Lincoln Electric PWF-2 Bedienungsanleitung

IM7101-1

July, 2018

Rev. D

PWFTM-2/PWFTM-4 Wire Feeder

For Use With Wire Feeder Part Number: PWF-2 K60024-3

PWF-2 Plus K60006-3

PWF-4 K60024-9

PWF-4 Plus K60006-6

The Shanghai Lincoln Electric Co., Ltd

No195, Lane 5008, Hu Tai Road Shanghai 201907

Tel: (021)6673 4530 Fax :( 021)5602 0345

Safety Depends on You

Lincoln arc welding and cutting equipment is

designed and built with safety in mind. However,

your overall safety can be increased by proper

installation and thoughtful 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

i SAFETY i

WARNING

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. Please see www.lincolnelectric.com.cn for details.

BE SURE THATALL INSTALLATION, OPERATION, MAINTENANCEAND REPAIR PROCEDURES

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

ELECTRIC AND MAGNETIC FIELDS

May be dangerous

1.a. Electric current flowing through any conductor causes localized Electric and Magnetic

Fields (EMF). Welding current creates EMF fields around welding cables and welding

machines.

1.b EMF fields may interfere with some pacemakers, and welders having a pacemaker

should consult with their physician before welding.

1.c. Exposure to EMF fields in welding may have other health effects which are now

not known.

1.d. All welders should use the following procedures in order to minimize exposure to

EMF fields from the welding circuit:

1.d.1. Route the electrode and work cables together. Secure them with tape when

possible.

1.d.2. Never coil the electrode lead around your body.

1.d.3. Do not place your body between the electrode and work cables. If the electrode

cable is on your right side, the work cable should also be on your right side.

1.d.4. Connect the work cable to the workpiece as close as possible to the area being

welded.

1.d.5. Do not work next to welding power source.

ii SAFETY ii

2.a The welding gun and work (or ground) circuits are electrically “hot” when the welding operator

presses the trigger. Do not touch these “hot” parts with your bare skin or wet clothing. Wear

dry, hole-free gloves to insulate hands.

2.b Insulate yourself from work and ground using dry insulation. Make certain the insulation is

large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding 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, kneeling or lying, if there is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following equipment:

Semiautomatic DC Constant Voltage Wire Welder

DC Manual (Stick) Welder

AC Welder with Reduced Voltage Control

2.c In semiautomatic or automatic wire welding, the electrode, electrode wire, electrode reel,

welding head, nozzle, or semiautomatic welding gun are also electrically “hot”.

2.d Always be sure the work cable makes a good electrical connection with the metal being

welded. The connection should be as close as possible to the area being welded.

2.e Ground the work or metal to be welded to a good electrical (earth) ground.

2.f Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe

operating condition. Replace damaged insulation.

2.g Never dip the electrode in water for cooling.

2.h Never simultaneously touch electrically “hot” parts of electrode holders connected to two

welders because voltage between the two can be total of the open circuit voltage of both

welders.

2.i When working above floor level, use a safety belt to protect yourself from a fall should you

get a shock.

ELECTRIC SHOCK can kill.

iii SAFETY iii

___

ARC RAYS can burn.

3.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and

the rays of the arc welding or observing open arc welding.

3.b. Use suitable clothing made from durable flame-resistant material to protect your skin and

that of your helpers from the arc rays.

3.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them

not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

4.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes

and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust

at the arc to keep fumes and gases away from the breathing zone.

When welding with electrodes which require special ventilation such as stainless or hard

facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below

Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or

in some circumstances, outdoors, a respirator may be required. Additional precautions are also

required when welding on galvanized steel.

4.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,

cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form

phosgene, a highly toxic gas, and other irritating products.

4.c. 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.

4.d. Read and understand the manufacturer’s instruction 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.

iv SAFETY iv

WELDING SPARKS can cause fire or explosion.

5.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent

the welding sparks from starting a fire. Remember that welding sparks and hot materials from

welding can easily go through small cracks and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

5.b. Where compressed gases are to be used at the job site, special precautions should be

used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard

Z49.1) and the operating information for the Equipment being used. See

www.lincolnelectric.com.cn for details.

5.c. When not welding, make certain no part of the electrode circuit is touching the work or

ground. Accidental contact can cause overheating and create a fire hazard.

5.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken

to insure that such procedures will not cause flammable or toxic vapors from substances inside.

They can cause an explosion even though they have been “cleaned”. For information, purchase

“Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and

Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society.

5.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

5.f. Sparks and spatter are thrown from the welding arc. Wear oil 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 welding area.

5.g. Connect the work cable to the work as close to the welding area as practical. Work cables

connected to the building framework or other locations away from the welding area increase the

possibility of the welding current passing through lifting chains, crane cables or other alternate

circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

v SAFETY v

CYLINDER may explode if damaged.

6.a. 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. All hoses,

fittings, etc. should be suitable for the application and maintained in good condition.

6.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed

support.

6.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat,

sparks, or flame.

6.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a

cylinder.

6.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder

valve.

6.f. If available, valve protection caps should always be in place if available and hand tight

except when the cylinder is in use or connected for use.

6.g. Read and follow the instructions on compressed gas cylinders and associated equipment.

FOR ELECTRICALLY Powered Equipment.

7.a. Turn off input power using the disconnect switch at the fuse box before working on the

equipment.

7.b. Install equipment in accordance with the local codes and the manufacturer’s

recommendations.

7.c. Ground the equipment in accordance with the local codes and the manufacturer’s

recommendations.

Thank 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 the nameplate of your machine.

Model Name & Number ______________________

Code & Serial Number ______________________

Date of Purchase ______________________

Purchased From ______________________

Whenever you request replacement parts for or information on this equipment

always supply the information you have recorded above.

Read this Operator’s 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

■ Installation Section A

Technical Specification A-1

Safety Precautions A-2

Interconnection Cable A-2

Welding cable A-2

Gas Hose A-2

Control Cable A-2

Welding Gun A-3

Connection Diagram: PWFTM Feeder to Lincoln POWERPLUS™ A-3

■ Operation Section B

Installing Feed Rolls B-1

Loading the Wire Spool B-1

■ Maintenance Section C

Maintenance C-1

■ Schematic Diagram Section D

Schematic Diagram D-1

■Parts List Section E

PWFTM-2/4 Remote Control E-2

PWFTM-2/4 General Parts E-3

PWFTM-2 Replacement Parts Diagram E-4

PWFTM-2 Replacement Parts List E-5

PWFTM-4 Replacement Parts Diagram E-6

PWFTM-4 Replacement Parts List E-7

PWFTM-2 Plus/ 4 Plus Special Spare Parts List (Diagram) E-8

Consumable Parts List Section F

PWFTM-2/4 Consumable Parts F-1

A-1 INSTALLATION A-1

TECHNICAL SPECIFICATIONS –PWF™ Wire Feeder

MODEL

PWFTM-2, PWFTM-4, PWFTM-2 Plus, PWFTM-4 Plus

VOLTAGE OF FEEDER MOTOR

Supplied by power source, DC 18.3 V

RECOMMENDED WIRE SIZES

0.8mm,1.0mm,1.2mm,1.4mm,1.6mm,2.0 mm

WIRE FEED SPEED

1.5-22m/min

WIRE SPOOL（Max. load 20 KG）

Shaft diameter

50mm

Outer diameter

280mm

Width

105mm

DIMENSIONS & WEIGHT (Without wire spool)

Specification

Model

HEIGHT

WIDTH

DEPTH

WEIGHT

PWFTM-2

350mm

280mm

450mm

10.5kg

PWFTM-4

11.0kg

PWFTM-2 Plus

350mm

280mm

550mm

12.0kg

PWFTM-4 Plus

12.5kg

Note: Please use this wire feeder with specified POWERPLUS™, INVERTEC® (Peak value of 50V for

DC pulse) power sources. Failure to do so could result in no output or damage to machine.

A-2 INSTALLATION A-2

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

Only qualified personnel should perform this installation,

maintenance and troubleshooting work.

Turn off the input power at the fuse box before working

on other equipment connected to the welding system at

the disconnect switch or fuse box before working on this

equipment.

Do not touch electrically hot parts.

■INTERCONNECTION CABLE

The interconnection cable assembly for the PWF™ feeders includes a control cable, welding cable and

gas hose. Preset lengths are available from Lincoln Electric.

■WELDING CABLE

Connect the welding cable to the stud at the rear of the wire feeder. For gas shielded wire, the welding

cable should be bolted to “+” output stud on the power source.

■GAS HOSE

The PWF™interconnection cable assembly has a gas hose which connects to the gas nipple on the rear of the

feeder. The other end of the gas hose, connects to the flow meter/regulator. Please secure both ends of gas

hose suitable hose clips. Shielding gas such as CO2, Ar, and blended gas can be used. (Gas pressure can not

be more than 0.7 MPa)

■CONTROL CABLE

The control cable is included in the interconnection cable assembly. When it is used with POWERPLUS™,

the 6-pin connector on the control cable will be connected to the rear panel of the wire feeder and 6-pin

connector on the power source.

**Notes: Please fix the gas hose and cables into the holding bracket on the rear of the

feeder after the connection.

WARNING

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