Lincoln Electric IM818 User Manual
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LINCOLN
ELECTRIC
®
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Push-Pull Gun
OPERATOR'S MANUAL
Prince®XL/Spool Gun
Model #350 (factory model)
For use with Cabinet K2259-1
IM818
MK 091-0531
April 2003
Rev A
Safety Depends on You
Lincoln arc welding equipment is
designed and built with safety
in mind. However, your overall
safety can be increased by proper
installation...and thoughful 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.
OPERATOR’S MANUAL
Copyright © 2003 Lincoln Global Inc.
World’s Leader in Welding and Cutting Prodcuts
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
Prince® XL - Owner's Manual - Page i
Prince® XL - Owner's Manual - Page ii
Prince® XL - Owner's Manual - Page iii
Prince® XL - Owner's Manual - Page iv
Prince® XL - Owner's Manual - Page v
For selecting a quality product. We want you to take
Thank You
pride in operating this product...as much pride as we
have in bringing the product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the
carrier. Consequently, claims for material damaged in shipment must be made by the
purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This
information can be found on your machine nameplate.
Model Name & Number _____________________
Code & Serial Number _____________________
Date of Purchase _____________________
Whenever you request replacements parts for, or information on this equipment always
supply the information you have recorded above.
Read this Owner’s 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.
Prince® XL - Owner's Manual - Page vi
Table of Contents
SAFETY CONSIDERATIONS .................................................... I-VI
INSTALLATION ........................................................ SECTION A
TECHNICAL SPECIFICATIONS ............................................................... 3
SUPPORT EQUIPMENT REQUIRED........................................................... 3
T
ORCH LEAD CONNECTION ................................................................ 3
INSTALLING SPOOL ASSEMBLY ............................................................. 4
INTERCONNECTIONS ...................................................................... 5
OPERATION .......................................................... SECTION B
GENERAL ............................................................................... 4
B
ARRELS ................................................................................ 6
CONTROLS AND SETTINGS................................................................. 6
D
RIVE ROLL AND IDLER ROLLS ............................................................ 7
ACCESSORIES ......................................................... SECTION C
CONTACT TIPS .......................................................................... 8
BARREL LINERS .......................................................................... 8
B
ARREL ASSEMBLIES ...................................................................... 9
OPTIONAL BARRELS ...................................................................... 9
OPTIONAL KITS.......................................................................... 9
OPTIONAL ACCESSORIES .................................................................. 9
PRINCE SPOOL GUN CONTROLS ..........................................................10
F
INNED COPPER GAS CUPS ............................................................... 8
MAINTENANCE........................................................ SECTION D
PERIODIC MAINTENANCE .................................................................11
R
ECOMMENDED SPARE PARTS LIST........................................................13
TROUBLESHOOTING ................................................... SECTION E
TROUBLESHOOTING GUIDE ...............................................................14
T
ESTING THE TORCH.....................................................................16
APPENDICES.......................................................... SECTION F
DIAGRAMS/PARTS LIST..................................................................17
MECHANICAL ...........................................................................18
ELECTRICAL ............................................................................25
MK REPAIR STATIONS
SAFETY WARNINGS
WARRANTY
THIS PAGE INTENTIONALLY BLANK
SECTION A INSTALLATION
TECHNICAL SPECIFICATIONS
PRINCE® XL TORCH - 25’- P/N K2296-2
Wire Capacity
• .023”-.045” (0.6 - 1.2mm)
solid and hard wire
• .030” - 1/16” (0.8 - 1.6mm)
aluminum and cored wire
Wire Speed
• 750 ipm (19.0 mpm) max.
Duty Cycle - 100%
All ratings are at 25V using Argon Gas
• 200 Amps Air cooled standard, using Air/Water barrel
Torch weight (less leads & standard barrels)
• 36.4 oz. (1.02 kilogram)
®
P
RINCE
XL SPOOL GUN - 25’ - P/N K2297-2
Wire Capacity
• .023” - .045” (0.6 - 1.2mm)
solid and hard wire
• .030” - 1/16” (0.8 - 1.6mm)
aluminum and cored wire
Wire Speed *
• 750 ipm (19.0 mpm) max.
Spool Size
• 4 inches (101.6mm)
Duty Cycle - 100%
All ratings are at 25V using Argon Gas
• 200 Amps Air cooled standard, using Air/Water barrel
Torch weight (less wire & leads)
• 46.5 oz (1.3 kilogram)
* Maximum ipm varies depending on input voltage, wire size
and the control box used.
SUPPORT EQUIPMENT REQUIRED
• CV or CC power source of suffi cient capacity for your needs.
• Regulated gas supply and hoses.
• Properly sized power leads from power source to wire feeder and
ground.
TORCH LEAD CONNECTIONS
POWER CABLE - AIR COOLED
A #2 AWG power cable is used on the Prince®XL air cooled torch. The torch
end is threaded into the torch body. The power cable fi tting connects to the
Power Block.
(MK P/N 003-1674) when using a Cobramatic
Prince®XL is purchased as a Spool Gun, the power cable comes standard
with a lug connector and should be connected to positive lug of power supply.
CONDUIT
The Prince™XL Torch comes standard with a poly lined conduit, for running
aluminum wire. The longer fi tting with a shallow groove is used on the torch
end. A set screw located on top of the torch handle secures the conduit in
®
wire feed cabinet. When the
Prince XL® - Owner's Manual - Page 3
place. A small spool liner (MK P/N 003-0198) is used on the spool gun and
held in place by the same set screw.
GAS HOSE
The gas hose is secured over the barbed gas fi tting with a tie wrap. The
cabinet end of the gas hose uses our standard gas fi tting (1/8” - 27 nps),
whereas the spool gun uses a 5/8” - 18 IAA RH male gas fi tting.
ELECTRIC CABLE
A seven conductor control cable is used on the Prince®XL Torch. The torch
end of the control cable is secured to the torch with a boot clamp and
plugged into the pot assembly and micro switch connectors. Slack is left in
the electric cable as it exits the back of the torch to prevent cable breakage.
The cabinet end has a seven pin "W" clocked amphenol connector. See
page 22 for torch electrical connections.
INSTALLING SPOOL ASSEMBLY (P/N 003-2090)
Loosen the screw that secures the conduit through access hole located on
top right rear handle with a 1/16" Allen wrench.
Conduit Securing Screw
Remove conduit by pulling it out of the back of the gun.
E-Ring
Rear Wire Guide
Spool Liner
2 Screws
Install spool liner, and secure with screw.
Remove both rear handle screws, and secure spool canister with longer
screws provided.
SPOOL GUN SETUP
LOADING ELECTRODE WIRE
Unscrew, and remove spool cover.
Apply tension to drive rolls, so the wire will be picked up and fed through
the contact tip.
Straighten out fi rst six inches of wire and push through liner.
Jog trigger until wire is picked up by drive rolls and fed through contact tip.
Hold brake assembly back towards top of gun, load spool onto shaft with
wire coming off the bottom of the spool. Release brake assembly to rest
on wire surface.
Replace spool cover, making sure opening is over liner.
Note:
The brake paddle assembly is designed to automatically control spool drag and
keep the wire from jumping off the spool.
SECTION B OPERATION
GENERAL
The Prince™XL torch maintains a constant, steady, uniform wire feed speed,
regardless of curved or looped wire conduit. The constant push exerted by
Prince XL® - Owner's Manual - Page 4
INTERCONNECTIONS
PRINCE® XL TORCH
TO
®
COBRAMATIC
I CABINET
(150-005,150-006, 150-205, 150-206,
K1853-1 & K2259-1)
WIRE CONDUIT
POWER CABLE
GAS HOSE
ELECTRICAL
CABLE
WATER HOSE OPTIONAL
PRINCE® XL SPOOL GUN
TO
WC-1 WELD CONTROL BOX
115VAC PLUG
NOTE: The Posa Start feature permits
the WC-1 to be used in
combination with any Constant
Current DC power source with
an open circuit voltage in exces
of 55 volts.
Weld Control Box
ELECTRICAL CABLE
GAS HOSE
COUPLER -AW-430-RH
MK P/N 753-3377
CONTACTOR LEADS
POWER CABLE
CC or CC POWER SUPPLY
White
Black
Red
WC-1 CONSTANT CURRENT
POSA START SENSING LEADS NOT NEEDED
WITH CONSTANT VOLTAGE SUPPLIES
Green
GROUND
Customer Supplied
Prince® XL - Owner's Manual - Page 5
the slave motor in the cabinet, combined with the pull of the torch motor,
causes the wire to literally fl oat friction-free through the wire conduit. The
24VDC torch motor is controlled by a 3-3/4 turn potentiometer in the torch
handle.
BARRELS
AIR/WATER COOLED
The Prince® XL air cooled systems come standard with a straight air/water
cooled barrel assembly. An optional curved air/water cooled barrel assembly
(LE P/N KP2298-2, MK P/N 003-2152) is also available. In cases where
these barrels need to be extended or the tip threads have been damaged,
a Tip Extender (LE P/N KP2244-1, MK P/N 621-0424) can be adapted. The
same tips and threads can be used, however a longer Tefl on liner (LE P/N
KP2226-1; MK P/N 931-0137) is required.
B
ARREL REMOVAL AND INSTALLATION
To remove a barrel assembly, loosen the patented EZ Lock™ Taper lock nut
assy MK P/N 003-2572 3/4 to 1 turn. This will push barrel away from the
body far enough so that it may be pulled out of the body.
To replace a barrel assembly, take care not to damage the “O” rings when
inserting into the body. Open the drive and idler roll door and seat the barrel
assembly until the inlet guide is almost touching the drive and idler roll and
the rear face of the barrel is fl ush with the aluminum body block. Tighten
taper lock nut assembly fi rmly so that barrel cannot rotate.
B
ARREL ROTATION
To rotate a barrel assembly, loosen the patented EZ Lock™ Taper lock nut
assembly no more than 1 turn. Rotate barrel to the position of your choice
and retighten taper lock nut assembly fi rmly so that the barrel cannot rotate.
WARNING:
Do not attempt to weld without the barrel being tightly secured in the torch body, or
damage to the barrel or body may result.
CONTROLS AND SETTINGS
POTENTIOMETER
The pot is located in the bottom of the pistol grip and provides 3-3/4 turns of
rotation and up to 750 ipm.
The pot is mounted to one side of a PC board and is held in place by a
support plate; both of which have slots that locate and secure the pot in the
handles. The other side of the PC board houses the motor connectors and
ribbon cable. Locking disks behind the pot knob provides a stop at the minimum and maximum pot settings.
T
RIGGER, GAS VALVE AND MICRO SWITCH
The torch trigger is designed so that when it is partially depressed, gas fl ow
starts via the valve located in the torch body, prior to ignition of the arc. When
the trigger is partially released after welding (extinguishing the arc), gas fl ow
continues until the trigger is fully released; built-in pre and post gas fl ow.
The micro switch is wired “Normally Open” and secured to the torch block
with two (2) screws. An insulator between the torch block and micro switch
prevents accidental shorting of the switch leads. The trigger pin reaches
through the handle and activates the micro switch just before the trigger bottoms out on the handle.
Prince XL® - Owner's Manual - Page 6
DRIVE AND IDLER ROLLS
GENERAL
The Prince®XL torch comes standard with knurled drive rolls which will
handle wire diameters from .023 - 1/16 inch. Optional grooved drive rolls are
also available for feeding aluminum wire if desired (see Optional kits).
Drive roll tension is accomplished by means of a pressure adjusting allen
screw located on the left hand side of the torch. Proper tension is achieved
when wire does not slip if a small amount of pressure is added to the wire as
it exits the tip.
----------- IMPORTANT -----------
NOTE: Over-tightening of the drive rolls will cause excessive knurling and/or
deformation of the wire. When the complete system is setup properly, feeding wire
out of the end of the torch and letting fall on the ground should form a large uniform
circle. If it forms a spiral or spring then there is too much tension in the system,
please refer to the Cabinet Owners Manual for adjustment to the tension setting.
INCORRECT DRIVE ROLL TENSION IS THE NUMBER ONE
CAUSE OF POOR WIRE FEED PERFORMANCE
---------------------------------------------
D
RIVE ROLL INSTALLATION AND REMOVAL
Note:
Neither of the handles needs to be removed to access the Drive or Idler Rolls.
1. Using a 5/32” hex wrench, loosen the Idler Roll tension screw. This will
relieve the pressure against the drive roll.
2. Align the Drive Roll Removal Tool (P/N 931-0100) over the fl ats of the drive
roll. Hold the torch with one hand or on a table top, with the other hand give
the Removal Tool a quick snap-turn in the CLOCKWISE DIRECTION.
3. Once the drive roll is loose, continue to spin drive roll in the clockwise
direction to remove the drive roll from the torch.
4. Install a new drive roll on the left-hand threaded shaft. The drive roll will
self-tighten when it is feeding wire.
I
DLER ROLL INSTALLATION AND REMOVAL
1. Using a slot type screwdriver, loosen idler screw, taking care not to lose
lock washer under idler roll.
2. Insert new idler roll and lock washer onto screw, insuring that idler groove
is toward top and lock washer is beneath.
Prince XL® - Owner's Manual - Page 7
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