Lincoln Electric IM777 User Manual

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

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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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATORʼS MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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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.

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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.

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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.

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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.

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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.

SAFETY

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

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.

SAFETY

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

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.

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

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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

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

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

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

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

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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

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vii

TABLE OF CONTENTS

Page

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

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

Troubleshooting Guide ...........................................................................................E-2 thru E-9

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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

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

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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.

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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 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:

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

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.

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.

• Constant Current

• 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

IR PORT

WELD MODE ARC CONTROL

FIGURE B.2

ALUMINUM

3/64"

PULSE 4043 Ar

SET

SETUP

START OPTIONS END OPTIONS

POWER FEED®10M DUAL WIRE FEEDER

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