Lincoln Electric IM658-A manual Control Cable Specifications, Available Cable Assemblies

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A-4

INSTALLATION

A-4

 

 

 

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.

Typical Boom Feeder Connection:

One control cable is connected from the Power Wave 455 output receptacle to the Control Box input recep- tacle. A second control cable is connected from the Control Box output receptacle to the input receptacle on the back of the Wire Drive.

Multiple Wire Drive Connection:

For proper multiple wire drive connections and DIP switch settings contact the Lincoln Electric Company, Customer Service Department.

Non-Typical Boom Feeder Connection:

One control cable is connected from the Power Wave 455 output receptacle to the the input receptacle on the back of the Wire Drive. A second control cable is connected from the output receptacle on the back of the Wire Drive to the Control Box input receptacle.

Control Box Mounted on Power Wave 455:

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

See CONTROL AND ELECTRODE CABLE INSTAL- LATION for cable installation instructions.

CONTROL CABLE SPECIFICATIONS

It is recommended that only genuine Lincoln control cables be used at all times. Lincoln cables are specifi- cally designed for the communication and power needs of the Power Wave 455 / Power Feed system. The use of non-standard cables, especially in lengths greater than 25 feet(7.6m), can lead to communication problems (system shutdowns), poor motor accelera- tion (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 twist- ed pair for network communications. This pair has an impedance of approximately 120 ohms and a propa- gation 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.

AVAILABLE CABLE ASSEMBLIES

K1543 Control cable only. Available in lengths of 8', 16', 25', 50' and 100'.

K1544 Control cable and a 3/0 (85 mm2 ) electrode cable with stud terminal. It is rated at 600 amps, 60% duty cycle and is available in lengths of 8', 16', 25', and 50'.

K1545 Control cable and a 3/0 (85 mm2) electrode cable with Twist-Mate™ connector on one end and a stud terminal on the other. It is rated at 500 amps, 60% duty cycle and is available in lengths of 8', 16', 25', and 50'.

ELECTRODE CABLE CONNECTIONS

Most welding applications run with the electrode being positive (+). For those applications, connect the elec- trode 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).

A work lead must be run 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. Excessive voltage drops at the work piece connection often result in unsatisfacto- ry pulse welding performance.

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

POWER FEED 10 DUAL

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Contents OPERATOR’S Manual Safety Electric Shock can kill Welding and Cutting Sparks can Cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a LʼArcThank You Table of Contents Section E Section FP346 Series Installation Safety Precautions Mounting the Wire Drive UnitBoom Mounting of Wire Drive Unit Mounting on Power Source Control CableMounting the Control BOX Boom or Separated Bench Models Control Cable ConnectionsControl Cable Specifications Available Cable AssembliesElectrode Cable Connections Wire Drive Gear Ratio High or LOW Speed Changing the Wire Drive RatioWork Cable Connections Selecting the Proper Gear RatioRatio Change Procedure DIP Switch Setup Setting DIP Switches in the Control BOXLSB Setting DIP Switches in the Wire Drive Figure A.4Wire Feed Drive Roll Kits Procedure to Install Drive Rolls and Wire GuidesGUN and Cable Assemblies with Standard Connection GUN and Cable Assemblies with FAST-MATECONNECTIONGeneral GUN Connection Guidelines Magnum 200 / 300 / 400 GunsWire Spindle Placement Wire Feed Shut Down Circuit OptionalGmaw Shielding GAS Water Connections for Water Cooled GunsGeneral Panel Installation Guidelines Boom and Bench ConversionsOptional Panels for Control BOX Product Description Recommended Processes and EquipmentDuty Cycle Control BOX OperationK1542-13 Dual Procedure / Memory Panel K1542-14 Head Select PanelControl BOX Panels -- ʻLARGEʼ Option Panels CV/Gouge PanelStdK1542-6 M Panel K1542-11 MX2 PanelControl BOX Panels -- SET UP Controls Description K1542-12 MSP2 PanelControl BOX -- Using Operating Limits Control BOX -- PC Board AdjustmentsWire Drive Operation Wire Drive Settings -- ExternalWhen using 2 Step Logic When using 4 Step Logic With Crater Fill OFFWire Reel Loading READI-REELS, Spools or Coils Electrode PolarityGear BOX Ratio Figure B.1 Feeding Electrode and Brake Adjustment Drive Roll Pressure SettingProcedure for Setting Angle of Feed Plate GAS Guard Regulator SettingWire Reel Changing Wire Feed Overload ProtectionMaking a Weld Component Status Lights Status Light StatesStatus Light States CONʼT Wire Size Solid Steel Electrode Cored ElectrodeAluminum Electrode Roll DH Drive 4-DrivenDescription and Installation of Optional Control BOX Panels CC/STICK/GOUGE Mode Constant Voltage CV/Weld, CV/MIG, CV/Flux Cored ProceduresK1542-11 MX2 Panel Large Panel 10 MS/STT Panel Large Panel K1542-13 Dual Procedure Memory Panel Small Panel K1542-14 Head Select Panel Small PanelK1543, K1544 and K1545 Input Cable Assemblies Feeder Head Enclosure Procedure K1548-1 Linc NET Receptacle KIT Input and OutputK162-1 Wire Spindle Adapter K1504-1 Coil AdapterK435 Coil Adapter K363P READI-REEL AdapterGuns and GUN Adapters GUN Receiver Bushings and AdaptersDual Procedure Switch Options Using Dual Procedure with FAST-MATE GunsConduit Adapters K590-6 Water Connection KIT for Drive only K1536-1 Water Flow Sensor KITK659-1 GAS Guard Regulator K1556-1 Light Duty Caster KITMaintenance Wire Drive Motor and GearboxGun and Cable Maintenance Drive Rolls and Guide Tubes1TROUBLESHOOTINGE-1 HOW to USE Troubleshooting GuideTroubleshooting Possible Cause Recommended Symptoms Course of Action Field Service FacilityYour local Lincoln Authorized Troubleshooting Possible Cause Course of ActionEither of these fail, the problem is Change Or harness disconnected from Fails the continuity test, repair or Possible Cause Err 001 Err 003Err 004 Err 005Err 020 Err 100Err 200 Err 201Err 211 Err 212Diagrams Control BOX Dimension Print Wire Feeder Bench Model Dimension Print DIAGRAMSF-4 Print Power Feed 10 Dual Precaucion Warnung
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