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IM945
May, 2009
™
AutoDrive 4R220
For use with machines having Code Number : 11455
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 opera-
tion 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
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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 Thank You ••• 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, purchasers may ask Linco
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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 INSTALLATION TECHNICAL SPECIFICATIONS – AutoDrive™ 4R220 (K2685-1) INPUT VOLTAGE, CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 40 VDC 7A RATED OUTPUT @ 104°F (40°C) DUTY CYCLE AMPERES MOTOR POWER WATTS 100% rating 500 220 GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING WFS RANGE WIRE SIZES WFS RANGE WIRE SIZES 50 – 1200 ipm .023 – 1/16" 50 – 1200 ipm .035 - 5/64” K2685-1 (0.8 – 30.5m/min) (0.6 – 1.6mm) (1.3 – 30.5m/min) (0.9 – 2.0mm) PHYSICAL DIMENSIONS HEIGHT WIDTH LE
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS WELD CABLE SIZE WARNING Table A.1 located below are copper cable sizes rec- ommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to ELECTRIC SHOCK CAN KILL. work and back to the welder again. Cable sizes are • Turn the input power OFF at the increased for greater lengths primarily for the purpose welding power source before of minimizing cable drop. installation or changing drive rolls and/or guides. • Do
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A-3 A-3 INSTALLATION COAXIAL WELD CABLE Coaxial welding cables are specially designed welding cables for STT™ and pulse welding. Coaxial weld cables feature low inductance, allowing fast changes in the weld current. Regular cables have a higher inductance which Electrode Electrode may distort the STT™ waveshape. Inductance becomes more severe as the weld cables become longer. Coaxial weld cables are recommended for STT™ weld- ing, especially when the total weld cable length (elec- trode ca
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A-4 A-4 INSTALLATION WIRE DRIVE CABLE, K1785-XX Wire drive cables are used to connect power sources and control boxes to remote wire drives. The cables have a 14 pin connector at each end. Both ends of the cable have a collar and the cables cannot be “daisy chained” to make a longer cable. POWER SOURCE WIRE FEEDER J A A J I B K K B I C H H N L N L C G M M D G D F E F E POWER SOURCE WIRE FEEDER Pin Function Pin Function A Motor Power Motor Power A B Motor Power B Motor Power C Gas Solenoid C
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A-5 A-5 INSTALLATION SHIELDING GAS CONNECTION 5. Attach one end of the inlet hose to the outlet fitting of the flow regulator. Attach the other end to the welding WARNING system shielding gas inlet. Tighten the union nuts with a wrench. CYLINDER may explode if damaged. 6. Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting •Keep cylinder upright and spring pressure is released. chained to support. 7. Standing to one side, open the cylinder
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A-6 A-6 INSTALLATION PROCEDURE TO INSTALL DRIVE ROLLS 4. Open the idle arms. AND WIRE GUIDES 5. Remove the drive rolls and inner wire guide. WARNING ELECTRIC SHOCK can kill. To install drive rolls and wire guides: • Turn the input power OFF at the weld- ing power source before installation 1. Turn off power at the welding power source. or changing drive rolls and/or guides. • Do not touch electrically live parts. 2. Open the idle arms. • When inching with the gun trigger, electrode and drive
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A-7 A-7 INSTALLATION PRESSURE ARM ADJUSTMENT CONDUIT INSTALLATION The K1546-xx series of conduits are compatible with WARNING K515-xx, K565-xx, Wire Wizard and Electron Beam ELECTRIC SHOCK can kill. Technologies conduits. • Turn the input power OFF at the weld- ing power source before installation or To install conduit to the wire drive: changing drive rolls and/or guides. • Do not touch electrically live parts. 1. Slide the conduit bushing into the feed plate and • When inching with the gun
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A-8 A-8 INSTALLATION SYSTEM SET-UP SYSTEM SET-UP (SINGLE ARM) AutoDrive™ 4R220 K1505-XX K1507-XX Electrode Connection Auto Drive 4R220 (Without Cover Shown) ArcMate 100iB ArcMate 100iC FANUC R-J30iA Controller with Integrated Op Box Wire Feeder (14 Pin) Gas Internal ArcLink XT Communication Robotic ArcLink XT Torch Connection Power Wave i400 K2669-1 Air * Electrode Optional Work Cable (+) Sense Lead (21) K884-5,-6 K1785-XX Wire Feeder Wire Feeder Control Cable (14 Pin) ArcLink Work (5 Pin
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B-1 B-1 OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON READ AND UNDERSTAND ENTIRE SECTION THIS MACHINE OR IN THIS MANUAL BEFORE OPERATING MACHINE. WARNING WIRE FEEDER • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ture, when feeding with gun trig- POSITIVE OUTPUT ger, the electrode and drive mechanism are always electri- cally energized and could NEGATIVE OUTPUT remain energized several sec- onds after the welding ceases.. • Do not touch electrically live part or electrode w
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B-2 B-2 OPERATION EQUIPMENT LIMITATIONS DEFINITION OF WELDING TERMS GMAW K2685-1 AutoDrive™ 4R220 • Gas Metal Arc welding ß• Maximum GMAW gun length =10’ (3.1m) FCAW ß• Maximum FCAW gun length = 15’ (4.6m) • Flux Core Arc Welding ß• Maximum wire drive control cable length = 100ft. STT™ (31m) • Surface Tension Transfer ß• Robot and power source software may need to be updated. ß• Drive rolls are not included with the feeder. PRODUCT DESCRIPTION ß• Mounts to FANUC ArcMate100iC arms. ß• Mou
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C-1 C-1 ACCESSORIES OPTIONAL KITS AND ACCESSORIES DRIVE ROLL KITS 4 ROLL DRIVE WIRE TYPE KITS ELECTRODE SIZE Includes: 4 V groove Steel Wires: KP1505-030S .023-.030 (0.6-0.8mm) drive rolls and inner KP1505-035S .035 (0.9mm) KP1505-040S .040 (1.0mm) wire guide. KP1505-045S .045 (1.2mm) Includes: 4 Knurled KP1505-035C .030-.035" (0.8-0.9mm) Cored Wires: drive rolls and inner KP1505-045C .040-.045" (1.0-1.2mm) wire guide. Includes: 4 polished KP1507-3/64A 3/64" (1.2mm) Aluminum
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C-2 C-2 ACCESSORIES Gun Receiver Bushing (for guns Includes: Gun receiver bush- K1500-1 with K466-1 Lincoln gun connec- ing, set screw and hex key tors; Innershield and Subarc guns) wrench. Gun Receiver Bushing (for guns with K466-2, K466-10 Lincoln gun Includes: Gun receiver bush- K1500-2 connectors; Magnum 200/300/400 ing with hose nipple, set screw guns and compatible with Tweco® and hex key wrench. #2-#4) Gun Receiver Bushing (for guns Includes: Gun receiver bush- K1500-3 with K613-7 Linco
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C-3 C-3 ACCESSORIES K2175-1 500 lb Accu-Pak Box Payoff Kit K2175-2 1000 lb Accu-Pak Box Payoff Kit K895-2 Rotary Wire Dispenser K836-1 Dereeler Adapter K884-5 Accu-Trak Drum Payoff Kit – 20 inch diameter K884-6 Accu-Trak Drum Payoff Kit – 23 inch diameter Includes: 1 cable of length “xx” K1796-xx Coaxial Cables feet. 14 pin connectors on both ends. Cable length can- not be extended by connecting K1785 cables together. K2593-xx Coaxial Cables Includes: 1 cable of length “xx” K1785-xx Wire Dri
