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IM849
June, 2009
™
POWER FEED 10A CONTROLLER
For use with machines having Code Numbers: 11139
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 thought-
ful 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.
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product T Th ha an nk k Y Yo ou u ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchas
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vi vi TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation.......................................................................................................................Section A Technical Specifications................................................................................................A-1 Safety Precautions ........................................................................................................
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A-1 A-1 GENERAL INFORMATION TECHNICAL SPECIFICATIONS: POWER FEED™ 10A CONTROLLER SPEC.# TYPE 142:1 SPEED RATIO 95:1 SPEED RATIO Wire Size Wire Size POWER FEED™ 10A CONTROLLER Speed Solid Cored Speed Solid Cored with Power Feed 10SF K2362-1 10-200 IPM 7/32 in. 5/32 in. 10-300 ipm 1/8 in. 5/32 in. (0.25 -5.08 m/min.) (5.6 mm) (4.0 mm) (0.25 -7.62 m/min.) (3.2 mm) (4.0 mm)
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A-2 A-2 INSTALLATION HIGH FREQUENCY PROTECTION SAFETY PRECAUTION Locate the POWER FEED™ 10A CONTROLLER away from WARNING radio controlled machinery. The normal operation of the POWER FEED™ 10A CONTROLLER may adversely affect ELECTRIC SHOCK can kill. the operation of RF controlled equipment, which may result • Only a qualified electrician should connect the POWER FEED™ 10A in bodily injury or damage to the equipment. CONTROLLER. Installation should be made in accordance with the AUXILIARY EQ
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A-3 A-3 INSTALLATION Auxiliary Input Power Connection Instructions: Terminal blocks 48 and 49 are shipped connected to CR2 and CR3 (532 and 531 leads) and these relays 1. Remove two Phillips Head screws on right side of are connected to the 3-pin and 4-pin connectors locat- front panel of hinged door to access terminal strip. ed on the bottom of the POWER FEED™ 10A CON- TROLLER. CR1 is available for a separate customer 2. Remove a plug button and install a box connector connection, but it w
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A-4 A-4 INSTALLATION 7. Remove one of the plug buttons located on the bot- 4. Replace the Switch Panel on the POWER FEED™ tom of the POWER FEED™ 10A CONTROLLER 10A CONTROLLER with the blank panel included control box and install some type of strain relief for with the pendant box. the interfacing leads. 5. Connect the Switch Panel to the mating 10-pin con- 8. Connect the interfacing leads to the Switch Panel nector inside the pendant box. circuits on the terminal strip (see Wiring Diagram for
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A-5 A-5 INSTALLATION FIGURE A.2 #39 #43 SWITCH GROUP SWITCH GROUP #2 SUPPLY #1 SUPPLY #40 #44 START TRAVEL AUTO #41 #45 STOP TRAVEL ON #42 #46 INCH UP FLUX FILL #47 INCH DOWN NOTE: TRAVEL AUTO and TRAVEL ON should not be closed at the same time. Either one OR the other should be closed at any time, and must remain closed to keep particular Travel Mode active. If neither switch is closed at any time, travel will be turned OFF, regardless of the welding state. Inching and Flux switches will
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A-6 A-6 INSTALLATION 8. Connect input supply voltage per the Auxiliary Input Power Connection Instructions listed earlier. Shutdown #2 can be configured for Output Lockout mode by enabling option P.21 in the Setup Menu 9. The relays could also be used to provide contact (Refer to Section B, General Setup Mode Options). closure for any interfacing signals out using the nor- when the input is opened, output is disabled, but cold mally open contacts. An external auxiliary supply feed of wire is
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A-7 A-7 INSTALLATION CONNECTION DIAGRAM SYSTEM POWER WAVE AC/DC 1000 K2344-1 POWER FEED 10A CONTROLLER CONTROL BOX K2362-1 A ARC RC 1 CONTROL CONTROL 1 3 8 8 2 4 5 6 7 7 K1543-XX ARCLINK CONTROL CABLE K1785-xx 14 —1 4 PIN FEEDER CABLE ELECTRODE SENSE LEAD POWER FEED 10SF WIRE DRIVE SUBARC CONTACT NOZZLE K2312-1 K231-xxx WORK WORK PIECE WORK SENSE LEAD POWER FEED™ 10A CONTROLLER
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A-8 A-8 INSTALLATION REMOTE SENSE LEAD SPECIFICATIONS Welding with Multiple Arcs Special care must be taken when more than one arc is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. Do not combine all of the work leads into one lead. Perform welding in the direction away from the work leads. Connect all of the work sense leads from each power source to the work
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B-1 B-1 OPERATION SAFETY PRECAUTIONS DESIGN FEATURES Read this entire section of operating instructions • Mode Select Panel for easy control of all weld para- before operating the machine. meters. • Memory Panel for easy storage and recall of weld WARNING schedules. • Weld parameter limit setting and lockout capabilities. • Digital communications for accurate and reliable per- ELECTRIC SHOCK can kill. formance. • Infrared red (IR) port for transferring weld settings. • Do not touch electrically
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B-2 B-2 OPERATION • When the POWER FEED™ 10A CONTROLLER is PRODUCT DESCRIPTION coupled to a Power Wave welding power source, the result is a welding system with the best arc perfor- General Physical Description mance on the market. The POWER FEED™ 10A CONTROLLER is a user RECOMMENDED PROCESSES interface. The control is used to set all welding para- meters and control any travel mechanisms. High- speed digital cables connect the control, wire drive, • The POWER FEED™ 10A CONTROLLER is best and
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B-3 B-3 OPERATION LOCATING FRONT PANEL CONTROLS AND INPUT, OUPUT CONNECTIONS 14-PIN RECEPTACLE CONTROL BOX WITH DOOR 4-PIN TRAVEL RECEPTACLE 3-PIN FLUX RECEPTACLE 5-PIN INPUT RECEPTACLE CONTROL BOX WITHOUT DOOR POWER FEED™ 10A CONTROLLER
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B-4 B-4 OPERATION CASE FRONT CONTROLS 1 2 10 3 4 5 6 7 8 9 11 12 13 CASE FRONT CONTROL DESCRIPTIONS 3. Status LED - The status LED indicates system sta- 1. DUAL DIGITAL DISPLAYS – Bright 7-segment dis- tus. Normal operation is a steady green light. plays showing welding parameter settings and actu- Note: During normal power-up, the LED may flash al levels while welding. red and/or green as the equipment performs self tests. 2. ARC ESTABLISH INDICATOR – Illuminates when LED condition Definition
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B-5 B-5 OPERATION 11. INCH DOWN – Feeds the wire downward, toward the Blinking green Occurs during a reset and indi- work. NOTE: The Power Feed 10A includes an option in cates the power source is identify- the Setup Menu (P.15) to enable the touch sense circuit- ing each component in the system. ry in the power source. Having this feature enabled will This is normal for the first 10 sec- stop the wire when it comes in contact with the work, onds after power-up, or if the sys- engaging the
