Power Feed 10A Controller v5

Power Feed 10A Controller v5
AUTOMATIC WIRE FEEDERS
Power Feed™
10A Controller
ArcLink Controller for Power Wave AC/DC Systems.
Built on the enduring and trusted foundation of the NA-5 controller and the innovations of the
new Power Feed 10M wire feeder, the Power Feed 10A Controller is the next generation in
automatic submerged arc feeding. Designed for use with the Power Wave AC/DC 1000 power
source, the Power Feed 10A eliminates the need for a separate AC and DC controller, making this
powerful hard automation system controllable, adaptable and easy to use. The user-friendly
control panel offers a single-point of control over the entire welding cell, including the Power
Wave's Waveform Control Technology™, delivering an unprecedented level of control over wave
balance, amplitude and frequency.
Processes
Description
Submerged Arc
Output
Input
40
VDC
Advantage Lincoln
Unit Includes:
• Versatile system set-up options for stand-alone or PLC
configurations help you customize the weld cell to make your
operations as efficient as possible.
Power Feed 10A Control Box, Remote Pendant, 10-ft. Remote Pendant
Cable
Unit Requires:
• Lincoln’s Waveform Control Technology™ gives you the ability
to select the right waveform for each application.
• The Power Feed 10A Controller provides clear dual digital display
of set-up and weld modes, six memories, AC controls,
strike/start/end options, travel stop/start, and timers.
• Controls can be adjusted on-the-fly to change penetration and/or
deposition rates with Variable Frequency, Variable Amplitude and
Variable Balance.
• Easy-to-use switch panel can be removed and used as a Remote
Control Pendant to create a versatile work station set-up.
• The Power Feed 10SF and Power Feed 10S wire drive systems
are reliable and durable.
• The motor conversion kit allows the use of existing NA-3, NA-4,
and NA-5 feed head mounting hardware.
• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.
Power Wave AC/DC 1000 power source, and either the K2312-1 Power
Feed 10SF Wire Feed Head for fixed hard automation, or the K2370-1
Power Feed 10S Head for mounting to a Lincoln TC-3 Travel Carriage.
(other options may apply.)
Recommended General Options
Power Feed 10SM Motor Conversion Kit (converts Lincoln NA-style wire
drives), ArcLink Cable, Flux Hopper, Feeder Control Cable (14-pin to 14pin and 5-pin to 5-pin), Contact Nozzle Assembly, Contact Jaw
Assembly, Positive Contact Assembly, Linc-Fill Attachments, Narrow
Gap Deep Groove Nozzle, Concentric Flux Cone Assembly, Tandem Arc
Framework, Tandem Reels, Twinarc Contact Assemblies, Tiny Twinarc
Assemblies, Tiny Twinarc Solid Wire Straightener, TC-3 Travel Carriage,
Vertical Lift Adjuster, Horizontal Adjuster, Wire Reel Assembly for 50-60
lb. Coils, Spindle Kit – 2 in. hub, SpreadArc Oscillator, Flux Screen,
Magnetic Flux Screen Separator
Recommended Power Source Option
Power Wave AC/DC 1000
• Three-year warranty on parts and labor.
Order
K2362-1
Power Feed 10A Controller
TECHNICAL SPECIFICATIONS
Product
Name
Product
Number
Input
Power (1)
Rated Output
Current / Duty Cycle
Gear
Box
Wire Feed
Speed Range (1)
ipm (m/min)
Wire Size Range (1)
Inches (mm)
Solid
Dimensions
HxWxD
Inches (mm)
Power Feed 10A
Controller with
Wire Drive
K2362-1
40 VDC
1000A/100%
142:1(1)
10-200 (.25-5.08)
5/32 - 7/32 (4.0 - 5.6)
95:1(1)
15 x 13 x 4
(381 x 259 x 102)
10-300 (.25-7.62)
1/8 - 5/32 (3.2 - 4.0)
Net Weight
lbs (kg)
25 (11.3)
(1) 142:1 gear box is standard. Conversion Kit supplied for conversion to 95:1 with Wire Drive (K2370-1, K2312-1, or K2311-1)
Publication E9.165 1/05
www.lincolnelectric.com
A CLOSER LOOK
FEATURES
A Closer Look
Power Feed 10A Control Panel
The Power Feed 10A control panel controls and monitors the advanced
capabilities of the Power Wave AC/DC 1000 in a single, simple, easyto-understand user interface display panel. The Power Feed 10A communicates using ArcLink, and can easily integrate with custom controls
and PLCs, in multiple configurations.
Dual Display Dual Encoder Panel
3.
1.
2.
1. Wire feed speed (WFS) or amps.
2. Voltage
3. Arc Established Indicator - illuminates when a true arc has been established.
4.
Status LED - indicates system component ArcLink communication
status. Normal operation is a steady green light.
®
4.
5.
1.
4.
Switch Panel
3.
2.
1. START –
2. STOP –
3. INCH –
4. FLUX FILL–
5. TRAVEL–
Starts the weld sequence, using strike controls.
Stops the weld sequence, using crater/burnback controls.
Up/Down. Inches wire up or down without welding current
Activates flux hopper.
Controls motion in either manual or automatic modes.
Remote Pendant - The switch panel can be removed and used as a
handheld pendant for remote control.
1. 14-PIN Remote Control Connector
2. 4-PIN TC-3 Carriage Connector
3. 3-PIN Flux Hopper Receptacle
4. 5-PIN ArcLink Connector
5. Auxiliary Circuit Access Holes
1.
2.
3.
4.
5.
[2]
Power Feed 10A Controller
www.lincolnelectric.com
A CLOSER LOOK
PERFORMANCE
WHAT IS NEXTWELD®?
Nextweld integrates Lincoln’s technologies, processes and products to create a comprehensive, flexible, user-friendly
welding system that can increase efficiency and reduce fabrication costs.
MSP4 and Memory Panel
Memory panel
Up to six user settings and two procedure settings can be saved and
retrieved using the Memory Panel. Allows the operator to save weld
parameters and set-up options, such as Timers, Start Options, End
Options, AC Controls, etc., before welding begins.
Weld Procedure Limit Controls
The MSP4 panel can be configured to limit the operator’s range of control of weld procedure settings (Wire Feed Speed, Crater Time,
Burnback Time, etc.)
Lockout/Security Controls
Configurations that prevent the operator from changing authorized weld settings can be set at four different lockout levels to provide a
custom level of control.
Mode Select Lockout
Locks START/END Options, AC Controls, Weld Modes and Wave
Options – or various combinations of each.
Encoder Panel Lockout
Locks either right, left or both control knobs.
Full Lockout
Locks all functions listed above.
Memory Panel Lockout
Locks any or all of six memories saved.
Infrared IR Port
Weld Manager™, the Lincoln Electric Palm® OS-based software product, builds upon the usability and efficiency of the Power Feed 10M
user interface design. It offers remote access and availability to system information, set-up, and configuration, allowing you to manage your
Power Wave system from the palm of your hand. The versatile design allows for wireless communication with the Infrared Port on the
Power Feed 10A Controller or through a serial connection and your cradle - the decision is yours.
• Quick and easy user interface set-up that can be transferred
across Power Feed/Power Wave systems.
• Ensure parameters are maintained by locking out numerous
options on the user interface panel.
• Easily set-up the system and ensure repeatability between
multiple cells by transferring memory through a
'back-up'/'restore' or a memory 'clone'.
• Verify current system information right on the production floor.
• Ensure security of the loaded settings through password
protection.
• Any Palm Operating System version 3.5 or higher.
[3]
Power Feed 10A Controller
www.lincolnelectric.com
A CLOSER LOOK
CV/CC
PERFORMANCE
AC
START
WFS/AMPS
WFS
VOLTS
VOLTS
RESTRIKE START TIME
ARC FORCE
TIME
Driving Superior Welding
Performance
Lincoln’s Waveform Control
Technology controls and shapes the
output waveforms (or weld modes)
to adapt to virtually any application,
material or weld position.
SETUP
WELD
UPSLOPE TIMER
STRIKE
WFS AMPS
VOLTS
ARC FORCE
FREQUENCY
BALANCE
DC OFFSET
PHASE
RELATIONSHIP
START OPTIONS
WELD MODE
AC CONTROL
DOWNSLOPE TIMER
Waveform Control Technology®
CRATER
BURNBACK
WFS/AMPS
VOLTS/
TIME
ARC FORCE
TIME
END OPTIONS
SET-UP OPTIONS (User Preferences)
Set-up Mode can store basic user preferences like those listed below, or it can be used to display configurations or
access diagnostic tools.
START ARC FORCE/CRATER ARC FORCE – The Arc Force setting allows the customer to set a specific level of
current during three stages of the welding process.
START: In the start state the arc force sets the starting current for the first 250 mS of the weld. The operator can
control the starting characteristics by adjusting arc force to get a hotter or colder start.
WELD/CRATER: Arc Force is used in these two states to set a specific amount of current if the arc goes into a short.
This setting can be adjusted to create more stable operation during the welding process.
UPSLOPE/DOWNSLOPE TIME – Adjustable time for smooth transition from start to weld and from weld to crater.
RESTRIKE TIME – The time between an electrode short and automatic shutdown – can prevent serious flaws in the
weld. Also shuts off output if the wire stops feeding.
TRAVEL START/END – Start Travel with arc or Start Button strike and End Travel with arc out or Stop Button.
START OPTIONS
STRIKE – Adjustable run-in speed that is used for optimizing arc starting. Set independently of weld wire feed speed.
START – Provides separate welding procedure for an adjustable time at the start of the weld. A Hot Start procedure is
used when penetration is required at the arc start location and when run-on tabs are being used.
WIRE FEED SPEED/AMPS/VOLTS/TIME – Set weld parameters to begin at arc start.
WELD MODE
Choose weld procedure-AC, DC, wire size, consumable type.
AC CONTROL
VARIABLE FREQUENCY – The Power Wave AC/DC 1000 and Power Feed 10A Controller system has the widest
range of wave frequency adjustment (0 – 100 Hz) in the industry. Increase Frequency for a more stable arc and less
penetration; dcrease frequency for more penetration.
VARIABLE BALANCE – By setting the correct wave balance (the ratio between positive and negative waveforms), the
operator has greater control of the welding process. Increase Balance to get more penetration and less deposition;
decrease balance to get more deposition and less penetration.
DC OFFSET (VARIABLE AMPLITUDE) – By setting the correct DC Offset, the operator can define the appropriate
penetration and deposition rate, depending on the application.
PHASE RELATIONSHIP – The Power Wave AC/DC 1000 balances the "push" and "pull" of the arc interactions in a
multi-arc environment by using phase shifting to prevent arc blow and optimize the arc stability of virtually any waveform combination.
END OPTIONS
CRATER – Provides a separate welding procedure for an adjustable time at the end of the weld. A crater fill procedure
is used to regulate the bead width and/or fill the crater at the end of the weld.
BURNBACK – Adjustable control over the time delay between the time that the wire feeding stops and the arc is
extinguished to prevent the wire from sticking in the crater.
[4]
Power Feed 10A Controller
www.lincolnelectric.com
A CLOSER LOOK
SYSTEM CONFIGURATION
Mounting and Motion Controls
The Power Feed 10S series of Automatic Wire Drives are specially designed for hard automation, submerged arc welding. The heavy-duty
gear box and feed plate are well-known in the industry for years of reliable performance. Now featuring a new high-torque, permanent
magnet motor with more power and even more reliable performance under high heat conditions, The Power Feed 10S series wire drives are
the most rugged in the industry.
Single or Tandem Arc
Power Feed 10S (K2370-1)
(3/32 to 7/32 in. solid wire)
The Power Feed 10S is required to mount to a TC-3 undercarriage for
moving parts. It has many axes of rotation for ease of fixturing and locating.
Sturdy feed plate houses knurled drive rolls for positive accurate wire
feeding of large diameter welding wire (includes flux hopper, wire
straightener cross seam adjuster, head mounting hardware, and 2-5ft 4/0
weld cables).
(95:1 Gear Ratio Conversion Kit included.)
Power Feed 10S
(K2370-1)
Power Feed
10SF (K2312-1)
Power Feed 10SF (K2312-1)
(3/32 to 7/32 in. solid wire) Use the Power Feed 10SF for fixed hard
automation applications. Fixture mount wire drive assembly includes motor,
gearbox, drive rolls, guidelines and straightener (fixture builder's head with
wire straightener - insulators not included).
(95:1 Gear Ratio Conversion Kit included.)
TC-3 Travel Carriage (K325S, F, HCS or HCF)
The self-propelled travel carriage carries the wire feed head and Power Feed
10A in either direction on a beam. It can operate manually or automatically with
the weld controls. The TC-3 comes in two speed ranges (S and F) in
standard or high capacity (HC) models. The standard carriage is equipped for
one wire feed head, and the high capacity carriage is for multi-head systems.
• Standard Carriage
– K3255S: 5-75 ipm (0.1-1.9 m/min.)
– K3255F: 15-270 ipm (0.4-6.9 m/min.)
• High Capacity Carriage – K325 HCS: 5-75 ipm (0.1-1.9 m/min.)
– K325 HCF: 15-270 ipm (0.4-6.9 m/min.)
TC-3 Travel
Carriage
(K325S, F, HCS
or HCF)
Power Feed 10SM
Motor (K2311-1)
Conversion Kit Power Feed 10SM (K2311-1)
For use with NA Series Gear Head. The ArcLink™ motor retrofit is used to
replace existing motor on NA-3/4 OR NA-5 wire feed head.
(95:1 Gear Ratio Conversion Kit included.)
Multiple Arc
Systems Interface (K2282-1)
This external controller is required for multi-arc applications. The arc-to-arc
interaction is controlled by offsetting the phase relationship in 90° increments,
as each arc is added.
Multi-Arc System
Interface (K2282-1)
Programmable Logic Controller (PLC)
The Power Wave AC/DC 1000 and Power Feed 10A can easily integrate
into a customer-supplied PLC system. Motion of the TC-3 travel carriage
can be controlled from the PLC, while individual weld controls such as
mode selection, amperage, and voltage are still controlled from the
Power Feed 10A.
[5]
Power Feed 10A Controller
www.lincolnelectric.com
A CLOSER LOOK
Set-up Options
1.
1. The Power Feed 10A is shipped configured for easy connection to
the Lincoln TC-3 Travel Carriage and the Automatic Flux Hopper.
(115V AC required to power this configuration.)
2.
2. The switch panel can be easily removed and used as a Remote
Control Pendant for versatile work station set-up.
3.
3. Terminal strip access inside the Power Feed 10A to interface your
custom controls and/or PLCs, or to connect auxiliary circuits.
• Shutdown inputs can be used for limit switches, PLC inputs, etc
in order to shut down the welding operation for any reason.
• Safe and easy to use with numbered and color-coded connectors
for clear identification of inputs.
QUALITY & RELIABILITY
• Powerful permanent magnet DC motor – 32 volt motor on a 40-volt
bus. Rugged aluminum die cast plate is durable and resilient in
high heat.
Printed circuit boards are environmentally-shielded using Lincoln's
engineered potting and protective
frame trays.
• Lincoln’s design philosophy adds an extra factor of safety in all
components and construction to maximize reliability and service.
• 100% software controlled — Software based controls can be
upgraded as new features become available.
• Easy access for serviceability.
• Modular construction allows for easy service/maintenance.
• Three-year warranty on parts and labor.
• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.
For system configuration details, see publication E10.96 on the Power Wave AC/DC 1000™ power source.
RECOMMENDED OPTIONS
ARCLINK®/LINC-NET CONTROL EXTENSION CABLES
Description
8 ft. (2.5m)
16 ft. (4.8m)
25 ft. (7.6m)
50 ft. (15.2m)
100 ft. (30.4m)
Order Number
Without weld cable
Without weld cable
Without weld cable
Without weld cable
Without weld cable
WELD POWER CABLES
CONTROL CABLE (14 PIN TO 14 PIN)
5
K1543-8
K1543-16
K1543-25
K1543-50
K1543-100
Description
Order Number
12 ft. (3.6m)
16 ft. (4.8m)
25 ft. (7.6m)
50 ft. (15.2m)
100 ft. (30.4m)
K1785-12
K1785-16
K1785-25
K1785-50
K1785-100
WELD POWER CABLES
0-250 ft. @ 80% Duty Cycle, Qty. 2
0-250 ft. @ 100% Duty Cycle, Qty. 3
Description
Order Number
Description
Order Number
Lug to Lug, 4/0, 600A, 60% duty cycle, 35 ft.
Lug to Lug, 4/0, 600A, 60% duty cycle, 60 ft.
Lug to Lug, 4/0, 600A, 60% duty cycle, 110 ft.
K2163-35
K2163-60
K1842-110
Lug to Lug, 3/0, 600A, 60% duty cycle, 10 ft.
Lug to Lug, 3/0, 600A, 60% duty cycle, 35 ft.
Lug to Lug, 3/0, 600A, 60% duty cycle, 60 ft.
K1842-10
K1842-35
K1842-60
[6]
Power Feed 10A Controller
www.lincolnelectric.com
RECOMMENDED OPTIONS
GENERAL OPTIONS
Tandem Arc Framework
Provides mountings with desired positioning adjustments for two standard
Automatic Wire Feed Heads. Includes
insulation and hardware to permit direct
mounting to a high capacity TC-3
Carriage, or to the user's gantry or
fixture for either direction of travel.
Order K387
Power Feed 10SFM Motor
Conversion Kit
Used to convert NA-series wire drives
into PF-10S wire drives. Includes an
ArcLink™ motor retrofit kit used to
replace existing motor on NA-3, 4 or 5
wire feed head. For use with NA-series
gear head.
Order K2311-1
Tandem Reels
Two Wire Reel Mounting for TC-3.
Order K390
ArcLink Cable (5-pin)
Includes two leads plus two mating
terminals. Connects Power Feed 10A
controller to Power Wave AC/DC 1000.
Order K1543-XX
Large Wire Twinarc® Contact
Assemblies
Feeds two 5/64" (2.0 mm), 3/32" (2.4
mm) or 1/8" (3.2 mm) wires for submerged arc welding on "Fast-Fill" joints
or hardfacing beads.
Order K225
Flux Hopper for Tandem Arc
Flux Hopper for K387 mountings.
Order K389
Feeder Control Cable (14-pin)
Connects Power Wave AC/DC 1000 to
wire feeder.
Order K1785-xx
Tiny Twinarc® Contact Assemblies
Feeds two electrodes for high speed
submerged arc welds. Includes contact
nozzle, wire guides, drive rolls and
guides, and a second wire reel and
mounting bracket.
Order K129-x
Contact Nozzle Assembly
Single arc contact nozzle assembly for
1/8" (3.2 mm) diameter wire. Operates
at currents generally below 600 amps.
Outer flux cone gives full flux coverage
with minimum consumption.
Order K231-x
Tiny Twinarc Solid Wire Straightener
Straightens wire diameters .045 thru
3/32" (1.2 thru 2.4 mm). Particularly
valuable on longer electrical stickout
procedures.
Order K281
Contact Jaw Assembly
Single arc contact jaw assembly for
1/8-7/32" (3.2-5.6 mm) diameter wire.
Rugged contact jaws for maximum life
at currents over 600 amps.
Order K226R
TC-3 Self-Propelled Travel Carriage
Carries head and controls in either direction on a beam. Operates manually or
automatically with the weld controls.
Requires 115V AC 50 or 60 hertz input
power.
Order K325S, F, HCS, HCF
Positive Contact Assembly
For single arc welding at high currents
(optional T12928 water cooling attachment recommended when Innershield®
welding over 600 amps).
Order K148x
Vertical Lift Adjuster
Provides 4" (102 mm) hand crank
adjustment of vertical head position. It
also includes up to 3-3/4" (95.2 mm) inand-out horizontal adjustment with
stops that can be preset for simple repetition of the same adjustment.
Order K29
Linc-Fill® Long Stickout Extension
Linc-Fill long stickout extension for
K148A Single Arc Positive Contact
Nozzle Assembly. Required for long
stickout technique.
Order K149-x
Horizontal Adjuster
Provides crank adjustment of head position. Has 2" (51 mm) horizontal travel.
Order K96
Narrow Gap Deep Groove Nozzle
For single arc 3/32" (2.4 mm) diameter
wire welding on thick walled steel plate
with nearly parallel-sided, narrow gap
joint preparations.
Order K386
Wire Reel Assembly for 50-60 lb. Coils
Accommodates 50 lb. (22.7 kg) or 60 lb.
(27.2 kg) coils of wire on automatic wire
feeders. The unit includes a wire reel
mounting spindle and braking system.
Order K299
Concentric Flux Cone Assembly
For use with K148B, Positive Contact
Nozzle Assembly. Gives concentric flux
coverage around the electrode.
Order K285
[7]
Power Feed 10A Controller
www.lincolnelectric.com
RECOMMENDED OPTIONS
GENERAL OPTIONS CONT.
Flux Screen
For submerged arc welding. Removes
large particles from reused flux.
Includes air-driven vibrator.
Order K310
Spindle Kit - 2 in. hub
For fixture and other custom installations. Features 2" (51mm) O.D. spindle
for mounting Readi- Reels and 2"
(51mm) I.D. spools up to 60 lb. (27.2 kg)
capacity.
Order K162-1
Magnetic Flux Screen Separator
For submerged arc welding. Removes
foreign magnetic particles from reused
flux.
Order K58
SpreadArc Oscillator
Oscillates head across the line of travel.
Calibrated dwell time and oscillation
speed controls permit the Spreadarc to
cover large areas quickly with smooth
beads of minimum admixture.
Order K278
POWER FEED 10A CONTROLLER ORDER FORM
PRODUCT DESCRIPTION
ORDER NUMBER
POWER FEED 10A CONTROLLER
K2362-1
RECOMMENDED GENERAL OPTIONS
Power Feed 10SM Motor Conversion Kit
ArcLink Cable
Flux Hopper for Tandem Arc
Feeder Control Cable (14-pin to 14-pin)
Contact Nozzle Assembly
Contact Jaw Assembly
Positive Contact Assembly
Linc-Fill Long Stickout Extension
Narrow Gap Deep Groove Nozzle
Concentric Flux Cone Assembly
Tandem Arc Framework
Tandem Reels
Large Wire Twinarc Contact Assemblies
Tiny Twinarc Contact Assemblies
Tiny Twinarc Solid Wire Straightener
TC-3 Self-Propelled Travel Carriage – Standard
TC-3 Self-Propelled Travel Carriage – High Capacity
Vertical Lift Adjuster
Horizontal Adjuster
Wire Reel Assembly for 50-60 lb. Coils
Spindle Kit - 2 in. hub
SpreadArc Oscillator
Flux Screen
Magnetic Flux Screen Separator
K2311-1
K1543-xx
K389
K1785-xx
K231-x
K226R
K148x
K149-x
K386
K285
K387
K390
K225
K129-xx
K281
K325S, K325F
K325HCS, K325HCF
K29
K96
K299
K162-1
K278
K310
K58
RECOMMENDED POWER SOURCE OPTIONS
Power Wave AC/DC 1000
see publication E10.96
QUANTITY
PRICE
TOTAL:
C U S T O M E R A S S I S TA N C E P O L I C Y
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.
T H E L I N C O L N E L E C T R I C C O M PA N Y
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
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