Lincoln Electric 4R220 Welder Operator`s manual

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AutoDrive

™

4R220

For use with machines having Code Number : 11455

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful 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.

IM945

May, 2009

OPERATOR’S MANUAL

Copyright © 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

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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.

i

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 powered equipment.

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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS may be dangerous

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when the engine is running.

Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete.

Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

2.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

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

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

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

2.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.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

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

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

Mar ‘95

ii

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.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.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.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.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

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

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

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

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

SAFETY

ARC RAYS can burn.

4.a. 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 open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.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.

5.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 within applicable OSHA PEL and

ACGIH TLV limits 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.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable

OSHA PEL and ACGIH TLV limits.

5.c. 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.

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.

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Jan ‘09

iii

WELDING and CUTTING

SPARKS can cause fire or explosion.

6.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.

6.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.

6.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.

6.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

(see address above).

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

6.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.

6.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.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention

During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma

022690-9101.

6.j. Do not use a welding power source for pipe thawing.

SAFETY

CYLINDER may explode if damaged.

7.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.

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

7.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.

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

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

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

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

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

iii

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

SAFETY

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

iv

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.

e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

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 la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

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 enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

a. Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables.

1.

Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

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Thank You

v

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln

Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com

for any updated information.

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.

vi

TABLE OF CONTENTS

Page

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Installation.......................................................................................................................Section A

Technical Specifications .......................................................................................................A-1

Safety Precautions ...............................................................................................................A-2

Location ................................................................................................................................A-2

Weld Cable Sizes .................................................................................................................A-2

Coaxial Weld Cable ..............................................................................................................A-3

Wire Drive Cable .................................................................................................................A-4

Shielding Gas Connection ....................................................................................................A-5

Procedure to Install Drive Rolls and Wire Guides ................................................................A-6

Pressure Arm Adjustment, Conduit Installation ....................................................................A-7

System Set-Up .....................................................................................................................A-8

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Graphic Symbols that appear on this Machine or in this Manual .........................................B-1

Definition of Welding Terms .................................................................................................B-2

Product Description ..............................................................................................................B-2

Recommended Processes, Equipment Limitations, Recommended Power Sources ..........B-2

________________________________________________________________________________

Accessories ....................................................................................................................Section C

Optinal Kits and Accessories ...............................................................................................C-1

Drive Roll Kits used ..............................................................................................................C-1

Accessories Used.........................................................................................................C-2, C-3

________________________________________________________________________________

Maintenance ....................................................................................................................Section D

Safety Precautions ...............................................................................................................D-1

Routine Maintenance ...........................................................................................................D-1

________________________________________________________________________________

Troubleshooting .............................................................................................................Section E

How to Use Troubleshooting Guide .....................................................................................E-1

Troubleshooting Guide .................................................................................................E-2, E-3

________________________________________________________________________________

Wiring Diagram & Dimension Prints .............................................................................Section F

________________________________________________________________________________

Parts Pages ................................................................................................................P-613 Series

_______________________________________________________________________

________

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – AutoDrive™ 4R220 (K2685-1)

INPUT VOLTAGE, CURRENT

INPUT VOLTAGE ± 10%

40 VDC

RATED OUTPUT @ 104°F (40°C)

DUTY CYCLE AMPERES

INPUT AMPERES

7A

MOTOR POWER WATTS

100% rating 500 220

GEARING

GEARING - WIRE FEED SPEED RANGE-WIRE SIZE

GMAW

FCAW

WFS RANGE WIRE SIZES WFS RANGE WIRE SIZES

K2685-1

HEIGHT

50 – 1200 ipm

(0.8 – 30.5m/min)

.023 – 1/16"

(0.6 – 1.6mm)

50 – 1200 ipm

(1.3 – 30.5m/min)

.035 - 5/64”

(0.9 – 2.0mm)

PHYSICAL DIMENSIONS

WIDTH LENGTH WEIGHT

A-1

10.43 Inches 10.07 Inches 9.92 Inches 20.9 lbs.

(265 mm) (256 mm) (252 mm) (9.5 kg.)

OPERATION:

STORAGE:

TEMPERATURE RANGE

-40°F to 104°F (-40°C to 40°C)

-40°F to 185°F (-40°C to 85°C)

AutoDrive™ 4R220

A-2

SAFETY PRECAUTIONS

WARNING

INSTALLATION

WELD CABLE SIZE

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are

"hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

• Only qualified personnel should perform maintenance work.

------------------------------------------------------------------------

LOCATION

Firmly secure the AutoDrive™ 4R220 wire feeder to a robot arm or fixture.

A-2

Table A.1 located below are copper cable sizes recommended for different currents and duty cycles.

Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop.

See L15169 iB and L15169-1 iC Mechanical

Installation Instructions which are supplied with this

Instruction Manual in the literature package.

Mount only in a dry environment.

TABLE A.1

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

AMPERES PERCENT

DUTY

CYCLE

0 to 50Ft.

(0 to15m)

50 to 100Ft.

(15 to 30m)

100 to 150 Ft.

(30 to 46m)

150 to 200 Ft.

(46 to 61m)

200 to 250 Ft.

(61 to 76m)

300

325

350

400

400

500

200

200

225

225

250

250

250

250

60

100

20

40 & 30

30

40

60

100

60

100

60

60

100

60

2

2

4 or 5

3

3

2

1

1

1

2/0

1/0

2/0

3/0

2/0

2

2

3

3

3

2

1

1

1

2/0

1/0

2/0

3/0

2/0

2

2

2

2

2

1

1

1

1

2/0

2/0

2/0

3/0

3/0

1

1

1

1

1

1

1

1

1/0

2/0

2/0

3/0

3/0

3/0

2/0

3/0

3/0

4/0

4/0

4/0

1/0

1/0

1/0

1/0

1/0

1/0

1/0

1/0

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables larger than recommended, or cables rated higher than 167°F(75°C).


A-3

COAXIAL WELD CABLE

INSTALLATION

Coaxial welding cables are specially designed welding cables for STT™ and pulse welding. Coaxial weld cables feature low inductance, allowing fast changes in the weld current. Regular cables have a higher inductance which may distort the STT™ waveshape. Inductance becomes more severe as the weld cables become longer.

Coaxial weld cables are recommended for STT™ welding, especially when the total weld cable length (electrode cable + work cable) exceeds 50 feet (7.6m). See

Table A.2.

A coaxial weld cable is constructed with multiple small leads wrapped around one large lead. The large inner lead connects to the electrode stud on the power source and the electrode connection on the wire feeder. The small leads combine together to form the work lead, one end attached to the power source and the other end to the work piece.

To install:

1. Turn the input power off at the welding power source.

2. Connect one end of the center lead to the power source electrode connection, and the other end to the wire feeder electrode connection.

3. Connect the outer lead bundle to the power source work connection, and the other end to the work piece.

Minimize the length of any work lead extension for best results.

4. Insulate all connections.

TABLE A.2

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C)**

COAXIAL CABLE LENGTH

Amperes

250

300

350

Duty

Cycle

100%

60%

60%

0 to 25 Ft.

1

1

1/0

25 to 50 Ft.

1

1

1/0

50 to 75 Ft.

1

1

--

75 to 100 Ft.

1

1/0

--

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below.

Applications above 104°F(40°C) may require cables larger than recommended, or cables rated higher than 167°F(75°C).

A-3


A-4

INSTALLATION

WIRE DRIVE CABLE, K1785-XX

Wire drive cables are used to connect power sources and control boxes to remote wire drives.

The cables have a 14 pin connector at each end.

Both ends of the cable have a collar and the cables cannot be “daisy chained” to make a longer cable.

POWER SOURCE WIRE FEEDER

J

I

H

G

N

F

A

K

B

M

L

D

C

E

A

C

B

L

D

E

J

K

I

N

M

G

H

F

Pin

POWER SOURCE

Function

L

M

N

H

I

J

K

D

E

F

G

A

B

C

Motor Power

Motor Power

Gas Solenoid

Gas Solenoid

Reserved

Reserved

“2A” Differential Tachometer

“2B” Differential Tachometer

Reserved

Reserved



Reserved

“67” Electrode Sense Lead

Pin

WIRE FEEDER

Function

L

M

N

H

I

J

K

D

E

F

G

A

B

C

Motor Power

Motor Power

Gas Solenoid

Gas Solenoid


Reserved

+15VDC Tech Supply

Tachometer Common

Reserved

Reserved




“67” Electrode Sense Lead

A-4


A-5

SHIELDING GAS CONNECTION

WARNING

INSTALLATION

A-5

5. Attach one end of the inlet hose to the outlet fitting of the flow regulator. Attach the other end to the welding system shielding gas inlet. Tighten the union nuts with a wrench.

CYLINDER may explode if damaged.

• Keep cylinder upright and chained to support.

6. Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released.

7. Standing to one side, open the cylinder valve slowly a fraction of a turn. When the cylinder pressure gage stops moving, open the valve fully.

• Keep cylinder away from areas where it may be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live electrical circuits.

• BUILD UP OF SHIELDING GAS MAY

HARM HEALTH OR KILL.

• Shut off shielding gas supply when not in use.

• See American National Standard Z-49.1, "Safety in Welding and Cutting” Published by the

American Welding Society.

------------------------------------------------------------------------

Maximum inlet pressure is 100 psi. (6.9 bar.)

8. The flow regulator is adjustable. Adjust it to the flow rate recommended for the procedure and process being used before making a weld.

Install the shielding gas supply as follows:

1. Secure the cylinder to prevent it from falling.

2. Remove the cylinder cap. Inspect the cylinder valves and regulator for damaged threads, dirt, dust, oil or grease. Remove dust and dirt with a clean cloth. DO

NOT ATTACH THE REGULATOR IF OIL, GREASE

OR DAMAGE IS PRESENT! Inform your gas supplier of this condition. Oil or grease in the presence of high pressure oxygen is explosive.

3. Stand to one side away from the outlet and open the cylinder valve for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet.

4. Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. Note: if connecting to 100% CO

2 cylinder, insert regulator adapter between regulator and cylinder valve. If adapter is equipped with a plastic washer, be sure it is seated for connection to the CO

2 cylinder.


A-6

INSTALLATION

PROCEDURE TO INSTALL DRIVE ROLLS

AND WIRE GUIDES

WARNING




• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Do not operate with covers, panels or guards removed or open.


------------------------------------------------------------------------

To remove drive rolls and wire guides:

1. Turn power off at the welding power source.

2. Remove the outer wire guide.

4. Open the idle arms.

5. Remove the drive rolls and inner wire guide.

To install drive rolls and wire guides:

1. Turn off power at the welding power source.

2. Open the idle arms.

3. Assemble the inner wire guide.

IDLER ARM OPENED

A-6

INNER WIRE GUIDE

DRIVE ROLLS

OUTER WIRE GUIDE

3. Rotate all of the triangular rings to the unlocked position.

4. Slide the drive rolls onto the drive hubs.

5. Close the idle arms.

6. Rotate all of the triangular rings to the locked position.

7. Assemble the outer wire guide.

8. Adjust the pressure arms to the recommended setting.


A-7

PRESSURE ARM ADJUSTMENT

INSTALLATION

CONDUIT INSTALLATION

WARNING







------------------------------------------------------------------------

The pressure arm controls the amount of force the drive rolls exert on the wire. Proper adjustment of the pressure arm gives the best welding performance.

The K1546-xx series of conduits are compatible with

K515-xx, K565-xx, Wire Wizard and Electron Beam

Technologies conduits.

To install conduit to the wire drive:

1. Slide the conduit bushing into the feed plate and secure with the set screw.

SET

SCREW

A-7

2. Slide the conduit into the bushing and lock in place with the thumb screw.

THUMB

SCREW

Set the pressure arm as follows:

(See Figure A.3)

Aluminum wires between 1 and 3

Cored wires between 3 and 4

Steel, Stainless wires between 4 and 6

FIGURE A.3

CONDUIT

BUSHING

CONDUIT

LOADING WIRE

WARNING

• Keep hands, hair, clothing and tools away from rotating equipment.

• Do not wear gloves when threading wire or changing wire spool.

• Only qualified personnel should install, use or service this equipment.

------------------------------------------------------------------------


A-8

SYSTEM SET-UP

INSTALLATION

SYSTEM SET-UP (SINGLE ARM)

A-8


B-1

OPERATION


READ AND UNDERSTAND ENTIRE SECTION

BEFORE OPERATING MACHINE.

B-1

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

WARNING

• ELECTRIC SHOCK CAN KILL.

Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases..

• Do not touch electrically live part or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.


---------------------------------------------------------------------

• FUMES AND GASSES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

---------------------------------------------------------------------

• WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

----------------------------------------------------------------------

ARC RAYS can burn.

• Wear eye, ear and body protection.

---------------------------------------------------------------------

SEE ADDITIONAL WARNING INFORMATION

UNDER ARC WELDING SAFETY PRECAUTIONS

AND IN THE FRONT OF THIS OPERATING MAN-

UAL.

----------------------------------------------------------------------

U0

U1

U2

I1

I2

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

OPEN CIRCUIT

VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE

GROUND

WARNING OR

CAUTION


B-2

DEFINITION OF WELDING TERMS

OPERATION

EQUIPMENT LIMITATIONS

GMAW

• Gas Metal Arc welding

FCAW

• Flux Core Arc Welding

STT™

• Surface Tension Transfer

PRODUCT DESCRIPTION

General Physical Description

The AutoDrive™ 4R220 wire feeders are powerful yet compact wire drives for robotic and hard automation applications.

The MAXTRAC 4 roll wire drive gives steady feeding of all wire sizes and types. The drive features split wire guides, tool-less drive roll changing, dual spring pressure arms and changeable gun bushings all mounted in a precision die cast aluminum frame. A right angle gear box efficiently transfers motor power for both high torque and high speed.

The AutoDrive™ 4R220 features a powerful motor with an efficient two stage gearbox. This feeder is best for feeding larger diameter wires, pulling wire through long conduits, and in applications requiring extra ruggedness. A door covers the wire drive, protecting it from dust.

General Functional Description

A high resolution tachometer precision for wire feeding forwards and in reverse.

For more information go to the following Web site:

http://content.lincolnelectric.com/pdfs/products/ literature/RoboticFeederSelectionChart.pdf

RECOMMENDED PROCESSES

• GMAW

• FCAW

• STT™

PROCESS LIMITATIONS

K2685-1 AutoDrive™ 4R220:

ß • ßMaximum wire size = 1/16 (1.6mm)

B-2

K2685-1 AutoDrive™ 4R220

ß• Maximum GMAW gun length =10’ (3.1m)

ß• Maximum FCAW gun length = 15’ (4.6m)

ß• Maximum wire drive control cable length = 100ft.

(31m)

ß• Robot and power source software may need to be updated.

ß• Drive rolls are not included with the feeder.

ß• Mounts to FANUC ArcMate100iC arms.

ß• Mounts to FANUC ArcMate100iB arms.

• Maximum Conduit Length 50 Ft. (15m).

RECOMMENDED POWER SOURCES

ß• Power Wave F355i

ß• Power Wave 455 (all models)

ß• Power Wave 455/STT M

ß• Power Wave 655/ R

ß• Power Wave 400i


C-1

ACCESSORIES

OPTIONAL KITS AND ACCESSORIES

DRIVE ROLL KITS 4 ROLL DRIVE

WIRE TYPE KITS ELECTRODE SIZE

Steel Wires: KP1505-030S

KP1505-035S

KP1505-040S

KP1505-045S

.023-.030 (0.6-0.8mm)

.035 (0.9mm)

.040 (1.0mm)

.045 (1.2mm)

Includes: 4 V groove drive rolls and inner wire guide.

Cored Wires: KP1505-035C

KP1505-045C

.030-.035" (0.8-0.9mm)

.040-.045" (1.0-1.2mm)

Includes: 4 Knurled drive rolls and inner wire guide.

Aluminum Wires: KP1507-3/64A 3/64" (1.2mm)

Includes: 4 polished

U groove drive rolls, outer wire guide and inner wire guide.

C-1


C-2

ACCESSORIES

K1500-1

Gun Receiver Bushing (for guns with K466-1 Lincoln gun connectors; Innershield and Subarc guns)

Includes: Gun receiver bushing, set screw and hex key wrench.

K1500-2

Gun Receiver Bushing (for guns with K466-2, K466-10 Lincoln gun connectors; Magnum 200/300/400 guns and compatible with Tweco®

#2-#4)

Includes: Gun receiver bushing with hose nipple, set screw and hex key wrench.

K1500-3

Gun Receiver Bushing (for guns with K613-7 Lincoln gun connectors; Magnum 550 guns and compatible with Tweco® #5)


K1500-4

Gun Receiver Bushing (for gun with K466-3 Lincoln gun connectors; compatible with Miller® guns.)


K1500-5 Gun Receiver Bushing (compatible with Oxo® guns.)

Includes: Gun receiver bushing with hose nipple, 4 guide tubes, set screw and hex key wrench.

K489-7 Gun Receiver Bushing (for Lincoln

Fast-Mate guns.)

Includes: Gun receiver bushing with trigger connector.

K515-xx

K565-xx

Wire Conduit

Wire Conduit

Requires K1546-1

Requires K1546-1

K1546-1

Incoming Bushing, for Lincoln

Conduit .025- 1/16" (0.6 - 1.6mm) wire. Compatible with Electron

Beam Conduit.

Includes: Incoming bushing and hex key wrench.


C-2

C-3

K2175-1

K2175-2

K895-2

K836-1

K884-5

K884-6

K1796-xx

K2593-xx

K1785-xx

K2709-xx

K1733-1

ACCESSORIES

500 lb Accu-Pak Box Payoff Kit

1000 lb Accu-Pak Box Payoff Kit

Rotary Wire Dispenser

Dereeler Adapter

Accu-Trak Drum Payoff Kit – 20 inch diameter

Accu-Trak Drum Payoff Kit – 23 inch diameter

Coaxial Cables

Includes: 1 cable of length “xx” feet. 14 pin connectors on both ends. Cable length cannot be extended by connecting

K1785 cables together.

Coaxial Cables

Wire Drive Cables

Wire Drive Cables

Wire Straightener

Includes: 1 cable of length “xx” feet. 14 pin connectors on both ends. Has collars at both ends. Used with FANUC arms that have an integrated cable.

Includes: 1 cable of length “xx” feet. 14 pins connectors on both ends. May be daisy chained to make a longer cable. Used with FANUC arms that do not have an integrated cable.

Includes: 1 wire straightener

C-3


D-1


MAINTENANCE

WARNING







----------------------------------------------------------------------

ROUTINE MAINTENANCE

To Install or remove the AutoDrive™ 4R220 for servicing:

See Installation Section of this Instruction Manual.

D-1


E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

E-1

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 locate and repair possible machine malfunctions.

Simply follow the three-step procedure listed below.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the

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-

TOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

If you do not understand or are unable to perform the

Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

Step 2. POSSIBLE CAUSE.

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

WARNING





• Welding power source must be connected to system ground per the National Electrical

Code or any applicable local codes.


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.


E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

The wire feeder does not feed wire and the drive rolls do not spin.

1. Verify the power source is turned on.

2. Verify the circuit breaker for the wire feeder on the power source has not tripped.

3. Verify power is being supplied to the wire feeder.

The wire feeds erratically.

1. Verify the correct drive rolls and inner wire guide are installed in the wire drive.

2. Check for sharp bends in the gun liner or conduit.

3. Examine the contact tip for wear and proper size. Replace as necessary.

4. Check the gun liner and conduit.

The welding electrode should slide easily through both.

5. Verify the proper gun liner is installed.

No shielding gas

Variable or "hunting" arc.

6. Verify the pressure arms are set properly. Too much pressure may crush the wire.

7. Inspect the motor for worn brushes.

1. Verify the gas supply is turned on and not empty.

2. Check the gas hose for cuts.

Make sure it is not crushed.

3. Verify the shielding gas hose is connected to the gun bushing or welding gun.

CAUTION




E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

Variable or "hunting" arc.

Output Problems

1. Check for proper size contact.

Make sure the contact tip is not worn, free of spatter and not melted.

The motor overload errors occur.

2. Clean and tighten all electrode and work connections.

3. Verify the proper polarity is being used for the weld procedure.

4. Make sure the proper electrode stick-out is being maintained.

5. Check the gas flow rate and mixture.

6. Verify the gun bushing is tightly mounted to the wire drive.

7. Verify the gun is tightly mounted to the gun bushing.

8. Verify the electrode lead is connected to the proper connection block on the feed head.

9. Inspect the motor for worn brushes.

1. Check for sharp bends in the gun liner and conduit.

2. Examine the contact tip for wear and proper size. Replace as necessary.

3. Check the gun liner and conduit.

The welding electrode should slide easily through both.

4. Verify the proper gun liner is installed.

5. Reduce the pressure arm setting.

CAUTION




F-1

DIAGRAMS

F-1


F-2

DIMENSION PRINT

F-2


NOTES


Chinese

Korean

Arabic

German

WARNING

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

WARNUNG

Portuguese

ATENÇÃO

●

●

Do not touch electrically live parts or electrode with skin or wet clothing.

Insulate yourself from work and ground.

●

●

No toque las partes o los electrodos bajo carga con la piel o ropa mojada.

Aislese del trabajo y de la tierra.

●

Keep flammable materials away.

●

Mantenga el material combustible fuera del área de trabajo.

●

Wear eye, ear and body protection.

●

Protéjase los ojos, los oídos y el cuerpo.

●

●

Ne laissez ni la peau ni des vêtements mouillés entrer en contact avec des pièces sous tension.

Isolez-vous du travail et de la terre.

●

Gardez à l’écart de tout matériel inflammable.

●

Protégez vos yeux, vos oreilles et votre corps.

●

●

Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem

Körper oder feuchter Kleidung!

Isolieren Sie sich von den

Elektroden und dem Erdboden!

●

●

Não toque partes elétricas e electrodos com a pele ou roupa molhada.

Isole-se da peça e terra.

●

Entfernen Sie brennbarres Material!

●

Tragen Sie Augen-, Ohren- und Körperschutz!

●

Mantenha inflamáveis bem guardados.

●

Use proteção para a vista, ouvido e corpo.

Japanese

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.

Use ventilation or exhaust to remove fumes from breathing zone.

●

Turn power off before servicing.

●

Do not operate with panel open or guards off.

WARNING

●

●

Los humos fuera de la zona de respiración.

Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases.

●

●

Gardez la tête à l’écart des fumées.

Utilisez un ventilateur ou un aspirateur pour ôter les fumées des zones de travail.

●

Desconectar el cable de alimentación de poder de la máquina antes de iniciar cualquier servicio.

●

Débranchez le courant avant l’entretien.

●

No operar con panel abierto o guardas quitadas.

●

N’opérez pas avec les panneaux ouverts ou avec les dispositifs de protection enlevés.

●

●

Vermeiden Sie das Einatmen von

Schweibrauch!

Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

●

Strom vor Wartungsarbeiten abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

●

Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in

Betrieb setzen!

●

●

Mantenha seu rosto da fumaça.

Use ventilação e exhaustão para remover fumo da zona respiratória.

●

●

●

Não opere com as tampas removidas.

Desligue a corrente antes de fazer serviço.

Não toque as partes elétricas nuas.

●

●

Mantenha-se afastado das partes moventes.

Não opere com os paineis abertos ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

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

Lincoln Electric 4R220 Welder Operator`s manual

AutoDrive

™

4R220

IM945

OPERATOR’S MANUAL

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

ELECTRIC AND

MAGNETIC FIELDS may be dangerous

ELECTRIC SHOCK can kill.

ARC RAYS can burn.

FUMES AND GASES can be dangerous.

WELDING and CUTTING

SPARKS can cause fire or explosion.

CYLINDER may explode if damaged.

FOR ELECTRICALLY powered equipment.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

PRÉCAUTIONS DE SÛRETÉ

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

v

Thank You

v

Please Examine Carton and Equipment For Damage Immediately

On-Line Product Registration

vi

TABLE OF CONTENTS

vi

A-1

TECHNICAL SPECIFICATIONS – AutoDrive™ 4R220 (K2685-1)

GMAW

FCAW

A-1

A-2

SAFETY PRECAUTIONS

WELD CABLE SIZE

LOCATION

A-2

A-3

COAXIAL WELD CABLE

A-3

A-4

WIRE DRIVE CABLE, K1785-XX

POWER SOURCE

WIRE FEEDER

A-4

A-5

SHIELDING GAS CONNECTION

A-5

A-6

PROCEDURE TO INSTALL DRIVE ROLLS

AND WIRE GUIDES

A-6

A-7

PRESSURE ARM ADJUSTMENT

CONDUIT INSTALLATION

A-7

LOADING WIRE

A-8

SYSTEM SET-UP

SYSTEM SET-UP (SINGLE ARM)

A-8

B-1

SAFETY PRECAUTIONS

B-1

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

U0

U1

U2

I1

I2