Lincoln Electric PF22 Manual de usuario

IM3046

06/2016

REV01

PF22

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

www.lincolnelectric.eu

English English

Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the welding machine:

K14110-1

PF 22

conforms to the following directives:

2014/35/EU, 2014/30/EU

and has been designed in compliance with the

following standards:

EN 60974-5:2013; EN 60974-10:2014

20.04.2016

Piotr Spytek

Operations Director

Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

07/11

English English

12/05

THANKS! For having chosen the QUALITY of the Lincoln Electric products.

Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

For future reference record in the table below your equipment identification information. Model Name, Code &

Serial Number can be found on the machine rating plate.

Model Name:

………………...…………………………….…………………………………………………………………………………………..

Code & Serial number:

………………….………………………………………………..

…………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………...

……………………….…………………………………………..

ENGLISH INDEX

Technical Specifications..................................................................................................................................................1

Electromagnetic Compatibility (EMC)..............................................................................................................................2

Safety ..............................................................................................................................................................................3

Introduction......................................................................................................................................................................4

Installation and Operator Instructions..............................................................................................................................4

Location and Environment ...........................................................................................................................................4

Duty cycle and Overheating .....................................................................................................................................4

Input Supply Connection..............................................................................................................................................5

Controls and Operational Features..............................................................................................................................5

User Panel...................................................................................................................................................................6

Welding Process Change.............................................................................................................................................7

The assignment of the weld program to the user memory........................................................................................8

Welding Parameters.................................................................................................................................................8

Crater .......................................................................................................................................................................8

Wave Controls..........................................................................................................................................................9

Setting and Configuration Menu...................................................................................................................................9

Welding SMAW (MMA) Process.............................................................................................................................16

Welding GTAW / GTAW-PULSE Process ..............................................................................................................17

Welding GMAW, FCAW-GS and FCAW-SS Process in non-synergic mode..........................................................18

Welding GMAW and FCAW-GS Process in synergic mode CV .............................................................................19

Welding GMAW-P Process in synergic mode ........................................................................................................20

Aluminum Welding GMAW- PP Process in synergic mode....................................................................................21

Welding STT® Process ...........................................................................................................................................22

Wire Spool Loading....................................................................................................................................................23

Loading the Electrode Wire........................................................................................................................................25

Adjustments of Brake Torque of Sleeve.....................................................................................................................25

Adjusting Pressure Roll Force....................................................................................................................................26

Inserting Electrode Wire into Welding Gun ................................................................................................................26

Changing Driving Rolls...............................................................................................................................................26

Maintenance ..............................................................................................................................................................27

WEEE............................................................................................................................................................................28

Spare Parts....................................................................................................................................................................28

Electrical Schematic ......................................................................................................................................................28

Suggested Accessories.................................................................................................................................................28

Connection Diagram......................................................................................................................................................30

English English

Technical Specifications

NAME

INDEX

PF 22

K14110-1

INPUT

Input Voltage U1

Input Amperes I1

EMC Class

40Vdc

RATED OUTPUT

Duty Cycle 40°C

(based on a 10 min. period)

Output Current

100%

385A

60%

500A

OUTPUT RANGE

Welding Current Range

Peak Open Circuit Voltage

5 ÷500A

113Vdc or Vac peak

DIMENSION

Weight

Height

Width

Length

14,8 kg

380 mm

220 mm

590 mm

WIRE FEED SPEED RANGE / WIRE DIAMETER

WFS Range

Drive Rolls

Drive roll

diameter

Solid Wires

Aluminum Wires

Cored Wires

1 ÷22 m/min

Ø37

0.8 ÷2.4 mm

1.0 ÷ 2.4 mm

0.9 ÷2.4 mm

Protection Rating

Maximum Gas Pressure

Operating Temperature

Storage Temperature

IP23

0,5MPa (5 bar)

from -10°C to +40°C

from -25°C to 55°C

English English

Electromagnetic Compatibility (EMC) 01/11

This machine has been designed in accordance with all relevant directives and standards. However, it may still generate

electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or

other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand

this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.

This machine has been designed to operate in an industrial area. To operate in a domestic area it is

necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The

operator must install and operate this equipment as described in this manual. If any electromagnetic

disturbances are detected the operator must put in place corrective actions to eliminate these disturbances

with, if necessary, assistance from Lincoln Electric.

Before installing the machine, the operator must check the work area for any devices that may malfunction because of

electromagnetic disturbances. Consider the following.

Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the

machine.

Radio and/or television transmitters and receivers. Computers or computer controlled equipment.

Safety and control equipment for industrial processes. Equipment for calibration and measurement.

Personal medical devices like pacemakers and hearing aids.

Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure

that all equipment in the area is compatible. This may require additional protection measures.

The dimensions of the work area to consider will depend on the construction of the area and other activities that are

taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.

Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take

additional precautions such as filtering the input supply.

The output cables should be kept as short as possible and should be positioned together. If possible connect the

work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting

the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.

Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special

applications.

WARNING

EMC classification of this product is class A in accordance with electromagnetic compatibility standard EN 60974-10 and

therefore the product is designed to be used in an industrial environment only.

WARNING

The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public

low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,

due to conducted as well as radio-frequency disturbances.

English English

Safety 01/11

WARNING

This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair

procedures are performed only by qualified person. Read and understand this manual before operating this equipment.

Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this

equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible

for damages caused by improper installation, improper care or abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,

loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or

death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this

equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause

serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the

electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from the

electrode, work clamp and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the

fuse box before working on this equipment. Ground this equipment in accordance with local electrical

regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp

cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder

directly on the welding table or any other surface in contact with the work clamp to avoid the risk of

accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any

conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers

and welders having a pacemaker shall consult their physician before operating this equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and EN

12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal Protective

Equipment (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169

Standard.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to

health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough

ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from

sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable

flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel with

suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to the

arc.

English English

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area

and have a fire extinguisher readily available. Welding sparks and hot materials from the welding

process can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks,

drums, containers, or material until the proper steps have been taken to insure that no flammable or

toxic vapors will be present. Never operate this equipment when flammable gases, vapors or liquid

combustibles are present.

WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and

materials in work area can cause serious burns. Use gloves and pliers when touching or moving

materials in the work area.

CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct

shielding gas for the process used and properly operating regulators designed for the gas and pressure

used. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or

transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder,

work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located

away from areas where they may be subjected to physical damage or the welding process including

sparks and heat sources.

MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which can

cause serious injury. Keep your hands, body and clothing away from those parts during machine

starting, operating and servicing.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an

environment with increased hazard of electric shock.

The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time

the operator’s manual.

Introduction

PF 22 is digital wire feeder which has been designed to

work with all Lincoln Electric power sources using

ArcLink®protocol to communication.

Digital wire feeder allows the welding:

GMAW (MIG/MAG)

FCAW-GS / FCAW-SS

SMAW (MMA)

GTAW (arc ignition using lift TIG)

Recommended equipment, which can be bought by

user, was mentioned in the chapter "Suggested

Accessories".

Installation and Operator Instructions

Read this entire section before installation or operation

of the machine.

Location and Environment

This machine will operate in harsh environments.

However, it is important that simple preventative

measures are followed to assure long life and reliable

operation.

Do not place or operate this machine on a surface

with an incline greater than 15° from horizontal.

Do not use this machine for pipe thawing.

This machine must be located where there is free

circulation of clean air without restrictions for air

movement to and from the air vents. Do not cover

the machine with paper, cloth or rags when

switched on.

Dirt and dust that can be drawn into the machine

should be kept to a minimum.

This machine has a protection rating of IP23. Keep

it dry when possible and do not place it on wet

ground or in puddles.

Locate the machine away from radio controlled

machinery. Normal operation may adversely affect

the operation of nearby radio controlled machinery,

which may result in injury or equipment damage.

Read the section on electromagnetic compatibility in

this manual.

Do not operate in areas with an ambient

temperature greater than 40°C.

Duty cycle and Overheating

The duty cycle of a welding machine is the percentage of

time in a 10 minute cycle at which the welder can

operate the machine at rated welding current.

Example: 60% duty cycle

Welding for 6 minutes.

Break for 4 minutes.

English English

Excessive extension of the duty cycle will cause the

thermal protection circuit to activate.

Minutes

or decrease

Duty Cycle

Input Supply Connection

Check the input voltage, phase, and frequency of the

power source that will be connected to this wire feeder.

The allowable input voltage source is indicated on the

rating plate of the wire feeder. Verify the connection of

grounding wires from the power source to the input

source.

Controls and Operational Features

Figure 1

1. EURO Socket: For connecting a welding

gun (for GMAW / FCAW-SS process).

2. Quick Connect Coupling: Coolant outlet

(supplies cool coolant to the gun).

3. Quick Connect Coupling: Coolant inlet

(takes warm coolant from the gun).

WARNING

Maximum coolant pressure is 5 bar.

4. Remote Control Connector Plug: To install

Remote Control Kit. This connector allows

connection Remote Control. See

"Accessories" chapter.

5. Output Socket for the Welding Circuit: For

connecting an electrode holder with lead.

6. User Panel: see the section dedicated.

7. Gas Connector: Connection for gas line.

Figure 2

WARNING

The welding machine supports all suitable shielding

gases at a maximum pressure of 5,0 bar.

8. Control Receptacle: 5 pins receptacle for

wire feeder connection. To communication

wire feeder with power source is used

ArcLink®protocol.

9. Current Socket: Input power connection.

10.Quick Connect Coupling: Coolant outlet

(takes warm coolant from welding machines

to cooler.)

11.Quick Connect Coupling: Coolant inlet

(supplies cool coolant from cooler to the

welding machines).

WARNING

Maximum coolant pressure is 5 bar.

To ensure failure-free work and right flow of coolant, use

only coolant that is recommended by the manufacturer

of welding gun or cooler.

12.Gas Flow Regulator: Regulate flow between 0-25

LPM (liter/min).

13.Chain Pin: Fasten source/wire feeder cable.

English English

Figure 3

14.Lighting Switch

15.Cold Inch / Gas Purge Switch: This switch enables

wire feeding or gas flow without turning on output

voltage.

16.Gun Mode Switch: changes the function of the gun’s

trigger.

2 Step trigger operation turns welding on and off

in direct response to the trigger. Welding process

is performed when the gun’s trigger is pulled.

4-Step mode allows to continue welding, when

the gun’s trigger is released. To stop welding, the

gun’s trigger is pulled again. 4-step mode

facilitates to making long welds.

The functionality of 2T/4T mode is shown in the Figure 4.

Trigger pressed

Trigger released

Welding current

Burnback Time (fixed)

Wire Feed

Gas

Figure 4

Note: 4-Step does not work during Spot Welding.

17.Wire Spool Support: Maximum 15kg spools. Accepts

plastic, steel and fiber spools onto 51mm spindle.

Also accepts Readi-Reel®type spools onto included

spindle adapter.

18.Wire Drive: 4-Roll wire drive.

WARNING

The wire drive door has to be completely closed during

welding.

WARNING

Not use handle to move the machine during work. See

"Accessories" chapter.

User Panel

Figure 5

19.Display:

Left display: Shows wire feed speed or welding

current. During welding shows the actual

welding current value.

Right display: Depending on the source

welding and the welding program shows the

welding voltage in volts units or Trim. During

welding shows the actual welding voltage

value.

20.Status LED: A two color light that indicates system

errors. Normal operation is steady green light. Error

conditions are indicated, per Table 1.

Note: The status light will flash green, and sometimes

red and green, for up to one minute when the machine is

first turned on. When the power source is powered it can

take as long as 60 seconds for the machine to be ready

to weld. This is a normal situation as the machine goes

through initialization.

English English

Table 1

LED Light

Condition

Meaning

Only machines which using ArcLink®

protocol for communication

Steady Green

System OK. Power source is

operational, and is communicating

normally with all healthy peripheral

equipment.

Blinking Green

Occurs during power up or a system

reset, and indicates the power source

is mapping (identifying)

each component in the system.

Normal for first 1-10 seconds after

power is turned on, or if the system

configuration is changed during

operation.

Alternating Green

and Red

If the status lights are flashing any

combination of red and green, errors

are present in the power source.

Individual code digits are flashed in

red with a long pause between digits.

If more than one code is present, the

codes will be separated by green

light. Read the error code before the

machine is turned off.

If occurs, to clear the error try to turn

Off the machine, wait for a few

seconds, then turn ON again. If the

error remains, a maintenance is

required. Please contact the nearest

authorized technical service center or

Lincoln Electric and report the error

code read.

Steady Red

Indicate no communication between

the power source and device which

has been connected to this power

source.

21.Thermal Overload Indicator: It indicates that the

machine is overloaded or that the cooling is not

sufficient.

22.LED Indicator: Informs that the value on the right

display is in volts unit.

23.LED Indicator: Informs that the value on the right

display is Trim. Trim is adjustable from 0.50 to 1.50.

1.00 is the nominal setting.

24.Right Control: Adjusts values on the right display.

25.LED Indicator: Informs that the Crater Procedure is

activated.

26.LED Indicator: Informs that the Wave Control

Procedure is activated.

27.Right Button: Enables scrolling, changing and setting

welding parameters:

Crater

Wave Controls

28.LED Indicator: Indicates that the Settings and

Configuration Menu is activated.

29.Left Button: Enables:

Checking the program number assigned to

active memory. To check the program number,

press the Left Button ones.

Changing the Welding Process.

30.Welding Programs Indicators (unchangeable): LED

indicates the unchangeable program for non-

synergic process is active. See the table 2.

31.Welding Programs Indicators (changeable): In the

user memory can be stored four user programs. LED

indicates that the changeable program is active. See

the table 3.

32.Left Control: Adjusts values on the left display.

33.LED Indicator: Informs that the value on the left

display is in ampere units.

34.LED Indicator: Informs that the wire feed speed is on

the left display.

Welding Process Change

It is possible to quick recall of one of the eight welding

programs. Four programs are fixed and cannot be

changed - Table 2. Four programs can be changed and

assigned to one of four user memory - Table 3.

Table 2: Unchangeable Welding Programs [30]

Symbol

Process

Program Number

GMAW

(non-synergic)

FCAW-GS

7(155)

SMAW

GTAW

Note: The list of available programs depends on the

power source. If the power source does not operate the

one of four unchangeable programs, the LED [30]

indicating this program does not light up.

Table 1. Changeable Welding Programs [31]

Symbol

Process

Program Number

Synergic GMAW

Ø1.0, Steel, MIX

Synergic GMAW

Ø1.2, Steel, MIX

Synergic GMAW

Ø1.2, AlMg, Ar

Synergic GMAW

Ø1.0, Stainless,

MIX

Note: The list of available programs depends on the

power source. If the power source does not operate the

program form table 3, the first available welding program

is loaded in lieu of an unsupported welding program.

To change the welding process:

Press the Left Button [29]. "Pr" is shown on the left

display and the program number on the Right [19].

Again, press the Left Button [30] the weld program

indicator [30 or 31] will jump to the next in the

sequence shown in Figure 6.

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