Lincoln Electric PF 56D User manual

IM3188

04/2023

REV02

PF 56D

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

www.lincolnelectric.eu

English I English

12/05

THANK YOU! For choosing the QUALITY of the Lincoln Electric products.

Please check packaging and equipment for damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

For ease of use, please enter your product identification data in the table below. 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 ......................................................................................................................................................................... 5

Installation and Operator Instructions.................................................................................................................................. 5

WEEE ............................................................................................................................................................................... 11

Spare Parts ....................................................................................................................................................................... 11

Authorized Service Shops Location .................................................................................................................................. 11

Electrical Schematic.......................................................................................................................................................... 11

Accessories....................................................................................................................................................................... 12

Connection Diagram ......................................................................................................................................................... 14

English 1 English

Technical Specifications

NAME INDEX

PF 56D K14392-1

INPUT

Input Voltage U1Input Amperes I1EMC Class

40Vdc 4Adc A

RATED OUTPUT

Duty Cycle 40°C (based on a 10 min. period) Output Current

100% 420A

60% 500A

Welding Current Range Peak Open Circuit Voltage

5 ÷ 500A 113Vdc peak

DIMENSION

Weight Height Width Length

17,7 kg 516 mm 302 mm 642 mm

WIRE FEED SPEED RANGE / WIRE DIAMETER

WFS Range Drive Rolls Drive roll diameter

1.5 ÷ 22 m/min 4 Ø37

Solid Wires Aluminum Wires Cored Wires

0.8 ÷ 1.6 mm 1.0 ÷ 1.6 mm 0.9 ÷ 1.6 mm

OTHERS

Protection Rating Maximum Gas Pressure

IP23 0,5 MPa (5 bar)

Operating Temperature Storage Temperature

from -10°C to +40°C from -25°C to 55°C

English 2 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, if necessary with 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 as short as possible and positioned together as close as possible to each other. 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 which

means that 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 may be potential difficulties in ensuring electromagnetic compatibility in those locations,

due to conducted as well as radiated disturbances.

English 3 English

Safety

01/11

WARNING

This equipment have to 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 equipment damage. 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 equipment damage. 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 equipment damage.

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

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

electrode, work clamp, and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off the 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.

ELECTROMAGNETIC FIELD MAY BE DANGEROUS: Electric current flowing through any conductor

creates electromagnetic field (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. To protect the skin, use suitable clothing made

of durable, fireproof material. Protect other nearby personnel with suitable, non-flammable screening and

warn them not to watch the arc nor expose themselves to the arc.

English 4 English

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

and have a fire extinguisher easily accessible. 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 use this equipment when flammable gases, vapors or flammable liquids 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 certificate, 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 risk 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.

English 5 English

Introduction

PF 56D is digital wire feeder which have been designed to

work with Lincoln Electric power sources:

POWER WAVE®350CE,

POWER WAVE®500CE.

The ArcLink®protocol is used for communication

between the power source and the wire feeder. All signals

from the power source are displayed on the User Interface

located in the wire feeder machine.

Set of power source and wire feeder allow welding in

listed processes:

GMAW (MIG/MAG),

FCAW,

SMAW (MMA),

GTAW,

CAG.

The complete package contains:

Wire feeder.

USB memory with operator’s manual.

Easy Start

Recommended equipment, which can be bought by user,

was mentioned in the chapter "Accessories".

Installation and Operator Instructions

Read this entire section before installation or operating the

machine.

Exploitation conditions

This machine can operate in harsh environments.

However, it is important to use the following simple

preventive measures that will ensure its long life and

reliable operation:

Do not place or operate this machine on a surface with

an incline higher 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. 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 away from the item.

This machine has a protection rating of IP23. Keep it

dry when possible and do not place it on a wet ground

or in puddles.

Locate the machine away from a radio controlled

machinery. Normal operation may adversely affect the

operation of a 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.

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 acceptable level of input voltage is indicated in the

section „Technical Specificationsʺand on the rating plate

of the power source. Verify the connection of grounding

wires from the power source to the input source.

English 6 English

Controls and Operational Features

Figure 1

Figure 2

1. EURO Socket: For connecting a welding

gun (for GMAW, FCAW process).

2. Quick Coupling Socket: Coolant outlet

(supplies cool coolant to the welding gun).

3. Quick Coupling Socket: Coolant inlet (takes

warm coolant from the welding gun).

WARNING

Maximum coolant pressure is 5 bar.

4. Output Socket for SMAW and CAG

welding: For connecting welding cable with

an electrode holder.

5. U7 User Interface: See „User Interfaceʺsection.

6. Gas Quick Coupling Socket: For connecting

a gas pipe.

WARNING

The machine allows the use all suitable shielding gases

with a maximum pressure of 5 bar.

7. Control Socket: 5 pins socket for

connecting a control cable. The ArcLink®

protocol is used for communication

between the power source and wire feeder.

8. Current Socket: For connecting a welding

cable.

9. Quick Coupling Socket: Coolant inlet

(supplies cool coolant from cooler to the

welding machine).

10. Quick Coupling Socket: Coolant outlet

(takes warm coolant from welding machine

to cooler).

11. Gas Flow Regulator Plug: Gas Flow Regulator can

be purchased separately. See "Accessories"

section.

12. Switch: Cold Inch / Gas Purge: This switch allows

wire feeding (wire test) and gas flow (gas test)

without switching on the output voltage.

13. Transport Holder: For the feeder lifting and

transporting using a crane.

14. Wire Spool Holder: For wire spool with maximum

16kg weight. Holder allows mounting plastic, steel

and fiber spools on the 51mm spindle.

WARNING

Be sure that wire spool case has to be completely closed

during welding.

15. Spool with Wire: Not supplied as standard.

16. Wire Drive: 4-rolls wire drive.

WARNING

The side panel and wire spool case have to be completely

closed during welding.

WARNING

Do not use handle to move the machine during operation.

English 7 English

1211 18 14 15

Figure 3

17. Remote Control Socket: For connecting a Remote

Control (see "Accessories" chapter).

18. USB Port: For connecting the USB memory and

software updates.

User Interface Advanced (U7)

Figure 4

Detailed operation of User Interface U7 can be found in

the Advanced (U7) IM3170 user manual.

Loading the Wire Spool

Spools of wire with a maximum weight of 16 kg can be

used without an adapter. Holder allows mounting plastic,

steel and fiber spools on the 51mm spindle.

It is possible to use other spools after using the

appropriate adapter, which can be purchased separately

(see "Accessories" chapter).

Loading the Electrode Wire

Turn the input power OFF.

Open the spool wire case.

Unscrew the locking nut of the sleeve [14].

Load the spool wire on the sleeve so that the spool

turns clockwise when the wire is feed into the wire

feeder.

Make sure that the spindle brake pin goes into the

fitting hole on the spool.

Screw in the locking nut of the sleeve.

Open the wire drive door.

Put on the wire roll with the correct groove

corresponding to the wire diameter.

Free the end of the wire and cut off the bent end

making sure it has no burr.

WARNING

Sharp end of the wire can hurt.

Rotate the wire spool clockwise and thread the end of

the wire into the wire feeder as far as the Euro Socket.

Adjust force pressure roll of the wire feeder properly.

Adjustments of Brake Torque of Sleeve

To avoid spontaneous unrolling of the welding wire the

sleeve is fitted with a brake.

Adjustment is carried by rotation of its screw M10, which

is placed inside of the sleeve frame after unscrewing the

brake locking nut.

Figure 5

19. Locking Nut.

20. Adjusting Screw M10.

21. Pressing Spring.

Turning the M10 screw clockwise increases the spring

tension and increase the brake torque

Turning the M10 screw anticlockwise decreases the

spring tension and decrease the brake torque.

After finishing of adjustment, you should screw brake

locking nut again.

English 8 English

Adjusting of Pressure Roll Force

The pressure arm controls the amount of force the drive

rolls exert on the wire. Pressure force is adjusted by

turning the adjustment nut clockwise to increase force,

counterclockwise to decrease force. Proper adjustment of

pressure arm gives the best welding performance.

WARNING

If the roll pressure is too weak, the roll will slide on the

wire. If the roll pressure is set too heavy the wire may be

deformed, which cause feeding problems in the welding.

The pressure force should be set properly. For this

purpose decrease the pressure force slowly until the wire

just begins to slide on the drive roll and then increase the

force slightly by turning of the adjustment nut by one turn.

Inserting Electrode Wire into Welding

Torch

Turn the welding machine off.

Depending of welding process connect proper welding

torch to the euro socket [1]. Rated parameters of the

torch and welding machine should be matched.

Depends on type of gun must be remove the nozzle

from the gun and contact tip or protection cap and

contact tip.

Turn the welding machine on.

Hold the Cold Inch/Gas Purge Switch [12] or use torch

trigger until wire appear over threaded end of the gun.

When the Cold Inch Switch [12] or torch trigger is

released the spool of wire should not unwind.

Adjust wire spool brake accordingly.

Turn the welding machine off.

Install a proper contact tip.

Depending on the welding process and the type of the

gun, install the nozzle (GMAW process) or protection

cap (FCAW process).

WARNING

Take precaution to keep eyes and hands away from the

end of the gun while the wire is being come out of the

threaded end.

Changing Driving Rolls

WARNING

Turn the input power off before installation or changing

drive rolls.

Wire Feeders PF 56D is equipped with drive roll

V1.0/V1.2 for steel wire. For others wires and sizes it is

required to install proper drive rolls kit (see "Accessories"

chapter) and follow instruction:

Turn the input power OFF.

Unlock 4 rolls by turning 4 Quick-Change Carrier

Gear [26].

Release the pressure roll levers [27].

Change the drive rolls [25] corresponding to the used

wire.

WARNING

Be sure that the gun liner and contact tip are also sized to

match the selected wire size.

WARNING

For wires with the diameter larger than 1.6mm, the

following parts have to be changed:

The guide tube of the feeding console [23] and [24].

The guide tube of the Euro Socket [22].

Lock 4 new rolls by turning 4 Quick-Change Carrier

Gear [26].

Insert the wire through the guide tube, over the roller

and through the guide tube of Euro Socket into liner of

gun. The wire can be pushed into the liner manually

for a few centimeters, and should feed easily and

without any force.

Lock the pressure roll levers [27].

Figure 6

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