire Feeders are shipped with both high
speed and a low speed gears. As shipped from the
factory, the low speed (high torque) gear is installed
on the feeder. If this is the desired gear ratio, no
changes need be made.

If a change in gear ratio is desired, the systems needs
to be made aware of which gear has been installed on
the Wire Drive, low or high speed. This is accom­plished through the selection of a dip switch on the
wire drive PCB.

SELECTING THE PROPER GEAR RATIO

See Technical Specifications at the front of the
Installation 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:

3.

The control board is on the left side of
the power source. Locate the 8-position
DIP switch and look for switch 8 of the
DIP switch.

4. Using a pencil or other small object,
slide the switch right to the OFF posi­tion if the work sense lead is NOT con­nected. Conversely, slide the switch left
to the ON position if the work sense
lead is present.

5. Replace the cover and screws. The PC board will
“read” the switch at power up, and configure the
work voltage sense lead appropriately.

Electrode Voltage Sensing

Enabling or disabling electrode voltage sensing is
automatically configured through software. The 67
electrode sense lead is internal to the cable to the
wire feeder and always connected when a wire feeder
is present.

12 3456 78

O

N

CAUTION

• If you need to operate at wire feed speeds above
800 IPM (20 m/m), you will need to install the high
speed gear (large 30 tooth, 1.6 inch diameter gear).

• If you do not need to run at wire feed speeds in
excess of 800 IPM (20 m/m), you should use the
low speed gear (small, 20 tooth, 1.1 inch diameter
gear). Using the low speed ratio will provide the
maximum available wire driving force.

Note: If you are feeding only small diameter wires you
may, at your option, install the high speed ratio.

Important: The electrode polarity must be config-

ured at the feed head for all semi-automatic
processes. Failure to do so may result in extreme­ly high welding outputs.

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

POWER FEED®10M DUAL WIRE FEEDER

A-6

INSTALLATION

A-6

CHANGING THE WIRE DRIVE GEAR RATIO

Changing the ratio requires a gear and a dip switch
setting change. The Power Feed®Wire Feeders are
shipped with both high speed and a low speed gears.
As shipped from the factory, the low speed (high
torque) gear is installed on the feeder. For identifica­tion purposes, the low speed (high torque) gear has
20 teeth and is 1.1 inches in diameter. The high speed
gear has 30 teeth and is 1.6 inches in diameter.

WARNING

Power down the Power Feed
Feeder by turning off its companion Power Wave
power source. For maximum safety, disconnect
the control cable from the Power Feed
Wire Feeder.

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

GEAR

1. Pull open the Wire Drive Door.

2. Remove the Phillips head screw retaining the pin-

3. Loosen, but do not remove, the screw on the

4. Remove the screw on the left face of the feed

RATIO CHANGE PROCEDURE:

ion gear to be changed and remove the gear. If
the gear is not easily accessible or difficult to
remove, remove the feed plate from the gearbox.
To remove feed plate:

a. Loosen the clamping collar screw using a

3/16" Allen wrench. The clamping collar screw
is accessed from the bottom of the feed plate.
It is the screw which is perpendicular to the
feeding direction.

b. Loosen the retaining screw, which is also

accessed from bottom of feeder, using a 3/16"
Allen wrench. Continue to loosen the screw
until the feed plate can be easily pulled off of
the wire feeder.

lower right face of the feed plate with a 3/16" Allen
wrench.

plate. If changing from high speed (larger gear) to
low speed (smaller gear), line the lower hole on
the left face of the feed plate with the threads on
the clamping collar. Line the upper hole with the
threads to install larger gear for high speed feeder.
If feed plate does not rotate to allow holes to line
up, further loosen the screw on right face of feed
plate.

®

10M Dual Wire

®

10M Dual

5. Remove the small gear from the output shaft.
Lightly cover the output shaft with engine oil or
equivalent. Install gear onto output shaft and
secure with flat washer, lock washer, and Phillips
head screw which were previously removed.

6. Tighten the screw on lower right face of feed plate.

7. Re-attach feed plate to wire feeder if removed in
Step 2.

8. Feed plate will be rotated out-of-position due to
the gear change. Adjust the angle of the feed plate
per the instructions above.

9. Set the wire drive gear ratio switch on Wire Drive
PC board as follows:

GEAR RATIO RECOGNITION:

1. Remove the rear access door from the wire feeder
case.

2. Locate the dip switch bank on the P.C. board (refer
to table A.3)

3. Locate dip switch # 8 and move it to the appropriate
gear ratio setting as described below:

FIGURE A.2

sw1

UP - High Speed Gear Ratio
DOWN - Low Speed Gear Ratio

4. Replace the rear access door of the wire feeder
case.

Note: The system recognizes dip switch settings only

during system power-up.

PF-10M Feeder location PF-10M P.C. board location

(Facing rear of unit) (Facing rear of unit)

Feeder 1 Right On inside divider panel
Feeder 2 Left On rear access door

}

TABLE A.3

POWER FEED®10M DUAL WIRE FEEDER

A-7

WIRE FEED DRIVE ROLL KITS

INSTALLATION

• Insert inner Wire Guide, groove side out, over the

two locating pins in the feedplate.

A-7

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 roll and
guide tube are stenciled on each part. Check the kit
for proper components. Kit specifications can be
found in the ACCESSORIES section.

PROCEDURE TO INSTALL DRIVE
ROLLS AND WIRE GUIDES

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such
as output terminals or internal wiring.

•

When feeding without Power Feed 10 Dual “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.

Drive Roll Kit Installation (KP1505-[ ])

• 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).

• Install Outer Wire Guide by sliding over locating pins
and tightening in place.

• Engage upper drive rolls if they are in the “open”
position and close Pressure Door.

TO SET DRIVE ROLL PRESSURE, see “Drive Roll
Pressure Setting” in OPERATION.

GUN AND CABLE ASSEMBLIES
WITH STANDARD CONNECTION

The Power Feed®10 Dual Wire Feeder is equipped
with a factory installed K1500-2 gun connection Kit.
This kit is for guns having a Tweco™ #2-#4 connec­tor. The Power Feed
designed to make connecting a variety of guns easy
and inexpensive with the K1500 series of gun connec­tion kits. Gun trigger and dual procedure lead connec­tions connect to the single 5 pin receptacle on the
front of the feed head box. See “Gun Adapters” in
ACCESSORIES section.

®

10 Dual Wire feeder has been

GUN AND CABLE ASSEMBLIES
WITH FAST-MATE™ CONNECTION

(including the Magnum 450 Water Cooled gun)

• Turn OFF Welding Power Source.

• Pull open Pressure Door to expose rolls and wire
guides.

• Remove Outer Wire Guide by turning knurled thumb
screws counter-clock-wise to unscrew them from
Feedplate.

Observe all additional Safety Guidelines detailed
throughout this manual.

• Remove drive rolls, if any are installed, by pulling
straight off shaft. Remove inner guide.

POWER FEED®10M DUAL WIRE FEEDER

A K489-7 adapter will install directly into the wire drive
feedplate, to provide for use of guns with Fast-Mate™
or European style gun connections. This K489-7 will
handle both standard Fast-Mate™and Dual Schedule
Fast-Mate™ guns.

Another way to connect a gun with a Fast-Mate™ or
European style gun connector to the Power Feed
Dual Wire feeder, is to use the K489-2 Fast-Mate™
adapter kit. Installation of this adapter also requires a
K1500-1 gun connector. See “Gun Adapters” in
ACCESSORIES section.

®

10

A-8

INSTALLATION

A-8

GENERAL GUN CONNECTION
GUIDELINES

The instructions supplied with the gun and K1500
series gun adapter 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 and guide tubes are

proper for the electrode size and type being used.
If not, change them.

b. Lay the cable out straight. Insert the connector

on the welding conductor cable into the brass
conductor block on the front of the wire drive
head. Make sure it is all the way in and tighten
the hand clamp. Keep this connection clean and
bright. Connect the trigger control cable polarized
plug into the mating 5 cavity receptacle on the
front of the wire drive unit.

Note: for Fast-Mate and European connector style

guns, 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.

c. For GMA Gun Cables with separate gas fittings,

connect the 3/16” I.D. gas hose from the wire
drive unit to the gun cable barbed fitting.

d. For water cooled guns see WATER CONNEC-

TIONS in this section.

GMAW SHIELDING GAS

WARNING

CYLINDER may explode if damaged.

• Keep cylinder upright and chained to
support.

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

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

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

BUILDUP 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.

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

NOTE: Gas supply pressure must be regulated to a
maximum of 80 psi(5.5 bar).

Customer must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve, and a hose
from the flow valve to the gas inlet fitting of the wire
drive unit.

Connect a supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on the
back panel of the wire drive or, if used, on the inlet of
the Gas Guard regulator. (See Below).

Gas Guard Regulator - The Gas Guard Regulator is
an optional accessory (K659-1) on these models.

Install the 5/8-18 male outlet of the regulator to the
5/8-18 female gas inlet on the back panel of the wire
drive. Secure fitting with flow adjuster key at top.
Attach gas supply to 5/8-18 female inlet of regulator
per instructions above.

POWER FEED®10M DUAL WIRE FEEDER

A-9

INSTALLATION

A-9

WIRE SPINDLE PLACEMENT

The reel stand provides two mounting locations for the
2 inch diameter wire reel spindle to accommodate var­ious reel sizes. Each mounting location consists of a
tube in the center of the reel stand, and locating slots
on the outside of the reel stand. The bolt, used with a
plain washer and lock washer, slides through the tube
from the side of the reel stand. The bolt should be
threaded into the wire spindle such that the tabs on
the brake mechanism align with the locating slots,
then tighten.

The upper location must be used for 50-60 lb. Spools
and Coils.

For smaller coils (44lb, 30lb, 10lb, etc.), the spindle
can be placed in either the upper or lower location.
The goal is to make the wire path from the coil to the
wire drive an entry into the incoming guide tube that is
as straight as possible. This will optimize wire feeding
performance.

WATER CONNECTIONS (FOR
WATER COOLED GUNS)

Flow Sensor Kit installation is as follows:

1. Remove rear access door of the wire feeder case.

2. Locate the shutdown circuit leads inside feeder
case cavity (refer to table A.4).
Note: The leads will be connected together with
insulated (pink) quick disconnects.

3. Disconnect pink quick-connect tabs (.25 inch tab
terminals).

4. Locate and remove plastic plug on rear of wire
feeder case.

5. Insert Flow Sensor leads through hole.

6. Connect Flow Sensor leads with shutdown circuit
leads.

7. Replace rear access door.

TABLE A.4

PF-10M Shutdown Feeder Cavity Location

Leads (Facing rear of unit)
Feeder 1 Shutdown 570 570 A/B Upper Right Corner
Feeder 2 Shutdown 670 670 A Upper Left Corner

If a water cooled gun is to be installed for use with the
Power Feed®10 Dual, a K590-6 Water connection kit
can be installed for each gun requiring water cooling.
Contained in the kit are the water lines and quick con­nect water line fittings that install in the wire feed
head. Follow the installation instructions included in
the kit. Water cooled guns can be damaged very
quickly if they are used e ven mo men tarily without
water flowing. To protect the gun, we recommended
that a water flow sense kit be installed. This will pre­vent wire feeding if no water flow is present.

WIRE FEED SHUT DOWN CIRCUIT
(OPTIONAL)

This option is intended as a means of disabling weld­ing in the event that the water flow (for a water cooled
gun) is not present. Water cooled guns can be quickly
damaged if they are momentarily used without water
flow. This matter can be avoided when a Lincoln Flow
Sensor Kit (K1536-1) is applied to the wire feeder
shutdown circuit.

The Flow Sensor Kit has two control leads that
become electrically common when the water is flow­ing. When integrated with the wire feeder shut down
circuit, it forms a closed (common) circuit and enables
welding. In the event that water is not flowing, the
Flow Sensor circuit (shut down circuit) is electrically
opened which disables any further operation.

POWER FEED®10M DUAL WIRE FEEDER

A-10

INSTALLATION

EXAMPLES OF CONNECTING AN
ARCLINK POWER WAVE SYSTEM

ArcLink Power Wave®products may be configured in
many different ways. The flexible system allows multi­ple wire feeders to be connected to the same power
source. The diagrams represent some of the common
methods for connecting ArcLink Products.

Important: Bench model wire feeders cannot be sepa­rated into a separate control box and wire drive for a
boom system.

Shown with

®

• K2230-1 Power Feed

10M Single Wire Feeder

• K1780-2 Power Feed®-10/R

• K2203-1 Power Wave®455M/STT

• K2205-1 Wire Drive Module

Hard Automation System

A-10

Common ArcLink Systems

®

The following Power Wave

systems may all be
assembled without any changes to the equipment DIP
switches

Basic Semi-Automatic System

• Great for general fabrication.

Shown with

• K2230-1 Power Feed

®

10M Single Wire Feeder

• K2203-1 Power Wave®455M/STT

Boom Semi-Automatic System

• Often used when making large weldments.

Shown with

• Control Box (not available at the time of this writing)

®

• K1780-2 Power Feed

• K2203-1 Power Wave

-10/R

®

455M/STT

• K2205-1 Wire Drive Module

Multiple Wire Feeder System

• Load one feeder with solid wire, the other with flux
cored.

• Great for pipeline work.

Shown with

• K2429-1 ArcLink T Cable Connector

• K2196-1 Power Feed

®

15M

• K2203-1 Power Wave®455M/STT

Shown with

®

• K2314-1 Power Feed

10M Single Wire Feeder

Boom (includes wire drive and control box)

• K2203-1 Power Wave

®

455M/STT

Robotic/Semi-Automatic System

• Use the bench feeder for offline welding.

POWER FEED®10M DUAL WIRE FEEDER

ArcLink Systems

Many other ArcLink systems may be assembled
besides those shown in this manual. The majority will
self configure. If an assembled system flashes the sta­tus light green rapidly on all components, contact the
Lincoln Electric Company for further assistance.

®

Current Power Feed

10M models that will not self

configure...

• K2316-1 Power Feed®10M Dual Boom

These configurations will require Dip Switches to be
set. See the power source instruction manual on how
to disable self configuration.

B-1

OPERATION

SAFETY PRECAUTIONS

Read entire Operation section before
operating the Power Feed
Feeder.

®

10M Dual Wire

WARNING

B-1

COMMON WELDING ABBREVIATIONS

WFS

• Wire Feed Speed

ELECTRIC SHOCK can kill.

• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.

• Always wear dry insulating
gloves.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

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

WELDING SPARKS can
cause fire or explosion.

• Keep flammable material away.

• Do not weld on closed contain­ers.

ARC RAYS can burn eyes
and skin.

• Wear eye, ear and body protec­tion.

CC

• Constant Current

CV

• Constant Voltage

GMAW (MIG)

• Gas Metal Arc welding

GMAW-P (MIG)

• Gas Metal Arc welding-(Pulse)

GMAW-PP (MIG)

• Gas Metal Arc welding-(Pulse-on-Pulse)

GTAW (TIG)

• Gas Tungsten Arc welding

SMAW (STICK)

• Shielded Metal Arc welding

FCAW

• Flux Core Arc Welding

Observe all safety information throughout
this manual.

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

DEFINITIONS OF WELDING MODES

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding

process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of

single knob control. The machine will select the cor­rect voltage and amperage based on the wire feed
speed (WFS) set by the operator.

POWER FEED®10M DUAL WIRE FEEDER

B-2

OPERATION

B-2

PRODUCT DESCRIPTION

The Power Feed®10M Dual Wire Feeder unit consists
of a user interface and two wire drives. This unit will
be available as a bench model or a boom model.

The Power Feed
performance, digitally controlled, modular wire feeder.
Properly equipped, it can support the GMAW, GMAW­P, FCAW, SMAW, GTAW, and STT processes. The
Power Feed
a part of a modular, multi process welding system.
The Power Feed
Automatic unit that is designed to interface with the
Power Wave®M family of welding machines. It con­sists of a user interface (UI) and wire drive (WD) that
operate on 40VDC input power. The user interface is
designed to act as a means to access the functionality
(weld mode, run-in, volts, current etc.) of the welding
system. The wire drive unit is a 4 driven roll feeder
that can "push" various types of welding wire.

Each component in the system has special circuitry to
"talk with" the other system components, so each
component (power source, wire feeder, electrical
accessories) knows what the other is doing at all
times. This shared information lays the groundwork for
a system with superior welding performance.

®

10M Dual Wire Feeder is a high

®

10M Dual Wire Feeder is designed to be

®

10M Dual Wire Feeder is a Semi-

RECOMMENDED PROCESSES AND
EQUIPMENT

RECOMMENDED PROCESSES

The Power Feed®10M Dual Wire Feeder can be set
up in a number of configurations. They are designed
to be used for GMAW, GMAW-P, FCAW and STT
processes for a variety of materials, including mild
steel, stainless steel, and cored wires. Other process­es such as STT, SMAW and GTAW can be controlled
using the user interface portion of the unit. (See
Accessories Section for Part numbers and connec­tions.

RECOMMENDED EQUIPMENT

The Power Feed®10M Dual Wire Feeder must be
used with communication compatible welding equip­ment. That is, the communication protocol that is used
in the welding system must be capable of communi­cating with the wire feeder. This would be any power
source that has the Arclink receptacle available and
is operating with LincNet or Arclink software.

EQUIPMENT LIMITATIONS

DUAL HEAD UNIT

Two Control PC boards: one board supports user
interface and wire drive functions and second board
supports second wire drive functions.

• The memory panel is required to set limits.

• The boom model does not support push-pull guns
or GTAW welding.

• 12 pin foot and hand amptrols are not compatible.

POWER FEED®10M DUAL WIRE FEEDER

B-3

OPERATION

OPERATIONAL FEATURES AND
CONTROLS

B-3

• After the 5 second "Hold" period, the meter displays the
set WFS (CV modes) or Amp (CC modes) value.

Power Feed®10M SERIES SYSTEM CONFIGURATION

2. VOLT / TRIM METER

The specific system component function of the pc board will
be configurable by dip switch or by software configuration
tool. Dip switch configuration is as follows: Refer to DIP
switch settings of figures below.

Notes:

1. Basic Power Feed® 10M systems consist of one User
Interface (UI), and up to two wire drives (a dual head wire
drive counts as two).

CV Processes

Power Feed® 10M DUAL BENCH DIP SWITCH SETTINGS

UI/WD PCB - S25629
(located on Wire Drive divider panel)

WD only PCB - S25616
(located on Wire Drive rear access door)

1 2 3 4 5 6 7 8

O
N

1 2 3 4 5 6 7 8

O
N

Power Feed® 10M DUAL BOOM DIP SWITCH SETTINGS*

UI only PCB - S25952
(located in Control Box)

WD only PCB #1 - S25616
(located on Wire Drive divider panel)

WD only PCB #2 - S25616
(located on Wire Drive rear access door)

1 2 3 4 5 6 7 8

O
N

1 2 3 4 5 6 7 8

O
N

1 2 3 4 5 6 7 8

O
N

CC Processes

* See power source manual for additional dip switch settings.

This meter displays either the voltage or trim value
depending on the status of the machine. Located
below the display are the text "Volts" and "Trim." An
LED light is illuminated next to one of these in order
to indicate the units of the value displayed in the
meter.

• Prior to CV-GMAW and CV-FCAW operation, the
meter displays the desired preset Voltage value.

• Prior to CV-GMAW-P operation, the meter displays
the desired preset Trim value.

• During Welding, the meter displays actual average
volts.

• After welding, the meter holds the actual voltage
value for 5 seconds. During this time, the display is
blinking to indicate that the machine is in the "Hold"
period. Output adjustment while in the "Hold" period
results in the "prior to operation" characteristics stat­ed above.

• After the 5 second "Hold" period, the meter displays
the set Voltage (GMAW, FCAW) or Trim (GMAW-P)
value.

• The meter displays the status of the output.

• When output is enabled, the meter will display "ON."

• When there is no output, the meter will display
"OFF."

CONTROLS (Refer to Figure B.2)

1. WIRE FEED SPEED (WFS) / AMP METER

This meter displays either the WFS or current value
depending on the status of the machine. Located below
the display are the text "WFS" and "Amps."
is illuminated next to one of these in order to indicate
the units of the value displayed in the meter.

• Prior to CV operation, the meter displays the desired pre­set WFS value.

• Prior to CC-Stick and CC-GTAW operation, the meter
displays the preset current value.

• During Welding, the meter displays actual average
amps, but may be configured to display actual WFS.

• After welding, the meter holds the actual current or WFS
value for 5 seconds. During this time, the display is blink­ing to indicate that the machine is in the "Hold" period.
Output adjustment while in the "Hold" period results in
the "prior to operation" characteristics stated above.

An LED light

5

IR PORT

WELD MODE
ARC CONTROL

FIGURE B.2

ALUMINUM

3/64"

72

PULSE 4043 Ar

SET

SETUP

START OPTIONS
END OPTIONS

4

POWER FEED®10M DUAL WIRE FEEDER

B-4

OPERATION

3. OUTPUT CONTROLS

• The Power Feed®10M Dual Wire Feeder has 2
encoder knobs to adjust weld parameters.

• Each encoder changes the displayed value of the
meter located directly above that encoder.

• In CC-GTAW modes when equipped with a foot or
hand amptrol, the left encoder sets the maximum
welding current. Full depression of a foot or hand
amptrol results in the preset level of current.

• In CC-Stick and CC-GTAW, the right encoder acti­vates and de-activates the output. Turning the
encoder clockwise enables the output. To de-ener­gize the output, turn the encoder counter-clockwise.
The display above will indicate the "ON" or "OFF"
status of the output.

4. DUAL PROCEDURE / DUAL HEAD SELECT
W/MEMORY PANEL

(See Mode Select Panel Section for a Functional
Description and detailed explanation)
This panel is intended for dual head applications, and
is essentially the same as the Dual Procedure with
Memory panel except for the addition of a second pro­cedure select push button. It contains two procedure
select buttons, one for each head, and six memory
(storage) buttons.

In general terms, dual procedure and memory are
essentially independent storage locations for informa­tion.

5. MODE SELECT PANEL 4 (MSP4)

B-4

ITEM DESCRIPTION

1 IR (Infrared) Port.
2 Weld Mode Number.
3 Weld Wire Type.
4 Wire Size.
5 Weld Mode Description.
6

Status LED Lights-Weld Mode/Arc Control.

7 Selection Pushbutton Weld Mode or Arc

Control.
8
9

“Set” (Adjustment) Dial / Knob

Selection Pushbutton Start and End

Options.

10 Status LED Lights-Start/End Options.

Through the use of alphanumeric displays
provides standard text messages designed to
enhance the userʼs understanding of the machineʼs
operation as well as provide advanced capabilities
The panel provides:

• Clear identification of the selected weld mode.

• Identification of weld modes not listed on the
preprinted weld mode list label.

• Control of up to four wave controls (arc controls.)

• Weld mode specific wave control name display
(Peak, Background, Pinch, etc.).

• Unit values are displayed (Amps, in/min, etc.).

• User-friendly machine setup and configuration.

• Limit setting for restricting the operators range of
control.

• Lockout to prevent unauthorized changes to
machine configuration.

(Codes 11194 and Below)

, the MSP4

OVERVIEW:

The MSP4 is the standard mode select panel for the
Power Feed®10M Dual Wire Feeder wire feeders. The
MSP4 is capable of:

- Weld mode selection.

- Arc Control adjustment.

- Weld sequence control (Preflow Time, Run-in
WFS, etc.)

FIGURE B.3

1

WELD MODE
ARC CONTROL

6

IR PORT

2

72

7

3

ALUMINUM

3/64"

PULSE 4043 Ar

SET

8

4

SETUP

START OPTIONS
END OPTIONS

9

5

10

(For Codes 11194 and below)
Additionally, the MSP4 includes an infrared (IR) port
for wireless communication and configuration using a
Palm OS based hand held computer and a simplified
control layout.

LAYOUT-CONTROLS
(SEE FIGURE B.3)

The MSP4 panel controls (Items 7 and 9) set consist
of an encoder knob Item 8 and two push buttons. The
encoder is primarily used to change the value of the
selected attribute.

The left pushbutton (Item 7)

is used to toggle between
Weld Mode selection and any active Arc Controls
(a.k.a. wave controls). The choices of wave controls
varies by weld mode. For example, weld mode 31 has
one wave control, “Pinch”. Weld mode 110 has three
wave controls, “Peak Current”, “Background Current”
and “Tailout”. If the selected weld mode has no wave
controls, pressing the left pushbutton will have no
effect.

POWER FEED®10M DUAL WIRE FEEDER

B-5

If the selected weld mode uses one or more wave con­trols, pressing the left pushbutton will sequence the
selection from weld mode -> wave control 1 (if active) ->
wave control 2 (if active) -> wave control 3 (if active) ->
wave control 4 (if active) then back to weld mode.

The right pushbutton (Item 9)
that affect the available weld parameters such as pre­flow time, burnback time, etc. Since most users will
require infrequent access to these attributes, they are
separate from weld mode selection and wave control
adjustment.

LAYOUT-DIGITAL DISPLAY

is used to select attributes

OPERATION

B-5

All discrete LEDʼs are turned on, all 7-segment displays
will show a pattern of "8." and all alphanumeric displays
will show a hatch pattern where every-other pixel is illu­minated. The lamp test will last for two seconds, after
which all displays are turned back off. The 16-character
alphanumeric display will show "Initializing…" while
waiting for the Weld Sequencer to announce bus avail­able. The MSP4 alphanumeric displays will then dis­play the name of the weld table loaded in the power
source while the user interface prepares the machine
for operation. After all initialization is complete, the
MSP4 will display the weld mode information for the
mode number that was selected when the machine was
last powered down.

The MSP4 display consists of a large 4-digit, 7-segment
LED display, two 8-character alphanumeric LED dis­plays and one 16-character alphanumeric LED display.
The information shown on the various displays depends
on the state of the user interface as described below.

When the MSP4 is being used to select a weld mode,
the 4-digit display (Item 2) indicates the selected weld
mode number. The upper 8-character alphanumeric dis­play (Item 3) indicates the electrode type (steel, alu­minum, etc.) The lower 8-character alphanumeric dis­play (Item 4) indicates the electrode size (.035", 1/16",
etc.).

The 16-character alphanumeric display (Item 5) indi­cates the process type and other information, the exact
content of which depends on the selected weld mode.
This additional information may include specific elec­trode type (e.g. 4043) and/or a description of the recom­mended gas (e.g. HeArCO2).

When the MSP4 is being used to change the value of
an attribute, the 7-segment displays show the selected
attributeʼs value. The upper 8-character alphanumeric
display is typically not used while changing an
attributeʼs value. The lower 8-character alphanumeric
display is used to indicate the units of the selected
attribute (e.g. seconds, in/min, etc.). The 16-character
alphanumeric display is used to display the name of the
selected attribute.

The content of the displays while the user interface is
being used for advance machine configuration (e.g. limit
setting, pass code entering, machine setup, etc.) is
described in later sections.

CHANGING WELD MODES

To select a weld mode, press the left MSP4 pushbutton
until the WELD MODE LED is illuminated. Turn the
MSP4 encoder until the desired weld mode number is
displayed. As the MSP4 encoder knob is rotated, only
the weld mode number is displayed. After 1 second of
encoder idle time, the user interface will change to the
selected weld mode and the new modeʼs electrode
type, electrode size and process information will
appear.

WELD MODE SEARCHING

The Weld Mode Search feature allows the selection of a
welding mode based on certain criteria (wire size,
process type, etc.).

SEARCHING FOR A WELD MODE

To search for a mode, turn the control knob until “Weld
Mode Search” is displayed. This will appear in between
the highest and the lowest weld mode numbers.

Once “Weld Mode Search” is displayed, pressing the
right pushbutton labeled “Begin” will start the search
process.

During the search process, pressing the right pushbut­ton typically acts as a “next” button and the left pushbut­ton typically acts as a “back” button.

Rotate the control knob then press the right pushbutton
to select relevant welding details such as welding
process, wire type, wire size, etc.

POWER-UP SEQUENCE

When power is first applied to the machine, a lamp test
is performed.

POWER FEED®10M DUAL WIRE FEEDER

When the final selection is made, the PF10M™ will
automatically change to the weld mode found by the
Weld Mode Search process.

Earlier products may not have this feature. To activate
this feature, a software update may be needed from
www.powerwavesoftware.com

B-6

CHANGING ARC WAVE CONTROL

OPERATION

LIMIT SETTING

B-6

If the selected weld mode uses any of the four available
wave controls, users can press the left MSP4 pushbutton
until the ARC CONTROL LED is illuminated. The value,
name and units (if applicable) of the available wave con­trols will appear. Note that the name of the control is
derived from the weld table and may not necessarily
appear as "Wave Control". Repeated pressing of the left
MSP4 pushbutton will cycle through all active wave con­trols and then the weld mode. Turning the MSP4 encoder
will change the value of the displayed wave control.

CHANGING WELD SEQUENCE BEHAVIOR

Weld sequencing attributes are grouped into two cate­gories, START OPTIONS and END OPTIONS. START
OPTIONS may include Preflow Time, Run-in Wire Feed
Speed, and Start Time. END OPTIONS may include
Spot Timer, Crater Time, Burnback Time and Postflow
Time. The attributes that appear in the START and END
OPTIONS are weld mode dependent. For example, if a
TIG weld mode is selected, Run-in WFS will not appear
since it is not relevant to the selected process. Repeated
pressing of the right MSP4 pushbutton will cycle through
all relevant START and END OPTIONS. Turning the
MSP4 encoder will change the value of the selected
option.

When the Start Time attribute is set to a value other than
OFF, the START OPTIONS LED will blink synchronous
with the WFS and VOLTS/TRIM LEDʼs on the dual-dis­play panel. This blinking is used to indicate that start wire
feed speed and voltage/trim can now be set to values dif­ferent from those used while welding. Similarly, if the
Crater Time attribute is set to a value other than OFF,
the END OPTIONS LED will blink synchronously with the
dual-display LEDʼs, indicating that crater wire feed speed
and voltage/trim now can be set to values different from
those used while welding.

The MSP4 can be optionally configured to limit the
operatorʼs range of control of any weld parameter
(weld WFS, arc control, etc.). Limits are only available
with the Dual Procedure/Memory Panel.

MACHINE SETUP/USER PREFERENCES

The MSP4 can be used to configure and troubleshoot
the machine.

ACCESSING THE MACHINE SETUP MENU

To access the Machine Setup menu, press both
MSP4 push buttons simultaneously. The MSP4 7-seg­ment display will display the first user preference,
"P.0", and the SETUP LED will illuminate.

• Pressing the left MSP4 pushbutton will exit the
entire Machine Setup menu while in the P.0 user
preference.

• Turning the MSP4 encoder knob will select other
available User Preferences.

• To exit the User Preference Menu, either rotate the
MSP4 encoder until P.0 is displayed and press the
left MSP4 pushbutton or press both MSP4 push but-

simultaneously at any time.

tons

INFRARED (IR) CONTROL

(For Codes 11194 and below)
The MSP4 interface includes an infrared transceiver.
This allows wireless machine configuration using a Palm
OS based hand held computer. A proprietary Palm OS
application, ALPalm, was developed for this purpose.
(Contact Lincoln Electric for more information on this fea­ture.)

LOCKOUT/SECURITY

The MSP4 can be optionally configured to prevent the
welder from changing selected MSP4 options. By default,
the welder will be able to change the weld mode, all rele­vant wave controls and all relevant start and end options.

POWER FEED®10M DUAL WIRE FEEDER

B-7

OPERATION

B-7

SET-UP FEATURES MENU

The Setup Menu gives access to the Setup Configuration. Stored in the setup configuration are user parameters
that generally only need to be set at installation. The parameters are grouped as shown in the following table.

PARAMETER

P.1 through P.99

P.100 through P.107

DEFINITION

Unsecured Parameters (always adjustable)

Diagnostic Parameters (always read only)

SET-UP FEATURES MENU

(See Figure B.3a)

1. To access the set-up menu, press the Right and

Left buttons of the MSP4 panel simultaneously.
Note that the set-up menu cannot be accessed if

the system is welding, or if there is a fault (The sta­tus LED is not solid green).

Change the value of the blinking parameter by rotat­ing the SET knob.

2. After changing a parameter it is necessary to press

the Right hand button to save the new setting.
Pressing the Left button will cancel the change.

3. To exit the set-up menu at any time, press the

Right and Left buttons of the MSP4 panel simulta­neously. Alternately, 1 minute of inactivity will also
exit the set-up menu.

2

6

3

Left

button

5

FIGURE B.3a - SETUP MENU

Mode Select

Panel (MSP4)

SET Knob

1

4

7

LED

Indicator

Right

button

8

POWER FEED®10M DUAL WIRE FEEDER

B-8

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

Exit Setup Menu

P. 0

This setup menu parameter can be used to exit the setup menu. When P.0 is displayed, press
the left Mode Select button to exit the setup menu.

P.1 Wire Feed Speed Units

This option selects which units to use for displaying wire feed speed.
English = inches/minute wire feed speed units (default).
Metric = meters/minute wire feed speed units.

P.2 Arc Display Mode

This option selects what value will be shown on the upper left display while welding.
Amps = The left display shows Amperage while welding (default).
WFS = The left display shows Wire Feed Speed while welding.

P.3 Display Options

This setup parameter was previously named "Display Energy"

B-8

If the previous software revision had this parameter set to display energy, that selection will
remain.

This option selects the information displayed on the alphanumeric displays while welding. Not all
P.3 selections will be available on all machines. In order for each selection to be included in the
list, the power source must support that feature. A software update of the power source may be
needed to include the features.

Standard Display = The lower displays will continue to show preset information during and after
a weld (default).
Show Energy = Energy is displayed, along with time in HH:MM:SS format.
Show Weld Score = The accumulative weld score result is shown.

P.4 Recall Memory with Trigger

This option allows a memory to be recalled by quickly pulling and releasing the gun trigger. To
recall a memory, quickly pull and release the trigger the number of times that correspond to the
memory number. For example, to recall memory 3, quickly pull and release the trigger 3 times.
To recall memory 1, quickly pull and release the trigger the number of user memories plus 1.
Memories cannot be recalled while the system is welding.
Disabled = The gun trigger cannot be used to recall user memories (default).
Enabled = The gun trigger can be used to recall user memories.

POWER FEED®10M DUAL WIRE FEEDER

B-9

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.5 Procedure Change Method

This option selects how remote procedure selection (A/B) will be made. The selected procedure
can be changed locally at the user interface by pressing the 'A-Gun-B' button. The following
methods can be used to remotely change the selected procedure:
* Use an external switch wired to the procedure select input.
* Quickly releasing and re-pulling the gun trigger.
* Using a dual-schedule gun which incorporates a procedure select switch in the trigger mecha-

nism (pulling the trigger more than half way changes the procedure from A to B)

The possible values for this parameter are:
* External Switch = Procedure selection may only be performed at the memory panel or an

external switch (e.g. K683).

* Quick Trigger = The selected procedure can be changed remotely by releasing and re-pulling

the trigger quickly while welding. This feature is disabled in 4-Step trigger mode. The external
procedure switch is disabled. To operate:

- Select "GUN" on the memory panel.

- Start the weld by pulling the gun trigger. The system will weld with procedure A settings.

- While welding, quickly release then pull the gun trigger once. The system will switch to pro­cedure B settings. Repeat to switch back to procedure A settings. The procedure can be
changed as many times as needed during the weld.

- Release the trigger to stop welding. The system will automatically return to procedure A
settings.

B-9

* Integral TrigProc = When using a Magnum DS dual-schedule gun (or similar) that incorpo-

rates a procedure switch in the gun trigger mechanism. While welding in 2-step, machine
operation is identical to the "External Switch" selection. When welding in 4-step, additional
logic prevents procedure A from being re-selected when the trigger is released at step 2 of the
4-step weld sequence. The machine will always operate in 2-step if a weld is made exclusive­ly in procedure A, regardless of the 2/4 step switch position (this is intended to simplify tack
welding when using a dual-schedule gun in 4-step).

P.6 Stall Factor Adjustment

This option allows the adjustment of the stall factor in Push/Pull operation. The stall factor con­trols the stall torque of the push motor when using a push-pull gun. The wire feeder is factory­set to not stall unless there is a large resistance to feeding wire. The stall factor can be reduced
to stall more easily and possibly prevent bird nesting. However, low stall factors can cause
motor stalling during normal welding conditions, which results in the wire burning back to the tip
or rapid tack welds. If you are experiencing bird nests, check for other feeding problems before
adjusting the stall factor. The default value for the stall factor is 75, with a range of 5 to 100.

POWER FEED®10M DUAL WIRE FEEDER

B-10

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.7 Gun Offset Adjustment

This option adjusts the wire feed speed calibration of the pull motor of a push-pull gun. This
should only be performed when other possible corrections do not solve any push-pull feeding
problems. An rpm meter is required to perform the pull gun motor offset calibration. To perform
the calibration procedure do the following:

1. Release the pressure arm on both the pull and push wire drives.

2. Set the wire feed speed to 200 ipm.

3. Remove wire from the pull wire drive.

4. Hold an rpm meter to the drive roll in the pull gun.

5. Pull the trigger on the push-pull gun.

6. Measure the rpm of the pull motor. The rpm should be between 115 and 125 rpm. If neces­sary, decrease the calibration setting to slow the pull motor, or increase the calibration set­ting to speed up the motor.The calibration range is -30 to +30, with 0 as the default value.

P.8 TIG Gas Control

This option allows control over which gas solenoid actuates while TIG welding.
"Valve (manual)" = No MIG solenoid will actuate while TIG welding, gas flow is manually con­trolled by an external valve.
"Solenoid (auto) = This selection only applicable to PWC300. The MIG solenoid will turn on and
off automatically while TIG welding.
"Feeder Solenoid" = No applicable to PWC300. The internal (feeder) MIG solenoid will turn on
and off automatically while TIG welding.
"Pwr Src Solenoid" = Not applicable to PWC300. Any gas solenoid connected to the power
source will turn on and off automatically while TIG welding. This selection will not appear in the
list if the power source does not support a gas solenoid.

B-10

Notes: Preflow is not available while TIG welding. Postflow is available - the same postflow

time will be used in MIG and TIG. When machine output on/off is controlled via the
upper right knob, gas flow will not start until the tungsten touches the work. Gas flow
will continue when the arc is broken until the Postflow time expires. When machine out­put on/off is controlled via an arc start switch or foot Amptrol, gas will begin flowing
when the output is turned on and will continue flowing until the output is turned off and
the Postflow time expires.

P.9 Crater Delay

This option is used to skip the Crater sequence when making short tack welds. If the trigger is
released before the timer expires, Crater will be bypassed and the weld will end. If the trigger is
released after the timer expires, the Crater sequence will function normally (if enabled).

P.14 Reset Consumable Weight

Use this option to reset the initial weight of the consumable package. Press the Right Button to
reset the consumable weight. This option will only appear with systems using Production
Monitoring.

POWER FEED®10M DUAL WIRE FEEDER

B-11

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.16 Push-Pull Gun Knob Behavior

This option determines how the potentiometer on the Push/Pull torch will behave.
Gun Pot Enabled = The welding wire feed speed is always controlled by the potentiometer on the push­pull gun (default). The left front panel knob is only used to adjust Start and Crater wire feed speed.
Gun Pot Disabled = The wire feed speed is always controlled by the left front panel knob. This setting is
useful when the operator wishes to have wire feed speed settings recalled from memories and not have
the potentiometer "overwrite" the setting.
Gun Pot Proc A = When in procedure A, the welding wire feed speed is controlled by the potentiometer on
the push-pull gun. When in procedure B, the welding wire feed speed is controlled by the left front panel
knob. This setting allows a fixed wire feed speed to be selected in procedure changes.

P.20 Display Trim as Volts Option

This option determines how trim is displayed.
False = The trim is displayed in the format defined in the weld set (default).
True = All trim values are displayed as a voltage.

P.22 Arc Start/Loss Error Time

This option can be used to optionally shut off output if an arc is not established, or is lost for a specified
amount of time. Error 269 will be displayed if the machine times out. If the value is set to OFF, machine
output will not be turned off if an arc is not established nor will output be turned off if an arc is lost. The
trigger can be used to hot feed the wire (default). If a value is set, the machine output will shut off if an arc
is not established within the specified amount of time after the trigger is pulled or if the trigger remains
pulled after an arc is lost. This is disabled while welding in Stick, TIG or Gouge. To prevent nuisance
errors, set Arc Start/Loss Error Time to an appropriate value after considering all welding parameters (run­in wire feed speed, weld wire feed speed, electrical stick out, etc). To prevent subsequent changes to Arc
Start/Loss Error Time, the setup menu should be locked out by setting Preference Lock = Yes using the
Power Wave Manager software.

B-11

P.80 Sense From Studs

Use this option for diagnostic purposes only. When power is cycled, this option is automatically reset to
False.
False = Voltage sensing is automatically determined by the selected weld mode and other machine set­tings (default).
True = Voltage sensing is forced to "studs".

P.81 Sense Leads Selection

Used in place of DIP switches for configuration of the work and electrode sense leads. This option will
only appear in the list if the power source has a hardware selection option.
67 pos polarity = An electrode sense lead is connected using positive polarity. This is used by most
GMAW welding procedures.
67 neg polarity = An electrode sense lead is connected using negative polarity. This is used by most
GTAW welding procedures and some Innershield procedures.
67 & 21 = An electrode sense lead and work sense lead are connected.
Hardware Config = The hardware determines the best remote sensing configuration. This is applicable to
MIG welding procedures only.

P.82 Voltage Sense Display

Allows viewing of Voltage Sense Lead Selection to aid in troubleshooting. The configuration is displayed
as a text string on the lower display whenever the output is enabled. This parameter is not saved on a
power cycle, but will be reset to False.

POWER FEED®10M DUAL WIRE FEEDER

B-12

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.99 Show Test Modes

Most power sources contain weld modes used for calibration and test purposes. By default, the machine
does not include test weld modes in the list of weld modes that are available to the operator. To manually
select a test weld mode, set this option to "Yes". When the power source is turned off and back on again,
the test modes will no longer appear in the mode list. Test weld modes typically require the machine out­put to be connected to a grid load and cannot be used for welding.

P.100 View Diagnostics

Diagnostics are only used for servicing or troubleshooting the Power Wave system.
Select "Yes" to access the diagnostic options in the menu. Additional parameters will
now appear in the setup menu (P.101, P.102, etc).

P.101 View Event Logs

Used for viewing all the system event logs. Press the Right Button to enter the option. Rotate Control
Knob to select the desired event log to read. Press the Right Button again to enter the selected log.
Rotating the Control Knob will scroll through the event log, displaying the log index number, event code
and some other data. Press the Left Button to back out to select another log. Press the Left Button again
to exit this option.

B-12

P.102 View Fatal Logs

Used for viewing all the system fatal logs. Press the Right Button to enter the option. Rotate Control Knob
to select the desired fatal log to read. Press the Right Button again to enter that log. Rotating the Control
Knob will scroll through the log, displaying the log index number and fatal code. Press the Left Button to
back out to select another log. Press the Left Button again to exit this option.

P.103 View Software Version Information

Used for viewing the software versions for each board in the system. Press the Right Button to
enter the option. Rotate Control Knob to select the desired board to read. Press the Right
Button again to read the firmware version. Press the Left Button to back out to select another
board. Rotate the Control Knob to select another board, or press the Left Button to exit this
option.

P.104 View Hardware Version Information

Used for viewing the hardware version for each board in the system. Press the right MSP
Button to enter the option. Rotate Set knob to select the desired board to read. Press the right
button again to read the hardware version. Press the left button to back out to select another
board. Press the left button again to exit this option.

P.105 View Welding Software Information

Used for viewing the Weld Set in the Power Source. Press the Right Button to read the Weld
Set version. Press the Left Button to back out and exit this option.

P.106 View Ethernet IP Address

Used for viewing the IP address of Ethernet compatible equipment. Press the Right Button to
read the IP Address. Press the Left Button to back out and exit this option. The IP address can­not be changed using this option.

P.107 View Power Source Protocol

Used for viewing the type of power source the feeder is connected to. Press the Right Button to
identify the power source as either LincNet or ArcLink. Press the Left Button to back out and
exit this option.

POWER FEED®10M DUAL WIRE FEEDER

B-13

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.501 Encoder Lockout

Locks one or both of the upper knobs (encoders), preventing the operator from changing wire feed speed,
amps, volts or trim. The function of each upper knob depends on the selected weld mode. When a costant
current weld mode is selected (e.g. Stick, TIG, Gouge), the upper right knob will always function as an
on/off switch. This parameter can only be accessed using Power Wave Manager software.

P.502 Memory Change Lockout

Determines if the memories can be overwritten with new contents.
No = Memories can be saved and limits can be configured (default).
Yes = Memories cannot be changed - saving is prohibited and limits cannot be re-configured.
This parameter can only be accessed using Power Wave Manager software.

P.503 Memory Button Disable

Disables the specified memory button(s). When a memory is disabled, welding procedures cannot be
restored from or saved to that memory. If an attempt is made to save or restore a disabled memory, a
message will be displayed on the lower display indicating the memory number is disabled. In multi-head
systems, this parameter disables the same memory buttons on both feed heads. This parameter can only
be accessed using Power Wave Manager software.

B-13

P.504 Mode Select Panel Lock

Selects between several Mode Select Panel lockout preferences. When a Mode Select Panel selection is
locked and an attempt is made to change that parameter, a message will be displayed on the lower dis­play indicating the parameter is locked.
All MSP Options Unlocked = All adjustable parameters on the Mode Select Panel are unlocked.
All MSP Options Locked = All knobs and buttons on the Mode Select Panel are locked.
Start & End Options Locked = The Start and End parameters on the Mode Select Panel are locked, all
others are unlocked.
Weld Mode Option Locked = The weld mode cannot be changed from the Mode Select Panel, all others
Mode Select Panel settings are unlocked.
Wave Control Options Locked = The Wave Control parameters on the Mode Select Panel are locked, all
others are unlocked.
Start, End, Wave Options Locked = The Start, End and Wave Control parameters on the Mode Select
Panel are locked, all others are unlocked.
Start, End, Mode Options Locked = The Start, End and Weld Mode Select parameters on the Mode Select
Panel are locked, all others are unlocked.
This parameter can only be accessed using Power Wave Manager software.

P.505 Setup Menu Lock

Determines if the setup parameters can be modified by the operator without entering a pass­code.
No = The operator can change any set menu parameter without first entering the passcode
even if the passcode is non-zero (default).
Yes = The operator must enter the passcode (if the passcode is non-zero) in order to change
any setup menu parameters.
This parameter can only be accessed using Power Wave Manager software.

POWER FEED®10M DUAL WIRE FEEDER

B-14

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.506 Set User Interface Passcode

Prevents unauthorized changes to the equipment. The default passcode is zero which allows full access.
A nonzero passcode will prevent unauthorized: changes to memory limits, saving to memory (if P.502 =
Yes), changes to setup parameters (if P.505 = Yes).
This parameter can only be accessed using Power Wave Manager software.

P.509 UI Master Lockout

Locks all user interface controls, preventing the operator from making any changes. This parameter can
only be accessed using Power Wave Manager software.

B-14

POWER FEED®10M DUAL WIRE FEEDER

B-15

OPERATION

B-15

POWER FEED®10M DUAL WIRE FEEDER

B-16

Each procedure contains/stores the following informa­tion:

• Basic weld parameters as applicable - WFS, Volts,
Trim, Amps

• Weld Mode - Mode Number

• Preflow/Postflow - Time in Seconds

• Run in - WFS Only (work point determined by next
active sequence state)

• Start Parameters - Status, Slope Time, WFS, Volts,
Trim, Amps

• Arc Control - Setpoint

• Crater Parameters - Status, Slope Time, WFS, Volts,
Trim, Amps

• Burnback - Time in Seconds

• Limits - All applicable limits.

OPERATION

DUAL HEAD / DUAL PROCEDURE WITH
MEMORY

In general terms, dual procedure and memory are essen­tially independent storage locations for information.
Procedures can be thought of as temporary or working
storage locations because they contain the weld settings
readily available for use, and when active, are easily
modified. The dual procedure feature allows the operator
to switch between procedures (A and B) "on the fly" while
welding. In addition to their procedure set-up functions,
the procedure select push buttons serve as a means to
manually select the active feed head (wire drive).
Memory is more of a permanent storage location that
cannot be accessed while welding. It contains one com­plete set of procedure information which can be recalled
into the active procedure (A or B). Conversely, the active
procedure can be saved into memory for safe keeping.

Dual Procedure / Head Select

This feature allows the user to select Procedure A, Gun
(Remote Select), or Procedure B, as well as selecting the
active feed head (wire drive). The active feed head is
indicated by the procedure group (A, Gun, B) with the
illuminated LED(s), and only one procedure group / feed
head can be active at a time. Changing the active feed
head can be done in one of two ways. Either remotely,
by pulling the trigger of the inactive feed head, or locally
by momentarily depressing the procedure select push­button of the inactive head.

When a procedure group / feed head is active, momen­tarily depressing the procedure select pushbutton will
change from A to Gun, from Gun to B, or from B to A.
The corresponding LED will be lit to let the user know
which procedure is active. When the Gun position is
selected, the Gun LED will be solid red, and the active
procedure LED (A or B) will be flashing.
The active procedure is determined by the dual proce­dure (Gun) input located in the gun receptacle, or
through the "Procedure Change with Trigger" feature if
properly configured.

B-16

Note:

When in the Gun position, if no dual procedure (Gun)
switch is plugged in, the Procedure defaults to A.

There are a total of four independent procedures avail­able on this panel. Two for each feed head.

Both the contents of the active procedure, and the active
procedure itself (A to B, or B to A) can be changed "on
the fly" during welding. Changing the active status of the
feed head can only be done when the system is in the
idle state. Procedure settings for each feed head, and
active procedure information are saved at power down.

Memory

This feature allows the user to save and recall up to six
individual procedures to/from a secured storage location.
Each of the six memory locations is capable of storing a
complete copy of the information associated with a single
procedure (A or B) including its individual limits. See the
complete list above.

Memories can be accessed at anytime, except when
welding. For wire fed processes this means anytime a
trigger is NOT activated. For CC processes it means
anytime current is NOT flowing.

Saving to Memory

To save an individual procedure (A or B) to memory, first
be sure the desired procedure of the desired feed head
is active (its LED is on). Press and hold the button of the
memory location you wish to store the procedure into.
After 2 seconds, the LED above the memory button will
begin to flash indicating that the procedure has been
saved. The LED will continue to flash as long as the
memory button is depressed. When released the memo­ry LED will stay on steady, and remain lit as long as the
contents of the memory remain equal to the contents of
the associated procedure.

If the memory button is released before the light begins
to flash (t < 2s), a memory recall function will occur
instead of a save function (i.e. the contents of the select­ed memory will copied to the active procedure).
Note:
It is not required to load all 6 memories at once, nor is it
necessary to load them in order.

POWER FEED®10M DUAL WIRE FEEDER

B-17

Recalling from Memory

To recall the contents of a memory into the active proce­dure, momentarily push the desired memory button (for
less than 2 seconds). The saved parameters will be
copied into the active procedure, and the LED of the
memory button will light indicating the source of the infor­mation. As with saving to memory, this light will remain lit
as long as the contents of the source memory remain
equal to the contents of the associated procedure.

If a constant current mode is saved to memory with the
power source in the "on" state, the "on" status will be
changed to "off" when the procedure is recalled. This
prevents a potential safety hazard if a memory button is
pushed and the power source unexpectedly turns on.

OPERATION

2 STEP / 4 STEP OPERATION

The Wire Drive has a 2 Step / 4 Step switch located
near the gun connector. 2-Step Trigger Mode opera­tion requires the operator hold the gun trigger closed
in order to weld. 4-Step Trigger Mode eliminates the
need to hold the gun trigger closed while welding.
User-selectable 4-step modes with or without current
interlock. The switch in the down position will enable
2-Step operation and in the up position enables 4 ­Step operation. This switch has no effect in CC modes
of operation, such as stick welding. Both 2 and 4 ­Step can be operated in Synergic and Non-Synergic
modes. In a Synergic mode, machine output tracks
Wire Feed Speed (WFS) during welding. In Non­Synergic modes, machine output is independent of
WFS.

2 Step Synergic Operation:

Without Start/Crater/Burnback functions active

Waveform Sequence:

1. Trigger is pulled; Preflow sequence begins and
runs until preflow timer expires.

2. Strike sequence initiates until Arc is established.

3. Arc established; Weld sequence begins.

4. Trigger released (Arc extinguished); Postflow
sequence begins and runs until postflow timer
expires.

5. End of sequence.

1 2 3 4 5

B-17

2 Step Synergic Operation:
With Burnback function active.

Waveform Sequence:

1. Trigger is pulled; Preflow sequence begins and
runs until preflow timer expires.

2. Run-In sequence initiates until Arc is established.

3. Arc established; Weld sequence begins.

4. Trigger released (Arc extinguished); Burnback
sequence begins and runs until burnback timer
expires.

5. Postflow sequence begins and runs until postflow
timer expires.

6. End of sequence.

1 2 3 4 5 6

WFS vs. Work point (Output) Waveform

= solid line represents WFS

---=

dashed line represents Work point or Machine Output

2 Step Synergic Operation:
With Start/Crater/Burnback functions active.

Waveform Sequence:

1. Trigger is pulled; Preflow sequence begins and

runs until preflow timer expires.

2. Run-In sequence initiates until Arc is established.

3. Arc established; Start sequence begins and runs

for the amount of time set.

4. Weld sequence begins.

5. Trigger released; Crater sequence begins and runs

until crater timer expires.

6. Arc Extinguished; Burnback sequence begins and

runs until burnback timer expires.

7. Postflow sequence begins and runs until postflow

timer expires.

8. End of process.

1 2 3 4 5 6 7 8

WFS vs. Work point Waveform

= solid line represents WFS

---=

dashed line represents Work point or Machine Output

POWER FEED®10M DUAL WIRE FEEDER

WFS vs. Work point (Output) Waveform

= solid line represents WFS

---=

dashed line represents Work point or Machine Output

B-18

OPERATION

B-18

4 Step Synergic Operation:
Without Start/Crater/Burnback functions active

Waveform Functionality:

1. Trigger is pulled and released; Preflow sequence
begins and runs until Preflow timer expires.

2. Run-In sequence begins and runs until Arc is estab­lished

3. Arc established; Weld sequence begins.

4. Trigger pulled; Weld sequence continues.

Note: This can be done anytime between Step 3
and 5.

5. Trigger released; Postflow sequence begins and
runs until Postflow timer expires.

6. End of sequence.

1 2 3 4 5 6

WFS vs. Work point Waveform

= solid line represents WFS

dashed line represents Work point or Machine Output

---=

1 2 3 4 5 6 7 8 9 10

WFS vs. Work point (Output) Waveform

= solid line represents WFS

--- = dashed line represents work point or machine output

Additional Comments:

• To achieve a Hot Start routine, the values in step 2 (Run­In and Strike) can be set such that work point (output) is
set to a desired level, while the Weld work point level will
be set to a normal or nominal level for the particular
process.

Example Strike Value: 350A
Strike Time: 0.1 sec.

Weld Value: 170A
When the process is initiated, the work point will jump to
Strike work point of 350A with the set Run-In WFS. When
the trigger is released, the work point will jump to 170A in
the 0.1 seconds and the Weld sequence will begin, travers­ing through the rest of the sequence using the functions
set forth.

4 Step Synergic Operation:
With Start/Crater/Burnback functions active

Waveform Functionality:

1. Trigger is pulled and released; Preflow sequence begins
and runs until Preflow timer expires.

2. Run-In sequence begins and runs until Arc is established.

3. Arc established; Work point moves to set value in Start
sequence.

4. Trigger released; Step 4 to 5 is start time set in Start
sequence to get to Weld sequence.

5. Weld sequence begins and runs until trigger is pulled.

6. Trigger pulled and held; Crater sequence begins.
Work point, WFS move to set value in Crater sequence in
the amount of time set within Crater sequence.

7. Work point, WFS Crater values held until trigger is
released.

8. Trigger released; Burnback sequence begins and runs
until Burnback timer expires.

9. Postflow sequence begins and runs until Postflow timer
expires.

10. End of sequence.

COLD FEED/GAS PURGE SWITCH

The Wire Drive has a Cold Feed/Gas Purge Switch located
near the gun connector. This is an up/down center-off
momentary toggle switch.

When held in the up position, the Wire Drive will feed wire,
but neither the power source nor the gas solenoid will be
energized. When cold feeding, the feed speed can be
adjusted by rotating the WFS encoder knob on the Control
Box. Adjusting the cold feed will not affect the run in or weld­ing wire feed speed. When the cold feed switch is released,
the cold feed value is saved.

When this switch is held in the down position, the gas sole­noid valve is energized, but neither the power source nor
the drive motor will be energized.

POWER FEED®10M DUAL WIRE FEEDER

B-19

OPERATION

HOT INCH

Hot inch occurs when the trigger is pulled and an arc
is not established. After a 2.5 second period, the
Sequencer will jump to the Weld state and the wire
feeder will run at the preset wire feed speed on the
display. The wire is hot (output is on) at this point.
Start, Upslope, Downslope, Crater, Burnback,
Postflow, etc are all skipped when Hot Inch is activat­ed.

FOOT AMPTROL

A Foot Amptrol Kit can be installed in order to operate
the output of the machine using a pedal. Located on
the Control Box, the Right encoder turns output on/off
if desired. The left encoder sets the max work point
limit. When the pedal is pressed OCV will be present
and gas will not flow. As soon as the tungsten touches
the work and there is current flow, the gas solenoid
will turn on. If the arc breaks the machine will enter
the postflow state. When the postflow timer expires,
the machine will return to OCV mode and no gas will
flow until the arc is established. If the pedal is
released it turns the machine off, postflow will be
entered until time out. When the postflow timer
expires the machine will return to idle state and wait
for trigger. Preflow will be presettable for external trig­gers if desired. Triggering machine with encoder will
skip preflow.

B-19

WIRE DRIVE -- PC BOARD ADJUSTMENTS

ELECTRODE POLARITY:

The system needs to be aware of the electrode polari­ty. A DIP switch setting on the Wire Drive PC boards
is used for this purpose. See INSTALLATION Section
“Setting DIP Switches in the Wire Drive”.

GEAR BOX RATIO:

The systems needs to know which gear has been
installed on the Wire Drive, low or high speed. A DIP
switch setting on the Wire Drive PC boards is used for
this purpose. See INSTALLATION section“Wire Drive
Ratio” for information on how to set the DIP Switch.

POWER FEED®10M DUAL WIRE FEEDER

B-20

OPERATION

The Spindle should be located in the LOWER mounting hole.

(For 8" (200 mm) spools, a K468 spindle adapter must
first be slipped onto spindle.)

(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil
Adapter must be used).

B-20

FIGURE B.5

SPINNER NUT

COVER
PLATE

1) Depress the Release Bar on the Retaining Collar

and remove it from the spindle.

2) Place the spool on the spindle making certain the

spindle brake pin enters one of the holes in the
back side of the spool. Be certain the wire comes
off the reel in a direction so as to de-reel from the
bottom of the coil.

3) Re-install the Retaining Collar. Make sure that the

Release Bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.

To Mount a 50-60 Lb. (22.7-27.2 kg) Coil:
(Using K1504-1 Coil Reel) (For 50-60 lb Readi-

Reels a K438 Readi-Reel Adapter must be used).

The Spindle must be located in the UPPER mounting hole.

1) With the K1504-1 Coil Reel mounted on to the 2"

(51 mm) spindle (or with reel laying flat on the
floor) loosen the spinner nut and remove the reel
cover. See Figure B.5.

SLOTS

CARDBOARD
COIL LINER

COIL

TIE WIRE

SPRING
LOADED ARM

REEL

2) Before cutting the tie wires, place the coil of elec-

trode on the reel so it unwinds from the bottom as
the reel rotates.

3) Tighten the spinner nut against the reel cover as

much as possible by hand using the reel cover
spokes for leverage. DO NOT hammer on the
spinner nut arms.

4) Cut and remove only the tie wire holding the free

end of the coil. Hook the free end around the rim
of the reel cover and secure it by wrapping it
around. Cut and remove the remaining tie wires.

CAUTION

Always be sure the free end of the coil is securely
held while the tie wires are being cut and until the
wire is feeding through the drive rolls. Failure to
do this will result in “backlashing” of the coil,
which may tangle the wire. A tangled coil will not
feed so it must either be untangled or discarded.

___________________________________________

5) Be sure the coil reel is engaged with the spindle

brake pin and the Release Bar on the Retaining
Collar “pops up” and that the collar retainers fully
engage the retaining groove on the spindle.

POWER FEED®10M DUAL WIRE FEEDER

B-21

OPERATION

B-21

FEEDING ELECTRODE AND BRAKE
ADJUSTMENT

1) Turn the Reel or spool until the free end of the

electrode is accessible.

2) While tightly holding the electrode, cut off the bent

end and straighten the first 6" (150 mm). Cut off
the first 1" (25 mm). (If the electrode is not proper­ly straightened, it may not feed or may jam causing
a "birdnest".)

3) Insert the free end through the incoming guide

tube.

4) Press the Cold Inch key or the Cold Feed Mode

gun trigger and push the electrode into the drive
roll.

WARNING

When feeding with the gun trigger, unless “COLD
FEED” trigger mode is selected, the electrode and
drive mechanism are always “HOT” to work and
ground and could remain “HOT” several seconds
after the gun trigger is released.

___________________________________________

5) Feed the electrode through the gun.

Adjust the brake tension with the thumbscrew on

6)

the spindle hub, until the reel turns freely but with
little or no overrun when wire feeding is stopped.
Do not overtighten.

DRIVE ROLL PRESSURE SETTING

The Power Feed 10 Dual Wire Feeder pressure is fac­tory pre-set to about position “2" as shown on the
pressure indicator on the front of the feedplate door.
This is an approximate setting.

1) Press end of gun against a solid object that is
electrically isolated from the welder output and
press the gun trigger for several seconds.

2) If the wire "birdnests", jams, or breaks at the drive

roll, the drive roll pressure is too great. Back the
pressure setting out one turn, run new wire through
gun, and repeat above steps.

3) If the only result is drive roll slippage, disengage

the gun, pull the gun cable forward about 6" (150
mm). There should be a slight waviness in the
exposed wire. If there is no waviness, the pres­sure is too low. Increase the pressure setting one
turn, reconnect the gun, tighten locking clamp and
repeat the above steps.

PROCEDURE FOR SETTING ANGLE
OF FEEDPLATE

1) Loosen the clamping collar screw using a 3/16"

Allen wrench. The clamping collar screw is
accessed from the bottom of the feedplate. It is
the screw which is perpendicular to the feeding
direction.

2) Rotate feedplate to the desired angle and tighten

clamping collar screw.

GAS GUARD REGULATOR SETTING

1) With the gas supply shut off, the Gas Guard regu-

lator flow adjusting Key should be set to maximum
(full clockwise) which is rated to be 60 SCFH (28
l/min).

2) Adjust gas supply flow rate for a level higher than

will be required, then adjust Gas Guard flow
adjusting Key counterclockwise to the desired gas
flow rate.

The optimum drive roll pressure varies with type of
wire, surface condition, lubrication, and hardness.
Too much pressure could cause “birdnesting”, but too
little pressure could cause wire feed slippage with
load and/or acceleration. The optimum drive roll set­ting can be determined as follows:

POWER FEED®10M DUAL WIRE FEEDER

B-22

OPERATION

B-22

MAKING A WELD

1) Use only a network compatible power source.

2) Properly connect the electrode and work leads for
the correct electrode polarity.

3) Set all desired parameters such as trigger logic,
Run-in Speed, Acceleration, Electrode polarity, etc.
per “DIP SWITCH SETUP” in the INSTALLATION
section.

4)

Set 2-step, 4-step switch on wire drive to desired
mode of operation. (Refer to “2-step/4-step switch
operation” in this section.)

5) Select Weld Mode. (Refer to Control Box
Operation in this section).

6) Use Control Select switches, increment/decrement
switches, and encoder knobs to set desired para­meters for weld depending on what options are
installed. (Refer to Control Box Operation in this
section).

7) Feed the electrode through the gun and cable and
then cut the electrode within approximately .38"
(9.5 mm) of the end of the contact tip for solid wire
and within approximately .75" (19mm) of the exten­sion guide for cored wire.

13) If required, starting can be optimized by adjusting
the acceleration and/or run-in speed. (Refer to
Control Box Operation in this section).

WIRE REEL CHANGING

At the end of a coil, remove the last of the old elec­trode coil from the conductor cable by either pulling it
out at the nozzle end of the gun or by using the follow­ing procedure:

1) Cut the end of the electrode off at the gun end. Do

not break it off by hand because this puts a slight
bend in the wire making it difficult to pull it back
through the nozzle.

2) Disconnect the gun cable from the gun connector

on the Power Feed 10 Dual wire drive unit and lay
the gun and cable out straight.

3) Using pliers to grip the wire, pull it out of the cable

from the connector end.

4) After the electrode has been removed, reconnect

the gun cable to the drive. Load a new reel of elec­trode per the instructions in “Wire Reel Loading” in
this section.

WIRE FEED OVERLOAD PROTECTION

8) Connect work cable to metal to be welded. Work
cable must make good electrical contact to the
work. The work must also be grounded as stated
in "Arc Welding Safety Precautions".

WARNING

When using an Open Arc
process, it is necessary to use
correct eye, head, and body pro­tection.

____________________________________

9) If used, be sure shielding gas valve is turned on.

10) Position electrode over joint. End of electrode

may be lightly touching the work.

11) Lower welding helmet, close gun trigger, and start

welding. Hold the gun so the contact tip to work
distance gives the correct electrical stickout as
required for the procedure being used.

12) To stop welding, release the gun trigger and then

pull the gun away from the work after the arc goes
out and Postflow time, if used, is over.

The wire drive provides overload protection of the wire
drive motor. If the wire drive motor becomes over­loaded for an extended period of time the wire drive
will issue a shutdown command to the Control Box
and force itʼs status light to blink between green and
red. The Control Box turns off the power source, wire
feed and gas solenoid. The status light on the wire
drive will continue to blink between green and red for
about 30 seconds before the wire drive will automati­cally reset. At that time, the wire drive will issue a
shutdown over command to the Control Box that will
return the system to normal operation. The wire drive
will force itʼs status light to solid green.

Overloads can result from improper tip size, liner,
drive rolls, or guide tubes, obstructions or bends in the
gun cable, feeding wire that is larger than the rated
capacity of the feeder or any other factors that would
impede normal wire feeding. (See “Avoiding Wire
Feeding Problems” in the MAINTENANCE section).

POWER FEED®10M DUAL WIRE FEEDER

B-23

OPERATION

B-23

COMPONENT STATUS LIGHTS

Each network component has a single status light.
The light is a bicolor, Green/Red, LED. The purpose
of the status light is to allow the operator to quickly
identify that the system is working properly or, if not,

NOTE: The green light ON and steady indicates a normal functioning system.

which component is causing the problem. By using
the status lights the operator can quickly pinpoint the
system problem to a particular component. See the
following table for a complete listing and description of
all status light conditions.

STATUS LIGHT STATES

LED State

Off

Green LED blink­ing at a “normal”
rate

Power Source LED

Power Source is not turned ON or is not
tioning correctly.

It should only blink for a few seconds while
the system is mapping (identifying compo­nents). If blinking continues every group may
have a mapping error. (DIP switches may be
set incorrectly).

func-

LED on any other nodes (components);
Wire Feeder, Control Box Etc.

The system component is not receiving input
power or

It should only blink for a few seconds until
the system component (node) has been rec­ognized. If the blinking continues at least
one node in the group has a mapping error
(DIP switches may be set incorrectly). The
node or nodes with mapping errors will be
blinking red.

• There may be too many components in the
group. All components in the group will be
blinking green.

• The power source bus may not be avail­able. The bus may be being used to program
another component.

• The LEDʼs of the power source and the
component being programmed will be solid
green.

is faulty.

Red LED blinking
at a “normal” rate

Red/Green LED
blinking at a “nor­mal” rate

Indicates a recoverable communication fault.
The power source should automatically
recover: If it cannot recover the LED will be
solid red.

Indicates a recoverable hardware fault such
as over temperature, overload shutdown etc.

POWER FEED®10M DUAL WIRE FEEDER

Indicates a recoverable communication fault
most likely caused by one of the following.

• More than one control box (UI) in the
group. All control boxes in the group will be
blinking red.

• No control box (UI) in the group. All nodes
in the group will be blinking red.

• More than one node, of the same equip­ment type, has the same group and feed
head (FH) numbers. All these nodes will be
blinking red.

• The feed head DIP switches may be set to
zero. The nodes with DIP switches set to
zero will be blinking red.

•The node bus may be off.

Indicates a recoverable hardware fault such
as over temperature, overload shutdown etc.
Could also be an open shutdown circuit at
the feed head (leads 570, 572 with tab termi­nals) typically used for water flow shutdown
switches.

B-24

OPERATION

STATUS LIGHT STATES (CONʼT)

B-24

LED State

Red LED blinking
at a fast rate

Red LED ON and
steady

Green LED ON
and steady

Power Source LED

Power source needs to be reprogrammed.
Contact your Local Authorized Lincoln Field
Service Facility.

Power source has a non-recoverable hard­ware fault. Contact your Local Authorized
Lincoln Field Service Facility.

System normal and functional.

Normal Blinking LED - Each illumination should exist for 0.5 seconds.

Fast Blinking LED - Each illumination should exist for 0.1 seconds.

LED on any other nodes (components);
Wire Feeder, Control Box Etc.

System component (node) needs to be
reprogrammed. Contact your Local
Authorized Lincoln Field Service Facility.

System component (node) has a non-recov­erable hardware fault. Contact your Local
Authorized Lincoln Field Service Facility.

System normal and functional.

POWER FEED®10M DUAL WIRE FEEDER

B-25

OPERATION

LIMIT SETTING

Each user memory can be optionally configured to limit
the userʼs range of control over some user interface set­tings. By default, user limits are not enabled. To set lim­its for a selected memory, first select a weld mode and
perform a memory save. Next, press and hold the mem­ory button for five seconds. Release the memory button
when the memory LED begins to blink rapidly and the
Mode Select Panel displays indicate "Set Limits".

If the passcode has been set to a value other than zero,
the user will be prompted to enter it. If the passcode is
zero, the Mode Select Panel will immediately display the
Limit Setup menu and the SETUP LED will illuminate:

HI= 220

IR PORT

WELD MODE
ARC CONTROL

200

WELD WFS

LO= 180

SETUP

START OPTIONS
END OPTIONS

SET

B-25

One of these four items will blink to indicate which item
will change when the Mode Select Panel Knob is rotated.
Initially, the selected item will be the attribute. To select
the high limit, press either Mode Select Panel button and
the high limit value will begin to blink. Pressing either
Mode Select Panel button again will cause the memory
value to blink, pressing a third time will cause the low
limit to blink.

Weld modes cannot be selected from the Limits Setup
menu; the mode must be selected and saved to memory
prior to entering the Limits Setup menu.

The memory value, high and low limit values are bound
by the limits of the machine. For example, weld mode 49
may allow the wire feed speed to be adjusted between
10 and 200 in/min. These are referred to as "machine
limits". Machine limits can vary between power sources
and are also weld mode dependent.

The memory value must always be less than or equal to
the high limit and greater than or equal to the low limit.
The high limit must always be greater than or equal to
the low limit and the low limit must always be less than or
equal to the high limit. The rules are enforced automati­cally. If the low limit is increased above the memory
value, the memory value will automatically increase.

The above example shows a wire mode, constant current
weld modes would show "Weld Amps" rather than "Weld
WFS".

There are four items displayed on each Limit Setup
screen. The long alphanumeric display shows the
selected attribute (e.g. Weld WFS,Volts, etc.). The short
alphanumeric displays show the selected attributeʼs high
and low user limits. The 7-segment displays show the
value that is copied to procedure memory when a memo­ry recall is performed.

Memory Value

IR PORT

WELD MODE
ARC CONTROL

200

WELD WFS

SET

HI= 220
LO= 180

High Limit

Low Limit

SETUP

START OPTIONS
END OPTIONS

Attribute

To lock an attribute to a specific value, set the high and
low limits to the desired value. The user will not be able
to change it.

After setting limits, press the memory button that is flash­ing. The Mode Select Panel displays will prompt the
user to save or discard the limit changes just made.

By pressing the Mode Select Panel button labeled YES,
changes to limits are saved and user limits are automati­cally enabled. By pressing NO, any changes made to
limits are discarded and the limit enable/disable state is
not changed.

WAVEFORM CONTROL TECHNOLOGY

Enable

IR PORT

Yes

WELD MODE
ARC CONTROL

To enable or disable limits that have been established for
any memory, press and hold the respective memory but­ton in for more than 10 seconds until the Mode Select
Panel displays "Enable Limits?" Pressing "Yes" will use
the established limits, while pressing "No" will ignore the
established limits. The limits that have been set for any
memory location will not be erased if they are disabled.

Limits?

SET

SETUP

No

START OPTIONS
END OPTIONS

POWER FEED®10M DUAL WIRE FEEDER

C-1

ACCESSORIES

TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS

C-1

Wire Size

Solid Steel Electrode

0.023” - 0.025” (0.6 mm) KP1505 - 030S

0.030” (0.8 mm) KP1505 - 030S

0.035” (0.9 mm) KP1505 - 035S

0.040” (1.0 mm) KP1505 - 040S

0.040” (1.0 mm) KP1505 - 045S

0.045” (1.2 mm) KP1505 - 045S

0.052” (1.4 mm) KP1505 - 052S

1/16” (1.6 mm) KP1505 - 1/16S

5/64” (2.0 mm) KP1505-5/64

3/32” (2.4 mm) KP1505-3/32

Cored Electrode

0.030 (0.8 mm) KP1505 - 035C

0.035” (0.9 mm) KP1505 - 035C

4-Roll

DH Drive

(4-Driven)

0.040” (1.0 mm) KP1505 - 045C

0.045” (1.2 mm) KP1505 - 045C

0.052” (1.4 mm) KP1505 - 052C

1/16” (1.6 mm) KP1505 - 1/16C

0.068” (1.7 mm) KP1505 - 068

5/64” (2.0 mm) KP1505 - 5/64

3/32” (2.4 mm) KP1505 - 3/32

7/64”

Lincore Hard Facing

7/64” (2.8mm) KP1505 - 7/64

.120” (3.0mm) KP1505 - 120

Aluminum Electrode

0.035” (0.9 mm) KP1507 - 035A

0.040” (1.0 mm) KP1507 - 040A

3/64” (1.2 mm) KP1507 - 3/64A

1/16” (1.6 mm) KP1507 - 1/16A

3/32” (2.2 mm) KP1507 - 3/32A

(2.8mm) KP1505 - 7/64H

POWER FEED®10M DUAL WIRE FEEDER

C-2
FIELD INSTALLED

OPTIONS/ACCESSORIES

• OPTIONAL CONTROL PANEL KITS

• Arclink Cables

- Without Weld Cable
Cable Lengths: 8 ft K1543-8

16 ft K1543-16
25 ft K1543-25
50 ft K1543-50
100 ft K1543-100

ACCESSORIES

• Coil Adapter

- Adapts 50-60 lb. Lincoln coils
to a 2" Spindle K1504-1

• Plastic Wire Cover for
30-44 lb. Wire Packages K1634-1

• Plastic Wire Cover for up

to 60 lb. Wire Packages K1634-2

• Water Connection Kit K590-6

C-2

• Co-Axial Power Cable
Cable Length: 25 ft. (350 amps) K1796-25

50 ft. (350 amps) K1796-50
75 ft. (325 amps) K1796-75
100 ft. (325 amps) K1796-100

• Weld Power Cables

- Lug to Lug - 3/0, 600A, 60% Duty Cycle, 10 ft
K1842-1

- Lug to Lug - 3/0, 600A, 60% Duty Cycle, 35 ft
K1842-35

- Lug to Lug - 3/0, 600A, 60% Duty Cycle, 60 ft
K1842-60

- Lug to Lug - 3/0, 600A, 60% Duty Cycle, 110 ft
K1842-110

• Feed Plate Gun Receiver Bushings. For use with:

- Lincoln Gun Connector (K466-1)

- Innershield/SubArc Guns K1500-1

- Tweco

- Magnum 200/300/400 Guns K1500-2

- Tweco

- Magnum 550 Guns K1500-3

- Miller®Adapted Gun (K466-3) K1500-4

- OXO

- Fast Mate Guns K489-7

- Magnum 200/300/400 to K1500-2 Adapter K466-2

- K613-7 Magnum 550 to K1500-3 Adapter K613-7

• Incoming Bushings

- Lincoln Conduit .025-1/16" K1546-1

- Lincoln Conduit 1/16-1/8" K1546-2

• Wire Straightener

- For 10-Series Feed Heads

• Spindle Adapters

- For Mounting

- For Mounting

- For 14 lb. Innershield Coils to be

- For 8" O.D. Small spools (10-12.5 lbs.)

®

4 Gun Connector (K466-2, K466-10)

®

5 Gun Connector (K1637-7)

®

Gun K1500-5

or Separate Mounting K1733-1

2" I.D. Spools up to 60 lbs. K162-1

2" I.D. Spools up to 60 lbs. K162-1H

mounted on 2" O.D. Spools K435

to be mounted on 2" O.D. spindles K468

• Water Connection Adapter KP1529-1

• Magnum Flow Sensor K1536-1

• Gas Guard Regulator K659-1

• Dual Procedure Switch (5 pin)
with Trigger Leads K683-3

• Large Panel Security Door K1574-1

• Swivel Platform K1557-1

• Light Duty Caster Kit K1556-1

• Insulated Lift Bail K1555-1

• Foot Amptrol K870-1

Includes: Foot Amptrol with 6 pin connector.

• Hand Amptrol K936-1

Includes: Hand Amptrol LA-9/-17/LW20 with 6 pin

connector.

• Hand Amptrol K932-2

Includes: Hand Amptrol LA-26/LW18 with 6 pin

connector.

• Foot / Hand Amptrol Kit K2320-1
Includes: Harness for connecting foot and hand

amptrols with 6 pin connector.

K162-1 - WIRE SPINDLE ADAPTER

Spindle for boom mounting 2” (51 mm) I.D. spools
with up to 60 lb. (27.2 kg) capacity. User mounted to
appropriately prepared boom framework. Includes an
easily adjustable friction brake for control of overrun (a
2” spindle is standard on Power Feed 10 Dual Bench
model).

When a 2” (51 mm) spindle is used with coils not on
12” (305 mm) or 8” (203 mm) O.D. spools, an adapter
is required:

POWER FEED®10M DUAL WIRE FEEDER

C-3

ACCESSORIES

K1504-1 - COIL ADAPTER

Permits 50 lb to 60 lb (22.7-27.2 Kg.) coils to be
mounted on 2” (51 mm) O.D. spindles.

NON-LINCOLN GUNS

Most competitive guns can be connected to the Power
Feed by using one of the K1500 series adapter kits.

GUN RECEIVER BUSHINGS AND
ADAPTERS

K489-7 (DUAL SCHEDULE FAST-MATE
ADAPTER)

This adapter installs directly into the wire drive feed­plate, to provide for use of guns with Fast-Mate or
European style gun connections. This K489-7 will
handle both standard Fast-Mate and Dual Schedule
Fast-Mate guns.

C-3

K1500-1 (LINCOLN INNERSHIELD GUN
STANDARD CONNECTION)

Use this kit to connect the following guns: Guns hav­ing a Lincoln standard innershield gun connector,
Magnum 200/300/400 with K466-1 connector kit, and
Magnum 550 guns with the K613-1 gun connection
kit.

K1500-2 (TWECO #2-#4 TYPE CONNEC­TION)

The K1500-2 gun adapter comes factory installed on
the Power Feed 10 Dual wire feeder. Use this adapter
for guns that have a Tweco #2-#4 connector. Such
guns include Magnum 200/300/400 guns with K466-2
connector kit, and completely factory assembled
Magnum guns that are factory equipped with the
K466-2 connector (such as the K471-21, -22, and -23
dedicated Magnum 400 guns and the K497-20 and ­21 Magnum 200 guns).

K1500-3 (TWECO #5 CONNECTION)

For Magnum 550 gun with K613-2 Connection Kit,
and any other gun having a Tweco #5 connector .

POWER FEED®10M DUAL WIRE FEEDER

C-4

ACCESSORIES

C-4

K1500-4 (MILLER CONNECTION)

For any gun having a newer style Miller connector.
Install gun adapters per the instructions shipped with
it.

K1500-5 (OXO CONNECTION)

For any gun having an OXO style connector. Install
gun adapters per the instructions shipped with it.

CONDUIT ADAPTERS

K1546-2 ADAPTER

For use with Lincoln Magnum conduit and E-Beam
conduit (wire sizes 1/16 - .120)

For Magnum conduit:

Install the K1546-2 gun adapter at the incoming end of
the feed plate, secure with the set screw located at
the back of the feed plate. If a brass fitting is supplied
with the conduit, remove it from the feeder end of the
conduit by unscrewing it. Insert the conduit into the
K1546-2, secure the conduit by fastening it the
adapter with the supplied knob screw.

For E-Beam Conduit:

Install the K1546-2 gun adapter at the incoming end of
the feed plate, secure with the set screw located at
the back of the feed plate. Insert the conduit into the
K1546-2, secure the conduit by fastening it the
adapter with the supplied knob screw.

K683-1 DUAL PROCEDURE SWITCH

The K683-3 Dual Procedure Switch is the recom­mended method of obtaining dual procedure for non­Fast-Mate guns; but a K683-1 can be used. For using
a K683-1 with a fast mate gun, see USING DUAL
PROCEDURE WITH FAST-MATE GUNS. A K683-1
Dual Procedure Switch can be used on the Power
Feed 10 Dual if a K686-2 adapter is used. The K686-2
kit includes the gun switch and mountings for Lincoln
Innershield and Magnum guns, with 15 ft. (4.5 m) con­trol cable and 3-pin plug. K686-2 Adapter permits the
3-pin plug from the K683-1 and 5-pin gun trigger plug
to be connected to the 5-pin trigger/dual procedure
receptacle on the wire feeder.

USING DUAL SCHEDULE WITH FAST­MATE GUNS ON -10 SERIES FEEDERS

Configuration 1

K489-7 Dual Schedule Fast-Mate adapter

K575-[ ] Magnum 400 DS/FM gun (or competitive
DS/FM gun)

Configuration 2
K489-7 Dual Schedule Fast-Mate adapter
K683-1 Dual Procedure Switch (3 pin)
K686-2 "Y" adapter (3pin + 5 pin to 5 pin)

* Non-DS Fast-Mate gun (Magnum 450WC, Magnum 200, Magnum 300,
Magnum 400, and others)

*

K590-6 WATER CONNECTION KIT

DUAL PROCEDURE SWITCH
OPTIONS

K683-3 DUAL PROCEDURE SWITCH

Kit includes gun switch, and mountings for Lincoln
Innershield and Magnum guns, with 15 ft. (4.5m) con­trol cable and 5-pin plug with two leads to connect to
gun trigger.

Connect the 5-pin plug of the K683-3 Dual procedure
Switch to the Power Feed 10 Dual Wire Feeder
Trigger/Dual Procedure 5-socket receptacle.

The two lead plug cord extending out of the 5-pin plug
of the Dual Procedure switch is to be connected to the
two trigger leads of the welding gun per instructions
shipped with the kit.

POWER FEED®10M DUAL WIRE FEEDER

Install per the instructions shipped with the kit.

K1536-1 WATER FLOW SENSOR
KIT

Install per the instructions shipped with the kit.

C-5

ACCESSORIES

C-5

K659-1 GAS GUARD REGULATOR

Adjustable flow regulator with removable adjuster key for
CO2 and Argon blend gases. Mounts onto feeder inlet,
and reduces gas waste and arc start “blow” by reducing
surge caused by excess pressure in supply hose.

Install the 5/8-18 male outlet of the regulator to the 5/8­18 female gas inlet on the back panel of the wire drive.
Secure fitting with flow adjuster key at top. Attach gas
supply to 5/8-18 female inlet of regulator per INSTALLA­TION section.

K1556-1 LIGHT DUTY CASTER KIT

This option provides 4 casters and all required hardware
to mount it to the Power Feed Wire Feeder.

K1555-2 INSULATED LIFT HOOK

For applications where an insulated lift hook is required.
This kit provides an easily installed, heavy duty insulated
lift eye that mounts to the wire reel stand mast. See the
instructions provided with the kit for installation.

K1733-1 WIRE STRAIGHTENER

Install per the Instructions shipped with the Kit.

K2339-1 PUSH-PULL KIT AND K2320-1
FOOT AMPTROL AMPHENOL

The push-pull kit provides direct connection of a
Cobra Gold or Prince XL torch to the

Dual Wire Feeder

The kit is intended for use with the following Cobra
Max, Python or Prince XL torches:

Cobra Max

K2252-1 Air Cooled 15ft.(4.5m)

K2252-2 Air Cooled 25ft.(7.6m)

Python

K2211-2 Air Cooled 25ft.(7.6m) K2212-2 Water Cooled 25ft.(7.6m)

K2211-3 Air Cooled 50ft.(15.6m) K2212-3 Water Cooled 50ft.(15m)

Prince XL

K2296-2 Air Cooled 25ft.(7.6) K1592-2 Water Cooled 25ft.(7.6)

wire feeder.

K2212-1 Water Cooled 15ft.(4.5m)

K1592-1 Water Cooled 15ft.(4.5)

K1592-3 Water Cooled 50ft.(15.6

Power Feed®10M

)

K1546-1 CONDUIT ADAPTER

Install per the Instructions shipped with the Kit.

K1551-2 INCOMING BUSHING (4 Ball Roller)

Remove all input power to the Power Feed®10M
Dual Wire Feeder before installing the Connection
Adapter Kit.

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

(Standard on codes 10600 and up)

This ball bearing equipped incoming bushing can be
used in place of the standard incoming wire bushing,
when feeding solid steel or cored wire electrodes. It
significantly reduces any abrasion to the electrode
wire where it enters the feed head. This results in
even smoother, more trouble free operation.

Refer to the Ownerʼs Manual of the Torch for
Amperage and Duty Cycle rating information. The
torch rating may not match the rating of the power
source.

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

MAKING A WELD WITH THE PRINCE XL
OR COBRA GOLD TORCH INSTALLED

• Set the idle roll pressure on the wire drive between
an indicator reading of 0-2. A recommended start
point is 1.5.

• Depending on the weld mode, set the Voltage or
Trim at the
right control knob located on the upper case front
panel.

• The Wire Feed Speed (WFS) is set using the control
knob on the Torch. The left control knob on the

®

Feed

WFS being set at the torch is displayed on the

®

Feed

10M Dual Wire Feeder

• All weld parameters normally available for the active
weld mode are available during push-pull operation.
Refer to the Operation Section of this manual.

CAUTION

WARNING

Power Feed®10M Dual Wire Feeder

10M Dual Wire Feeder

is inactive. The actual

.

using the

Power

Power

POWER FEED®10M DUAL WIRE FEEDER

D-1

MAINTENANCE

MAINTENANCE

Avoiding Wire Feeding Problems

D-1

Safety Precautions

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such
as output terminals or internal wiring.

•

When inching with gun trigger, 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 maintenance work.

Observe all additional Safety Guidelines detailed
throughout this manual.

ROUTINE MAINTENANCE

Wire feeding problems can be avoided by observing
the following gun handling and feeder set up proce­dures:
a) Do not kink or pull cable around sharp corners.

b) Keep the electrode cable as straight as possible

when welding or loading electrode through cable.

c) Do not allow dolly wheels or trucks to run over

cables.

d) Keep cable clean by following maintenance

instructions.

e) Use only clean, rust-free electrode. The Lincoln

electrodes have proper surface lubrication.

f) Replace contact tip when the arc starts to become

unstable or the contact tip end is fused or
deformed.

g) Do not use excessive wire spindle brake settings.

h) Use proper drive rolls, wire guides and drive roll

pressure settings.

Gun and Cable connection: After feeding every coil of
wire; check tightness of gun connection to wire feed
brass bushing.

Drive Rolls and Guide Tubes

After feeding every coil of wire, inspect the drive roll
section. Clean it as necessary. The driver rolls and
Inner Wire Guides are stamped with the wire sizes
they will feed. If a wire size other than that stamped
on the roll(s) is to be used, the roll(s) and Inner Wire
Guides must be changed.

All drive rolls have two identical grooves. The rolls
may be flipped over to use the other groove.

See “Procedure to Install Drive Rolls and Wire
Guides” in the INSTALLATION section for roll chang­ing instructions.

Wire Reel Mounting - Readi-Reels and
10 through 30lb (4.5-14kg) Spools

No routine maintenance required.

PERIODIC MAINTENANCE

• Every year inspect the gearbox and coat the teeth

with a Moly-disulfide grease. Do Not use graphite
grease.

• Every six months check the motor brushes.
Replace them if they are less than 1/4" long.

• Replace the drive rolls and inner wire guide when
they are worn.

• Replace the pig tail if the insulation is cut, abraded
or damaged.

Gun and Cable Maintenance

See appropriate Operatorʼs Manual.

Procedure for Removing Feedplate from
Wire Feeder

1) Loosen the clamping collar screw using a 3/16"
Allen wrench. The clamping collar screw is
accessed from the bottom of the feedplate. It is
the screw which is perpendicular to the feeding
direction.

2) Loosen the retaining screw, which is also
accessed from bottom of feeder, using a 3/16"
Allen wrench. Continue to loosen the screw until
the feedplate can be easily pulled off of the wire
feeder.

POWER FEED®10M DUAL WIRE FEEDER

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

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

Step 1. LOCATE PROBLEM (SYMPTOM).

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

Step 2. POSSIBLE CAUSE.

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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such
as output terminals or internal wiring.

•

When inching with gun trigger, 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
these trouble shooting procedures.

Step 3. RECOMMENDED COURSE OF ACTION

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

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

WARNING

Observe all additional Safety Guidelines detailed
throughout this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

Rough wire feeding or wire not feed­ing but drive rolls are turning.

1. Gun cable kinked and/or twisted.

2. Wire jammed in gun and cable.
Check for mechanical restrictions
in feeding path.

3. Check for current position of drive
rolls Relative to split wire guide
groove.

4. Drive rolls may not be seated
properly.

5. Gun cable dirty. - Clean if neces­sary.

6. Worn drive roll.

7. Electrode rusty and/or dirty.
Cable frayed, or poor solder joint
at work or electrode lug.

8. Worn nozzle or cable liner. ­Replace if necessary.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

9. Partially flashed or melted con-

tact tip. - Replace if necessary.

10. Incorrect drive roll pressure. -

Readjust if necessary.

11. Improper liner, tip or inner/outer

guides. - Replace if necessary.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

Variable or “hunting” arc.

Poor arc striking with sticking or
“blast-offs”, weld porosity, narrow
and ropy looking bead, or electrode
stubbing into plate while welding.

1. Wrong size, worn and/or melted
contact tip. - Replace if neces­sary.

2. Improper Drive Tension.

3. Worn work cable or poor work
connection. - Replace if neces­sary.

4 Loose electrode or work cable

connections.

5. Wrong polarity. - Make sure elec­trode polarity is correct for
process being used.

6. Gas nozzle extended beyond gun
tip or wire stickout too long while
welding.

7. Poor gas shielding on processes
requiring gas. - Check gas flow
and mixture.

1. Improper procedures or tech­niques. - See “Gas Metal Arc
Welding Guide” (GS-100).

2. Improper gas shielding - Clean
gas nozzle. Make certain that gas
diffuser is not empty or turned off.
Make certain gas flow rate is
proper.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

3. Remove gun liner and check rub­ber seal for any sign of deteriora­tion or damage. Be sure set
screw in connector block is in
place and tightened against the
liner bushing.

4. Improper gear box ratio configura-

tion.

5. Power Source calibration issues.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-4

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

E-4

Tip seizes in diffuser.

Unit shuts off while welding or
attempting to weld, status light is
red/green alternating between colors
every second. Unit tries to recover
after 30 seconds and may repeat
again.

Drive roll does not turn although arc
voltage is present, and solenoid is
on. Feed head and Control Box sta­tus LEDs are both solid green.

1. Tip overheating due to prolonged
or excessive high current and/or
duty cycle welding.

Note: A light application of high tem-

perature antiseize lubricant
(such as Lincoln E2067
Graphite Grease) may be
applied to tip of threads.

1. Wire feed shut down circuit
maybe electrically open. (Leads
570 and 572 in wire feed head.

2. The wire drive motor may be
overloaded. Check for mechani­cal restrictions in the wire feeding
path.

1. Check for loose or broken leads
at the wire drive motor.

2. Defective wire feed motor or feed
head Printed Circuit (PC) board.
Note: With WFS set to max con­trol board should supply 24 VDC
to motor (leads #550, #551).

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

No wire feed, solenoid, or arc volt­age. Status LEDs are solid green.

No control of wire feed.
All status lights are solid green.
Preset WFS is adjustable on Control
Box

Wire feed motor turns and solenoid
operates, but no arc voltage is pre­sent. Status light is solid green on
Control Box.

1. Faulty gun trigger switch. The gun

trigger switch or circuit may be
faulty. Check or Replace.

1. Defective motor tach or control
PC board, or harness. Check for
loose or faulty connections on
motor tach. See Wiring Diagram.

1. Power source may be defective.

See Power Source LED Status
Light Chart.

2. Check for broken/Hi impedance

connection in weld circuit.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-5

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

E-5

Speed does not change when weld
current flows. Status lights are solid
green.

Voltmeter and/or ammeter do not
function properly even though status
lights are solid green. Welding may
vary from normal procedure.

Purge switch on feed head does not
activate solenoid but trigger closure
in MIG or pulse modes does.

1. Run-in and weld speeds are set to

the same value.

2. Possible problem with current

sensor electronics in power
source. Check power source man­ual to trouble shoot current sensor
electronics.

1. 67 and/or 21 voltage sense leads

may have intermittent or poor con­nections. Check.

2. Possible problem with power
source electronics.

1. Defective gas purge switch or

feed head board. Check continuity
with gas purge switch held down
across J1 pins 3 and 5. Release
purge switch and note there
should be no continuity now. If
either of these fail, the problem is
either in the gas purge switch or
harnessing. If no failure, replace
feed head board.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Cold feed switch does not activate
the motor but trigger does in MIG or
Pulse modes. LEDs are solid green
on both control board and feed head
boards.

1. Defective cold feed switch or feed

head PC board. Check continuity
with cold feed switch held up
across plug pins 3 and 4 of J1.
Release the cold inch switch and
note that there should be no conti­nuity now. If either of these fail,
the problem is either in the purge
switch or harnessing. If continuity
O.K., replace feed head board.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-6

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

E-6

Displays and/or indicator lights do
not change when their correspond­ing switches and or knobs are acti­vated to request a change.

Display(s) and status lights are
blank.

Dual Procedure is not functioning
when using remote dual procedure
switch. Status lights are solid green
on CB and head boards.

1. The encoders or switches may be

faulty.

2. Check for broken harness wire(s)
or harness disconnected from
intended location.

1. Power source is OFF.

2. Feeder supply or fuse circuit at
power source is blown or tripped,
or defective harness or cabling.

3. Display or Control Board (CB)

boards may be faulty.

1. Gun has not been selected at the
control box. Set dual procedure
switch on CB to gun. Refer to
operating instructions.

2. Faulty remote dual procedure
switch. Remove switch. Check
continuity between switch pins
with switch open and closed. If it
fails the continuity test, repair or
replace switch.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

3. Faulty Local Dual procedure
switch.

Wire feed speed is consistent and
adjustable, but operates at the
wrong speed.

Status LED not solid green

Gas solenoid not operating properly
or intermittent.

1. Dip switch on feed head board
does not match gear ratio used at
gear box. If using a high speed
gear, the feed head PC board dip
switch 8 must be set to 1 or “ON”.

2. Feed head board is not properly
reading DIP switch. Replace feed
head PC board.

1. see LED Status Light Chart.

1. Inlet gas pressure exceeding 80

psi(5.5 bar). Verify that gas pres­sure regulator is operating prop­erly.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-7

Observe all Safety Guidelines detailed throughout this manual

Error Codes for the Power Wave 455: Code 10555 and below
Note: For any Err # listed below write down the error number for reference and try cycling power to see if the

error clears itself. If not, refer to the What to Do column for the given Err.

PROBLEMS

(SYMPTOMS)

Display shows any of the following:

TROUBLESHOOTING

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

E-7

Err 001

Err 003

Err 004

Err 005

More than 1 CB with the same group
number.

Too many objects in group.

More than 1 object of the same
equipment type with the same group
# and feed head #.

A feed head has its feed head dip
switches set to zero in a group with
more than one object.

Make sure the group dip switch set­ting is unique for each CB.

A given group can only support up to
7 objects. Remove any objects over
7 from the group either by changing
the group dip switch settings or
physically disconnecting any objects
over 7 in the group.

Adjust the dip switch setting to make
either the group # or feed head #
unique for all objects of the same
equipment type.

The appropriate feed head # is 1
through 7. Check the dip switch set­ting chart in INSTALLATION section
and set the switches to make the
Feed head ID non-zero.

Err 006

Did not receive a recognition com­mand from the power source.

Check to see if the status light is not
solid green on the power source
(refer to status light states in OPER­ATION section if not). Also, check
continuity in the communication lines
from CB to Power Source (refer to
wiring diagram). Refer to Power
source trouble shooting section for
additional information. If all these
avenues fail, replace CB mother PC
board.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-8

Observe all Safety Guidelines detailed throughout this manual

Error Codes for the Power Wave 455: Code 10555 and below
Note: For any Err # listed below write down the error number for reference and try cycling power to see if the

error clears itself. If not, refer to the What to Do column for the given Err.

PROBLEMS

(SYMPTOMS)

Display shows any of the following:

TROUBLESHOOTING

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

E-8

Err 020

Err 100

Err 200

Err 201

An attempt was made to reprogram
a CB or feed head but the program
did not verify.

The Power Source issued a shut
down command for some reason.

No Heart beat response from the
PS.

No heart beat response from an
object.

Check for potential electrical HF
noise generators in the area. Try
removing the noise source and pro­gramming again. If the Err 020 still
occurs, either replace the EEPROM
chip(s) in the board being repro­grammed or replace the whole PC
board being reprogrammed.

See what to Do on Err 006.

See what to Do on Err 006.

If this occurs while welding, the sta­tus LED should be flashing red on
the object that lost heart beat.
Otherwise, look for any nodes that
are flashing green. This indicates
they have not been recognized and
there is a power source problem
(see power source trouble shooting
section). If the status LED is either
flashing or solid red, there may be a
problem with continuity in the com­munication lines. Check the lines for
continuity, in the cable and harness­ing (refer to wiring diagram).

Err 210

EEPROM error.

Parameter recalled at power up was
out of range. Rotate Encoder Knob
to reset. Check all settings before
proceeding to weld. If this condition
persists then replace the CB mother
PC board.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-9

Observe all Safety Guidelines detailed throughout this manual

Error Codes for the Power Wave 455: Code 10555 and below
Note: For any Err # listed below write down the error number for reference and try cycling power to see if the

error clears itself. If not, refer to the What to Do column for the given Err.

PROBLEMS

(SYMPTOMS)

Display shows any of the following:

TROUBLESHOOTING

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

E-9

Err 211

Err 212

- - - (three dashes)

Microprocessor RAM error in Control
Box.

Microprocessor RAM Error in object
board other than Control Box (Such
as feed head)

Appears on right display of CB mod­ule that contains the status LED

Turn Power off at power source.
Wait 5 seconds. Turn power back
on. If Err 211 is displayed again,
then replace CB mother PC board.

Cycle power as in Err 211. If Err 212
is still displayed, then replace the PC
board in the object with the fault. The
object with the fault should be solid
red on its status LED.

Dash indicates that the encoder
does not control anything, including
On/Off output control.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-10

Observe all Safety Guidelines detailed throughout this manual

Error Codes for the Power Wave 455: Code 10675 and above.

ERROR CODES FOR THE POWER WAVE 455

As a troubleshooting aid, error code information will now persist on the user interface displays even after a fault is
cleared. When a fault occurs that the user interface needs to display, welding will be held back for 5 seconds. If
the fault has cleared, the error code information can be removed from the displays by pressing the Reset button,
by changing a user interface control or by starting a new weld.

The following is a list of possible error codes that the Power Feed
play on this user interface.
Note: For any Err # listed below write down the error number for reference and try cycling power to see if the

error clears itself. If not, refer to the What to Do column for the given Err.

TROUBLESHOOTING

®

10M Dual Wire Feeder can output via the dis-

E-10

PROBLEMS

(SYMPTOMS)

Display shows any of the following:

Err 11

Err 12

Err 21

Err 22

Err 23

POSSIBLE CAUSE

CAN communication bus off.

User Interface time out error.

Unprogrammed Weld Mode.

Empty Weld Table.

Weld Table checksum error.

RECOMMENDED

COURSE OF ACTION

Probably due to excessive number
of communication errors.

User Interface is no longer respond­ing to the Power Source. The most
likely cause is a fault/bad connection
in the communication leads or con­trol cable.

Contact the Service Department for
instructions on reloading the Welding
Software.

Contact the Service Department for
instructions on reloading the Welding
Software.

Contact the Service Department for
instructions on reloading the Welding
Software.

Err 31

Err 32

Err 33

Primary overcurrent error.

Capacitor "A" under voltage.
(Left side facing machine)

Capacitor "B" under voltage.
(Right side facing machine)

Excessive Primary current present.
May be related to a switch board or
output rectifier failure.

Low voltage on the main capacitors.
May be caused by improper input
configuration.
When accompanied by an overvolt­age error on the same side, it indi­cates no capacitor voltage present
on that side, and is usually the result
of an open or short in the primary
side of the machine.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-11

Observe all Safety Guidelines detailed throughout this manual

Error Codes for the Power Wave 455: Code 10675 and above.

ERROR CODES FOR THE POWER WAVE 455

The following is a list of possible error codes that the Power Feed
play on this user interface.
Note: For any Err # listed below write down the error number for reference and try cycling power to see if the

error clears itself. If not, refer to the What to Do column for the given Err.

TROUBLESHOOTING

®

10M Dual Wire Feeder can output via the dis-

E-11

PROBLEMS

(SYMPTOMS)

Display shows any of the following:

Err 34

Err 35

Err 36

Err 37

Err 41

POSSIBLE CAUSE

Capacitor "A" under voltage
(Left side facing machine)

Capacitor "B" under voltage
(Right side facing machine)

Thermal error

Softstart error

Secondary overcurrent error

RECOMMENDED

COURSE OF ACTION

Excess voltage on the main capaci­tors. May be caused by improper
input configuration.
When accompanied by an undervolt­age error on the same side, it indi­cates no capacitor voltage present
on that side, and is usually the result
of an open or short in the primary
side of the machine.

Indicates over temperature. Usually
accompanied by Thermal LED.
Check fan operation. Be sure
process does not exceed duty cycle
limit of the machine.

Capacitor precharge failed. Usually
accompanied by codes 32-35.

The secondary (weld) current limit
has been exceeded. When this
occurs the machine output will phase
back to 100 amps, typically resulting
in a condition referred to as "noodle
welding"
NOTE: For the Power Wave 455/R
the secondary limit is 570 amps for
the standard stud, and 325 amps for
the STT stud and all single phase
operation.

Err 43

Capacitor delta error

The maximum voltage difference
between the main capacitors has
been exceeded. May be accompa­nied by errors 32-35.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

E-12

Observe all Safety Guidelines detailed throughout this manual

Error Codes for the Power Wave 455: Code 10675 and above.

ERROR CODES FOR THE POWER WAVE 455

The following is a list of possible error codes that the Power Feed®10M Dual Wire Feeder can output via the dis­play on this user interface.
Note: For any Err # listed below write down the error number for reference and try cycling power to see if the

error clears itself. If not, refer to the What to Do column for the given Err.

TROUBLESHOOTING

E-12

PROBLEMS

(SYMPTOMS)

Display shows any of the following:

Err 49

Other

POSSIBLE CAUSE

Single phase error Indicates machine is running on sin-

COURSE OF ACTION

gle phase input power. Usually
caused by the loss of the middle leg
(L2).

Error codes that contain three or four
digits are defined as fatal errors.
These codes generally indicate inter­nal errors on the Power Source
Control Board. If cycling the input
power on the machine does not clear
the error, try reloading the operating
system. If this fails, replace the con­trol board.

RECOMMENDED

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED®10M DUAL WIRE FEEDER

F-1

FOR CODES 10962, 11897

DIAGRAMS

F-1

POWER FEED®10M DUAL WIRE FEEDER

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-2

DIAGRAMS

F-2

POWER FEED®10M DUAL WIRE FEEDER

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-3

DIAGRAMS

F-3

4.08

3.86

.90

3.06

10-17-97

18963

M

.218

(4 KEYHOLE SLOTS)

CONTROL BOX DIMENSION PRINT

8.50

.75

4.25

.75

.81

6.88

12.07

12.96

POWER FEED®10M DUAL WIRE FEEDER

F-4

A

19.89

A

DIAGRAMS

A

19.91

A

7-21-2000 C

F-4

L11044

WIRE FEEDER (BENCH MODEL) DIMENSION PRINT

A

30.61

A

5.41

POWER FEED®10M DUAL WIRE FEEDER

A

A

F-5

DIAGRAMS

F-5

A

8.56

A

A

A

15.55

14.10

7-2000

M19304

A

A

A

5.25

TYP.

A

A

DOOR OPEN

A

2.54 TYP.

A

A

2.25

WIRE DRIVE DIMENSION PRINT

19.43

11.12

A

A

A

4.43

A

A

A

A

2.93

A

A

6.00

A

A

A

4.25 TYP.

POWER FEED®10M DUAL WIRE FEEDER

NOTES

POWER FEED®10M DUAL WIRE FEEDER

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch electrically live parts or

electrode with skin or wet clothing.

 Insulate yourself from work and

ground.

 No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

 Isolez-vous du travail et de la terre.

 Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

 Isolieren Sie sich von den

Elektroden und dem Erdboden!

 Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

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

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

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

remove fumes from breathing zone.

 Turn power off before servicing.

 Do not operate with panel open or

guards off.

WARNING

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

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

teur pour ôter les fumées des zones
de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

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

remover fumo da zona respiratória.

 Desconectar el cable de ali-

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

 Débranchez le courant avant l’entre-

tien.

 Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

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

serviço.

 Não toque as partes elétricas nuas.

 No operar con panel abierto o

guardas quitadas.

 N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

 Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

 Mantenha-se afastado das partes

moventes.

 Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

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

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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