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IM772-A
Power Feed 10 Robotic October, 2006
K1780-2
For use with machines having code numbers: 10944, 11301

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.

OPERATOR’S MANUAL

Copyright © 2006 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• 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
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 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.

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

ELECTRIC AND
____________________________________________________ MAGNETIC FIELDS
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running. may be dangerous
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz- 2.a. Electric current flowing through any conductor causes
ing on contact with hot engine parts and localized Electric and Magnetic Fields (EMF). Welding
igniting. Do not spill fuel when filling tank. If current creates EMF fields around welding cables and
fuel is spilled, wipe it up and do not start welding machines
engine until fumes have been eliminated.
____________________________________________________ 2.b. EMF fields may interfere with some pacemakers, and
1.d. Keep all equipment safety guards, covers and devices in welders having a pacemaker should consult their physician
position and in good repair.Keep hands, hair, clothing and before welding.
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment. 2.c. Exposure to EMF fields in welding may have other health
____________________________________________________ effects which are now not known.

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove
minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving
them with tape when possible.
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. 2.d.2. Never coil the electrode lead around your body.
Do not attempt to override the governor or
idler by pushing on the throttle control rods 2.d.3. Do not place your body between the electrode and
while the engine is running. work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
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. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
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,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.

3.f. Maintain the electrode holder, work clamp, welding cable and 5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace by various factors including proper use and positioning of
damaged insulation. the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
3.g. Never dip the electrode in water for cooling. exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
3.h. Never simultaneously touch electrically “hot” parts of OSHA PEL and ACGIH TLV limits.
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
of both welders. coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.i. When working above floor level, use a safety belt to protect form phosgene, a highly toxic gas, and other irritating prod-
yourself from a fall should you get a shock. ucts.

3.j. Also see Items 6.c. and 8. 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.

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.

AUG 06
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.

6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.

6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique: 8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains. des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on câbles jusqu’à ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans 9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse. galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement. 10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir. chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines. 11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de voir le code “Code for safety in welding and cutting” CSA
courant pour soudage semi-automatique, ces precautions Standard W 117.2-1974.
pour le porte-électrode s’applicuent 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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, REDRESSEUR
donc:

a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I’installation et l’entretien du poste seront
l‘arc. effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 4. Garder tous les couvercles et dispositifs de sûreté à leur
de l’huile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
zones où l’on pique le laitier.
v v
for selecting a QUALITY product by Lincoln Electric. We want you

Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this 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.

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 WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. 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:

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 vi
Page
Installation .......................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Mounting the Wire Drive Unit ........................................................................................A-2
Electrode Routing..........................................................................................................A-2
Electrode and Work Cable Connections .......................................................................A-2
Negative Electrode Polarity ...........................................................................................A-3
Shielding Gas Connection.............................................................................................A-3
Control Cable .......................................................................................................................A-3
Control Cable Connections ...........................................................................................A-3
Control Cable Specifications .........................................................................................A-4
Wire Drive Gear Ratio (High or Low Speed) .................................................................A-4
Selecting the Proper Gear Ratio ...................................................................................A-4
Changing the Wire Drive Ratio......................................................................................A-5
Wire Feed Drive Roll Kits ..............................................................................................A-6
Procedure to Install Drive Rolls and Wire Guides .........................................................A-6
Drive Roll Kit Installation (KP1505-[ ]),(KP1507-[ ]) .................................................A-6
General Gun Connection Guidelines ............................................................................A-6
Gun Receiver Bushings and Adapters ..........................................................................A-7
Conduit Adapters ..........................................................................................................A-7
Remote Sense Lead Specifications ..............................................................................A-7
Installation of Field Installed Options ............................................................................A-7
Feeding Electrode and Brake Adjustment.....................................................................A-8
Drive Roll Pressure Setting ...........................................................................................A-8

Operation .........................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
Duty Cycle .....................................................................................................................B-1
General Description ......................................................................................................B-1
Recommended Processes ............................................................................................B-1
Process Limitations .......................................................................................................B-1
Recommended Equipment / Interface...........................................................................B-1

Accessories .....................................................................................................Section C
Optional Equipment..............................................................................................................C-1
Drive Roll and Guide Tube Kits ............................................................................................C-1

Maintenance ....................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ....................................................................................................D-1
Drive Rolls and Guide Tubes .............................................................................D-1
Avoiding Wire Feeding Problems..................................................................................D-1
Periodic Maintenance ...................................................................................................D-1
Procedure for Removing Feed plate from Wire Feeder ..........................................D-1

Troubleshooting ..............................................................................................Section E
Safety Precautions ...............................................................................................................E-1
Troubleshooting Guide ...........................................................................................E-2 thru E-4

Diagrams ..........................................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Dimension Print......................................................................................................F-2

Parts Lists ....................................................................................................P441 Series

A-1 INSTALLATION A-1

TECHNICAL SPECIFICATIONS – Power Feed 10 Robotic-K1780-2

WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER
SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO
Wire Size Wire Size
Speed Solid Cored Speed Solid Cored

K1780-2 Power Feed 10 50-800 IPM .025 - 3/32 in. .035 - .120 in 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in.
(1.27-20.3 m/m) (0.6 - 2.4 mm) (0.9 - 3.2 mm) (2.03 - 30.5 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
Dimensions
Height Width Depth Weight Operating Storage
K1780-2 Power 40 VDC 8.90 “ 12.04 “ 9.90 “ 22.40 Lbs -20° to +40° C -40° to +40° C
Feed 10 (226 mm) ( 306 mm) (251 mm) (10.2 Kg)
Wire
Feeder

POWER FEED 10 ROBOTIC

A-2 INSTALLATION A-2
SAFETY PRECAUTIONS
ELECTRODE ROUTING
WARNING
The electrode supply may be either from reels, Readi-
Reels, spools, or bulk packaged drums or reels.
ELECTRIC SHOCK can kill. Observe the following precautions:
• Do not bend the conduit more than 45°, and to use
• Only qualified personnel should the minimum amount of conduit necessary for the
perform this installation. wire reel to connect to the wire feeder.
• The electrode is "hot" while welding and must be
• Turn off the input power to the power source at
the disconnect switch or fuse box before work- insulated from the boom, conduit and wire payoff
ing on this equipment. Turn off the input power structure.
to any other equipment connected to the weld- • If more than one wire feed unit shares the same
ing system at the disconnect switch or fuse boom and are not sharing the some power source
box before working on this equipment. output stud, their wire and reels must be insulated
• Do not touch electrically hot parts. from each other as well as insulated from their
mounting structure.
• Always connect the Power Wave grounding lug
(located inside the reconnect input access ELECTRODE AND WORK CABLE
door) to a proper safety (Earth) ground.
---------------------------------------------------------------------------------------- CONNECTIONS

Most welding applications run with the electrode being

positive (+). For those applications, connect the elec-
MOUNTING OF THE PF10/R trode cable between the wire feeder and the positive
(+) output stud on the power source (located beneath
Mount the wire drive unit by means of the 4 holes in the spring loaded output cover near the bottom of the
the bottom of the wire drive base. (See Figure A.1) case front).
Note that the gearbox assembly is electrically “hot”
when welding. Therefore, make certain the gearbox A work lead must be run from the negative (-) power
does not come in contact with the structure on which source output stud to the work piece. The work piece
the unit is mounted. The wire feed unit should be connection must be firm and secure, especially if
mounted so that the drive rolls are in a vertical plane pulse welding is planned. Excessive voltage drops at
to prevent the accumulation of dirt in the drive roll the work piece connection often result in unsatisfacto-
area. Do not bend the conduit more than 45°. ry pulse welding performance.

Connect a work lead of sufficient size and length (per

FIGURE A.1 TABLE 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 con-
tact. To avoid interference problems with other equip-
ment and to achieve the best possible operation, route
1.97
all cables directly to the work or wire feeder. Do not
bundle the electrode and work leads tightly together.
1.77
Avoid excessive lengths and do not coil excess cable.

Use K1796 Coaxial welding cables wherever possible.

.284 (4 HOLES) Minimum work and electrode cables sizes are as follows:

TABLE 1
MINIMUM COPPER WORK
CABLE SIZE, AWG
Current (60% Duty Cycle) Up To-100 Ft. Length (30 m)
400 Amps 2/0 (67 mm2)
500 Amps 3/0 (85 mm2)
600 Amps 3/0 (85 mm2)

POWER FEED 10 ROBOTIC

A-3 INSTALLATION A-3

When using an inverter type power source, Use the SHIELDING GAS CONNECTION
largest welding (electrode and work) cables that are
practical. At least 2/0 copper wire - even if the aver- WARNING
age output current would not normally require it.
When pulsing, the pulse current can reach very high CYLINDER may explode if damaged.
levels. Voltage drops can become excessive, leading • Keep cylinder upright and chained
to poor welding characteristics, if undersized welding to support.
cables are used. • Keep cylinder away from areas
Connect the one end of the electrode cable, to the where it may be damaged.
power source output terminal of the desired polarity. • Never lift welder with cylinder attached.
Connect the other end of the electrode cable to the • Never allow welding electrode to touch cylin-
wire drive feed plate using the stud, lock washer, and der.
nut provided on the wire drive feed plate. The elec- • Keep cylinder away from welding or
trode cable lug must be against the feed plate. Be other live electrical circuits.
sure the connection to the feed plate makes tight BUILDUP OF SHIELDING GAS may
metal-to-metal electrical contact. The electrode cable harm health or kill.
should be sized according to the specifications given • Shut off shielding gas supply when
in the work cable connections section. not in use.

NEGATIVE ELECTRODE POLARITY SEE AMERICAN NATIONAL STANDARD Z-49.1,

When negative electrode polarity is required, such as “SAFETY IN WELDING AND CUTTING” PUB-
in some Innershield applications, reverse the output LISHED BY THE AMERICAN WELDING SOCIETY.
connections at the power source (electrode cable to ------------------------------------------------------------------------
the negative (-) stud, and work cable to the positive
(+) stud). The customer must provide a cylinder of shielding
gas, a pressure regulator, a flow control valve, and a
When operating with electrode polarity negative the hose from the flow valve to the gas inlet fitting of the
switch 7 must be set to ON. wire drive unit.
Connect a supply hose from the gas cylinder flow
Set the Negative Polarity switch on Wire Feed Head valve outlet to the 5/8-18 female inert gas fitting on the
PC board as follows: These instructions apply to back panel of the wire drive or, if used, on the inlet of
the PowerWave 455/R and PowerWave 655/R. the Gas Guard regulator.
Consult the manual for the power source if necessary.
CONTROL CABLE
WARNING
CONTROL CABLE CONNECTIONS
1. Turn off power to the power source at the dis- The Power Wave / Power Feed Wire Feeders offer
connect switch. flexibility in the connection of system components.
This system uses the same type of control cable
2. Remove the front cover from the power source. between all of the system components. Connections
can be “daisy chained” from one system component to
3. The wire feed head board is on the right another. Components can be connected in any order,
side of the power source. Locate the 8- as long as the proper input and output receptacles are
position DIP switch and look for switch present.
8

7 of the DIP switch.

7

Connect the control cable from the Power Feed 10

6

4. Using a pencil or other small object,

5

Robotic Wire Drive to the output receptacle on the

slide the switch to the on position for
4

PowerWave.
3

negative electrode polarity. Conversely,

2

slide the switch to the off position for NOTE: The maximum cable length between the
1

positive electrode polarity. Power Feed 10 Robotic and the power source
O
N

is 100 feet (33 m).

5. Replace the cover and screws. The PC board will
“read” the switch at power up, automatically adjust-
ing all control parameters for the selected polarity.

POWER FEED 10 ROBOTIC

A-4 INSTALLATION A-4
CONTROL CABLE SPECIFICATIONS SELECTING THE PROPER GEAR RATIO

It is recommended that genuine Lincoln control cables See Specification Section A-1 for feed speed and wire
be used at all times. Lincoln cables are specifically size capabilities with high and low speed gear ratios.
designed for the communication and power needs of To determine whether you should be using the high or
the Power Wave / Power Feed system. The use of low speed ratio use the following guidelines:
non-standard cables, especially in lengths greater • If you need to operate at wire feed speeds above
than 25 feet, can lead to communication problems 800 IPM (20 m/m), you will need to install the high
(system shutdowns), poor motor acceleration (poor speed gear (large 30 tooth, 1.6 inch diameter gear).
arc starting) and low wire driving force (wire feeding
problems). • If you do not need to run at wire feed speeds in
excess of 800 IPM (20 m/m), you should use the low
Lincoln control cables are copper 14 conductor cable speed gear (small, 20 tooth, 1.1 inch diameter gear).
in a SO-type rubber jacket. Using the low speed ratio will provide the maximum
available wire driving force.
TABLE 2 (CONNECTOR WIRING)
The full range of wire feed speed listed in Section A-1
Pin Lead # Function may not be useable for all welding programs. Check
A 539 Motor "+" your welding software to make sure the desired WFS
B 541 Motor "-" falls within the welding software limits.
C 552 +40vdc for solenoid
D 553 Solenoid Input
E Reserved for future use
F Reserved for future use
G 515 Tach 2A differential signal
H 500 Tach 2B differential signal
J Reserved for future use
K 842 Tach 1A differential signal
L 843 Tach 1B differential signal
M Reserved for future use
N 67 Voltage sense lead
AVAILABLE CABLE ASSEMBLIES:

Use K1785 series Control Cables.

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.

POWER FEED 10 ROBOTIC

A-5 INSTALLATION A-5
CHANGING THE WIRE DRIVE RATIO CHANGING THE ANGLE OF THE FEED
PLATE
WARNING
WARNING
• Turn off power to the power source at the dis-
connect switch. Turn off power to the power source at the discon-
------------------------------------------------------------------------ nect switch.
------------------------------------------------------------------------
Changing the ratio requires a gear change and a PC
board switch change. The Power Feed Wire Feeders 1. Pull open the Pressure Door.
are shipped with both high speed and a low speed
gears. As shipped from the factory, the low speed 2. Remove the screw on the lower right face of the
(high torque) gear is installed on the feeder. For iden- feed plate with a 1/4" Allen wrench.
tification purposes, the low speed (high torque) gear
has 20 teeth and is 1.1 inches in diameter. The high 3. Remove the screw on the left face of the feed plate
speed gear has 30 teeth and is 1.6 inches in diameter. with a 1/4” allen wrench. Note the location of the
screw. As shipped from the factory, the low speed
1. Pull open the Pressure Door. (high torque) gear is installed on the feeder. For
identification purposes, the low speed (high torque)
2. Loosen, but do not remove, the screw on the lower gear has 20 teeth and is 1.1 inches in diameter.
right face of the feed plate with a 1/4" Allen wrench. The high speed gear has 30 teeth and is 1.6 inches
in diameter. When using the high speed (larger
3. Remove the screw on the left face of the feed plate gear), the lower mounting hole is used. When using
with a 1/4” allen wrench. the low speed (smaller gear), the upper mounting
hole is used. Set the feed head assembly aside.
4. Remove the small gear from the output shaft.
Lightly cover the output shaft with engine oil or 4. Remove the four Torx head screws from the
equivalent. Install gear onto output shaft and secure adapter extension using a T25 Torx driver. Rotate
with flat washer, lock washer, and Phillips head the adapter extension. Secure with a flat washer,
screw which were previously removed. Tighten 16 lock washer and Torx head screw which were previ-
to 21 inch lbs.. ously removed. Tighten 38 to 50 inch lbs. with a
T25 Torx driver.
5. If changing from high speed (larger gear) to low
speed (smaller gear), line the upper hole on the left 5. Replace the feed head assembly removed in step
face of the feed plate with the threads on the 3. Secure with socket head screw and flat washer
adapter extension. Line the lower hole with the which were previously removed. Tighten the socket
threads to install larger gear for high speed feeder. head screw 6 to 8 ft. lbs. with a 1/4” allen wrench.
If feed plate does not rotate to allow holes to line
up, further loosen the screw on right face of feed
plate. Tighten the screw on the left side of the Feed
plate to 6 to 8 ft. lbs. with a 1/4” allen wrench.

6. Tighten the screw on lower right face of feed plate

tighten 6 to 8 ft. lbs. with a 1/4” allen wrench.

Set the High/Low switch code on Wire Drive PC board

which is located on the Power Wave 455/R and
Power Wave 655/R. Consult the Instruction Manual
for proper power source settings.

POWER FEED 10 ROBOTIC

A-6 INSTALLATION A-6
WIRE FEED DRIVE ROLL KITS 6. Install each drive roll by pushing over shaft until it
butts up against locating shoulder on the drive roll
NOTE: The maximum rated solid and cored wire shaft. (Do Not exceed maximum wire size rating of
sizes and selected drive ratios are shown on the wire drive).
the SPECIFICATIONS in the front of this sec-
tion. 7. Install Outer Wire Guide by sliding over locating
pins and tightening in place.
The electrode sizes that can be fed with each roll and
guide tube are stenciled on each part. Check the kit 8. Engage upper drive rolls if they are in the “open”
for proper components. Kit specifications can be position and close Pressure Door.
found in the ACCESSORIES section.
TO SET DRIVE ROLL PRESSURE, see “Drive Roll
PROCEDURE TO INSTALL DRIVE ROLLS Pressure Setting” in OPERATION.
AND WIRE GUIDES
GENERAL GUN CONNECTION GUIDELINES

The instructions supplied with the gun and K1500

WARNING series gun adapter should be followed when installing
and configuring a gun. The following guidelines are
ELECTRIC SHOCK can kill. general procedures only that are not intended to cover
• Do not touch electrically live parts such all guns.
as output terminals or internal wiring.
• When feeding without Power Feed 10 “Cold
Feed” feature, electrode and drive mechanism
1. Check that the drive rolls and guide tubes are prop-
are “hot” to work and ground and could remain er for the electrode size and type being used.
energized several seconds after the gun trigger
is released. 2. Lay the cable out straight. Insert the connector on
• Turn OFF input power at welding power the welding conductor cable into the brass conduc-
source before installation or changing drive
roll and/or guide tubes.
tor block on the front of the wire drive head. Make
• Welding power source must be connected
sure it is all the way in and tighten the hand clamp.
to system ground per the National Electrical Keep this connection clean and bright.
Code or any applicable local codes.
• Only qualified personnel should
perform this installation. Note: For Fast-Mate and European connector style
guns, connect gun to gun connector making
sure all pins and gas tube line up with appropri-
Observe all additional Safety Guidelines detailed ate holes in connector. Tighten gun by turning
throughout this manual. the large nut on gun clockwise.
DRIVE ROLL KIT INSTALLATION (KP1505-[ ])*
(KP1507-[ ])* 3. For GMA Gun Cables with separate gas fittings,
connect the gas hose from the wire drive unit to the
gun cable barbed fitting.
WARNING
1. Turn OFF Welding Power Source.
*See ACCESSORIES SECTION Table C.1, page C-1.
2. Pull open Pressure Door to expose rolls and wire
guides.

3. Remove Outer Wire Guide by turning knurled

thumb screws counter-clock-wise to unscrew them
from Feed plate.

4. Remove drive rolls, if any are installed, by pulling

straight off shaft. Remove inner guide.

5. Insert inner Wire Guide, groove side out, over the

two locating pins in the Feed plate.

POWER FEED 10 ROBOTIC

A-7 INSTALLATION A-7
GUN RECEIVER BUSHINGS AND
ADAPTERS The K1546-1 and K1546-2 Adapter for use with
Lincoln Magnum conduit (K515 or 565) and E-Beam
The Power Feed wire feeders are equipped with facto- conduit. The K1546-1 is to be used for wire sizes
ry installed K1500-1 gun connection kits, as described (.023 - 1/16), K1546-2 is to be used for wire sizes
below. The Power Feed 10/R has been designed to (1/16 - .120)
make connecting a variety of guns easy and inexpen-
sive with the K1500 series of gun connection kits. For Magnum conduit:
Install the K1546-1 or K1546-2 adapter at the incom-
Non-Lincoln Guns ing end of the feed plate, secure with the set screw
Most competitive guns can be connected to the Power located at the back of the feed plate. If a brass fitting
Feed 10/R by using one of the K1500 series adapter is supplied with the conduit, remove it from the feeder
kits, See “Gun Adapters” in ACCESSORIES section. end of the conduit by unscrewing it. Insert the conduit
into the K1546-1 or K1546-2, secure the conduit by
K489-7 (Dual Schedule Fast-Mate Adapter) fastening it the adapter with the supplied knob screw.
This adapter installs directly into the wire drive Feed
plate, to provide for use of guns with Fast-Mate or For E-Beam Conduit:
European style gun connections. This K489-7 will Install the K1546-2 gun adapter at the incoming end of
handle both standard Fast-Mate and Dual Schedule the feed plate, secure with the set screw located at
Fast-Mate guns. the back of the feed plate. Insert the conduit into the
K1546-2, secure the conduit by fastening it the
K1500-1 (Lincoln Innershield gun standard connec- adapter with the supplied knob screw.
tion)
Use this kit to connect the following guns: Guns hav- REMOTE SENSE LEAD SPECIFICATIONS
ing a Lincoln standard innershield gun connector,
Magnum 200/300/400 with K466-1 connector kit, and The Power Feed10/R should always be operated with
Magnum 550 guns with the K613-1 gun connection the voltage sense lead (67) attached to the feed plate.
kit.
INSTALLATION OF FIELD INSTALLED
K1500-2 (Tweco #2-#4 type connection) OPTIONS
The K1500-2 gun adapter comes factory installed on
the Power Feed 10/R wire feeder. Use this adapter for
Water Flow Sensor
guns that have a Tweco #2-#4 connector. Such guns
Water cooled guns can be damaged very quickly if
include Magnum 200/300/400 guns with K466-2 con-
they are used even momentarily without water flowing.
nector kit, and completely factory assembled Magnum
Recommend practice is to install a water flow sensor
guns that are factory equipped with the K466-2 con-
on the water return line of the torch. When fully inte-
nector (such as the K471-21, -22, and -23 dedicated
grated into the welding system, the sensor will prevent
Magnum 400 guns and the K497-20 and -21 Magnum
welding if no water flow is present.
200 guns).
Gas Guard Regulator
K1500-3 (Tweco #5 connection)
The Gas Guard regulator is available as an optional
For Magnum 550 gun with K613-2 Connection Kit, accessory (K659-1) for Power Feed Robotic wire drive
and any other gun having a Tweco #5 connector . unit. Install the 5/8-18 male outlet of the regulator to
the proper 5/8-18 female gas inlet on the back panel
K1500-4 (Miller connection) of the wire drive. Secure fitting with flow adjuster key
For any gun having a newer style Miller connector. at top.
Install gun adapters per the instructions shipped with it.

K1500-5 (Oxo connection)

For any gun having an Oxo style threaded connector.
Install gun adapter per the instructions shipped with it.

CONDUIT ADAPTERS

POWER FEED 10 ROBOTIC

A-8 INSTALLATION A-8
Feeding Electrode and Brake Adjustment
3. If the only result is drive roll slippage, disengage the
1. Turn the Reel or spool until the free end of the elec- gun, pull the gun cable forward about 6" (150 mm).
trode is accessible. If using a drum or large reel, There should be a slight waviness in the exposed
supply the electrode to the PF-10/R with an elec- wire. If there is no waviness, the pressure is too
trode conduit. Minimize the number of bends in the low. Increase the pressure setting 3 turns, recon-
conduit and the distance the electrode must travel. nect the gun, tighten locking clamp and repeat the
above steps.
2. While tightly holding the electrode, cut off the bent
end and straighten the first 6" (150 mm). Cut off the
first 1" (25 mm). (If the electrode is not properly
straightened, it may not feed or may jam causing a
"bird nest".)

3. Insert the free end through the incoming guide tube.

4. Activate the Cold Inch mode until the the drive rolls
grab the electrode.

WARNING
When feeding with the trigger, unless “Cold Feed”
trigger mode is selected the electrode and drive
mechanism are always “Hot” to work and ground
and could remain “Hot” several seconds after the
Gun trigger is released.

5. Feed the electrode through the gun.

6. Adjust the brake tension with the thumbscrew on

the spindle hub, until the reel turns freely but with
little or no overrun when wire feeding is stopped.
Do not over tighten.

Drive Roll Pressure Setting

The Power Feed 10/R drive roll pressures are factory

pre-set to about position “2” as shown on the pressure
indicator on the front of the feed plate door. This is an
approximate setting.

The optimum drive roll pressure varies with type of

wire, surface condition, lubrication, and hardness.
Too much pressure could cause “bird nesting,” but too
little pressure could cause wire feed slippage with
load and / or acceleration. The optimum drive roll set-
ting can be determined as follows:

1. Press end of gun against a solid object that is elec-

trically isolated from the welder output and press
the gun trigger for several seconds.

2. If the wire "bird nests", jams, or breaks at the drive

roll, the drive roll pressure is too great. Back the
pressure setting out 2 turns, run new wire through
gun, and repeat above steps.

POWER FEED 10 ROBOTIC

B-1 OPERATION B-1

SAFETY INSTRUCTIONS GENERAL DESCRIPTION

Read and understand this entire section of operat-
The Power Feed 10 Robotic is a high performance,
ing instructions before operating the machine.
digitally controlled, modular wire feeder. Properly
equipped, it can support the GMAW, GMAW-P and
WARNING FCAW processes. The Power Feed wire feeders are
ELECTRIC SHOCK can kill. designed to be a part of a modular, multi-process
welding system. The Power Feed 10 Robotic is a 4
• Unless using cold feed feature, driven roll feeder that operates on 40VDC input
when feeding with gun trigger, the power.
electrode and drive mechanism are
always electrically energized and The Power Feed Robotic wire feeders are designed to
could remain energized several sec- be used with Robotic PowerWaves. Close integration
onds after the welding ceases. of the feeder, power source and customer’s equip-
• Do not touch electrically live parts or electrodes ment creates the foundation for a system with superior
with your skin or wet clothing. welding performance.

• Insulate yourself from the work and ground. The Power Feed 10 Robotic is intended for automatic
• Always wear dry insulating gloves. applications. It specifically designed to mount to a
robot arm or to use in hard automation applications.

Operation for the Power Feed 10 Robotic is with a

FUMES AND GASES can be
Power Feed compatible robotic power source.
dangerous.
• Keep your head out of fumes. RECOMMENDED PROCESSES
• Use ventilation or exhaust to
The Power Feed Wire Feeders can be set up in a
remove fumes from breathing zone.
number of configurations. They are designed to be
used for GMAW, GMAW-P and FCAW for a variety of
materials, including mild steel, stainless steel, and
WELDING SPARKS can cause cored wires.
fire or explosion.
• Keep flammable material away. PROCESS LIMITATIONS
• Do not weld on containers that have The feeders are capable of handling only some sub-
held combustibles. merged arc applications.

RECOMMENDED EQUIPMENT/INTERFACE
ARC RAYS can burn.
The Power Feed Robotic Feeders must be used with
• Wear eye, ear, and body protection. PowerWave 455/R, PowerWave 655/R or other
Observe additional Safety Guidelines Robotic PowerWave source. These are the only
detailed in the beginning of this manual. power source to supply the correct operating voltage
(40 volts DC) and communication method (Arc-Link
DUTY CYCLE digital communications) required by the Power Feed
10 Robotic.
The Power Feed wire feeders are capable of welding
at a 100% duty cycle (continuous welding). The
power source will be the limiting factor in determining
system duty cycle capability.

POWER FEED 10 ROBOTIC

C-1 ACCESSORIES C-1
OPTIONAL EQUIPMENT PLATFORM COMMONALITIES
• Power Feed 10 series Feed head.
• CGA gas connections.
• KP1505 Drive Roll and Wire Guide Kits • Works with all PowerWave ArcLink systems. “It is
• KP1507 Drive Roll and Wire Guide Kits not compatible with the PowerWave 350, 450 or 500
or Linc-net PowerWave 455’s”
The KP1507 series of drive roll kits contain a number
of components, in addition to the drive rolls, to opti-
OPERATIONAL FEATURES AND CONTROLS
mize the wire feeder for aluminum feeding. These
• All procedure settings for the Power Feed 10 Robotic
components are specifically designed to protect the
wire feeder is through software control. A DIP switch
aluminum wire from abrasion and deformation, there-
is used to indicate hardware settings.
by avoiding many common aluminum feeding prob-
lems.

• K1546 Conduit

TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS

Wire Size

Solid Steel Electrode KP No. Series

0.023” - 0.025” (0.6 mm) KP1505 - 030S
0.030” (0.8 mm) KP1505 - 030S
0.035” (0.9 mm) KP1505 - 035S
0.040” (1.0 mm) KP1505 - 045S
0.045” (1.2 mm) KP1505 - 045S
0.052” (1.4 mm) KP1505 - 052S
1/16” (1.6 mm) KP1505 - 1/16S
5/64” (2.0 mm) KP1505-5/64
3/32” (2.4 mm) KP1505-3/32
Cored Electrode
0.030 (0.8 mm) KP1505 - 035C
0.035” (0.9 mm) KP1505 - 035C
0.040” (1.0 mm) KP1505 - 045C
0.045” (1.2 mm) KP1505 - 045C
0.052” (1.4 mm) KP1505 - 052C
1/16” (1.6 mm) KP1505 - 1/16C
0.068” (1.7 mm) KP1505 - 068
5/64” (2.0 mm) KP1505 - 5/64
3/32” (2.4 mm) KP1505 - 3/32
7/64” Lincore Hard Facing (2.8mm) KP1505 - 7/64H
7/64” (2.8mm) KP1505 - 7/64
.120” (3.0mm) KP1505 - 120
Aluminum Electrode
0.035” (0.9 mm) KP1507 - 035A
0.040” (1.0 mm) KP1507 - 040A
3/64” (1.2 mm) KP1507 - 3/64A
1/16” (1.6 mm) KP1507 - 1/16A
3/32” (2.2 mm) KP1507 - 3/32A

POWER FEED 10 ROBOTIC

D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS AVOIDING WIRE FEEDING PROBLEMS

Wire feeding problems can be avoided by observing

the following gun handling and feeder set up proce-
WARNING dures:
a) Do not bend the conduit more than 45°.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such b) Keep the minimum amount of conduit necessary
as output terminals or internal wiring. for the wire reel to connect to the wire feeder.
• When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
c) Do not allow dolly wheels or trucks to run over
seconds after the gun trigger is released. cables.
• Turn OFF input power at welding power
source before installation or changing d) Keep cable clean by following maintenance
drive roll and/or guide tubes. instructions.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
e) Use only clean, rust-free electrode. The Lincoln
codes. electrodes have proper surface lubrication.
• Only qualified personnel should
perform maintenance work. f) Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or
deformed.
Observe all additional Safety Guidelines detailed
throughout this manual. g) Do not use excessive wire spindle brake settings.

h) Use proper drive rolls, wire guides and drive roll

ROUTINE MAINTENANCE
pressure settings.
Drive Rolls and Guide Tubes
PERIODIC MAINTENANCE
After feeding every coil of wire, inspect the feed plate
and drive rolls. Clean them as necessary. Wire Drive Motor and Gearbox

All drive rolls have two identical grooves. The rolls Every year inspect the gearbox and coat the gear
may be flipped over to use the other groove. teeth with a moly-disulfide filled grease. Do not use
graphite grease.
See “Procedure to Install Drive Rolls and Wire
Guides” in the INSTALLATION section for roll chang- Every six months check the motor brushes. Replace
ing instructions. them if they are less than 1/4” long.

POWER FEED 10 ROBOTIC

E-1 TROUBLESHOOTING E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED 10 ROBOTIC

E-2 TROUBLESHOOTING E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
Rough wire feeding or wire not 1. Gun cable kinked and / or twist-
feeding but drive rolls are turning. ed.

2. Wire jammed in gun and cable.

Check for mechanical restric-
tions in feeding path.

3. Check for current position of

drive rolls relative to split wire
guide groove.

4. Drive rolls may not be seated

properly.

5. Gun cable dirty, clean if neces-

sary.

6. Worn drive roll.

7. Electrode rusty and/or

dirty.Cable frayed, or poor sol-
der joint at work or electrode
lug. If all recommended possible areas
of misadjustment have been
8. Worn nozzle or cable liner. checked and the problem persists,
Replace if necessary. Contact your local Lincoln
Authorized Field Service Facility.
9. Partially flashed or melted con-
tact tip. Replace if necessary.

10. Incorrect drive roll pressure.

Readjust if necessary.

11. Improper liner, tip or inner /

outer guides. Replace if neces-
sary.

12. Incorrect wire drive or gear

ratio selection on the control
P.C. board.

Variable or “hunting” arc. 1. Wrong size, worn and/or melted

contact tip.

2. Worn work cable or poor work

connection.

3. Loose electrode or work cable

connections.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER FEED 10 ROBOTIC
E-3 TROUBLESHOOTING E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
Variable or “hunting arc. 1. Wrong size, worn and/or melted
contact tip.

2. Worn work cable or poor work

connection.

3. Loose electrode or work cable

connections.

4. Wrong polarity. - Make sure

electrode polarity is correct for
process being used.
If all recommended possible areas of
5. Gas nozzle extended beyond misadjustment have been checked
gun tip or wire stickout too long and the problem persists, Contact
while welding. your local Lincoln Authorized
Field Service Facility.
6. Poor gas shielding on processes
requiring gas. - Check gas flow
and mixture.

Poor arc striking with sticking or 1. Improper procedures or tech-

“blast-offs”, weld porosity, narrow niques. - See “Gas Metal Arc
and ropy looking bead, or electrode Welding Guide” (GS-100).
stubbing into plate while welding.
2. Improper gas shielding - Clean
gas nozzle. Make certain that
gas diffuser is not empty or
turned off. Make certain gas flow
rate is proper.

3. Remove gun liner and check

rubber seal for any sign of dete-
rioration or damage. Be sure set
screw in connector block is in
place and tightened against the
liner bushing.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER FEED 10 ROBOTIC
E-4 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
Tip seizes in diffuser. 1. Tip overheating due to pro-
longed or excessive high current
and/or duty cycle welding.

Note: A light application of high

temperature antiseize lubri-
cant (such as Lincoln E2067
Graphite Grease) may be
applied to tip of threads.

Motor does not turn when trigger is 1. The wire drive motor may be
pulled. overloaded.

2. Fault occurred

The drive motor does not turn 1. Fault occurred

although arc voltage is present and If all recommended possible areas
the gas solenoid is on. of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
No control of wire feed speed 1. Damaged leads to the motor Authorized Field Service Facility.
motor. Gas solenoid operates tachometer.
properly and arc voltage is present.
Wire feed speed can be set through 2. Damaged tachometer.
ArcLink but WFS is erratic.

Wire feed motor turns and gas sole- 1. Power source is unable to pro-
noid operates, but no arc voltage is vide arc voltage because of ther-
present. mal shutdown or other failure.

Speed does not change when weld 1. Run-in and weld speeds are set
current flows. to the same value.

2. Fault occurred

Erratic arc length, especially with a 1. The work sense lead (#21) or the
pulse or STT program. Welding electrode sense lead (#67) may
may or may not vary from normal have intermittent or poor connec-
procedure. Wire feeds properly. tions.

2. Improper power source selection

on the control P.C. board.

3. Welding Program Error.

Wire feed speed is consistent and 1. DIP switch is incorrectly set for
adjustable, but operates at the the wrong wire drive or gear
wrong speed. ratio.

2. Fault occurred

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER FEED 10 ROBOTIC
 F-1
DIAGRAMS

POWER FEED 10 ROBOTIC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
F-2 DIAGRAMS F-2

POWER FEED 10 / R DIMENSION PRINT

POWER FEED 10 ROBOTIC

 NOTES

POWER FEED 10 ROBOTIC

 ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION ● Aislese del trabajo y de la tierra.

French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.

German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
 • World's Leader in Welding and Cutting Products •
• 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