Lincoln Electric Pf40 User manual

IM3045

02/2016

REV06

PF40

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

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

www.lincolnelectric.eu

English English

Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the welding machine:

PF40

conforms to the following directives:

2014/35/EU , 2014/30/EU

and has been designed in compliance with the

following standards:

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

20.04.2016

Piotr Spytek

Operations Director

Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland 07/11

English English

12/05

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

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

immediately to the dealer.

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

Serial Number can be found on the machine rating plate.

Model Name:

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

Code & Serial number:

………………….………………………………………………..

…………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………...

……………………….…………………………………………..

ENGLISH INDEX

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

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

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

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

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

WEEE............................................................................................................................................................................12

Spare Parts....................................................................................................................................................................12

Electrical Schematic ......................................................................................................................................................12

Suggested Accessories.................................................................................................................................................13

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

English English

Technical Specifications

NAME

INDEX

PF40

K14106-1

INPUT

Input Voltage U1

Input Amperes I1

EMC Class

40Vdc

RATED OUTPUT

Duty Cycle 40°C

(based on a 10 min. period)

Output Current

100%

385A

60%

500A

OUTPUT RANGE

Welding Current Range

Peak Open Circuit Voltage

5 ÷ 500A

113Vdc or Vac peak

DIMENSION

Weight

Height

Width

Length

17 kg

460 mm

300 mm

640 mm

WIRE FEED SPEED RANGE / WIRE DIAMETER

WFS RANGE

Drive roll

diameter

Solid wires

Aluminum wires

Cored wires

1 ÷ 22 m/min

Ø37

0.8 ÷ 1.6 mm

1.0 ÷ 1.6 mm

0.9 ÷ 1.6 mm

Protection Rating

Maximum gas pressure

Operating Temperature

Storage Temperature

IP23

0,5MPa (5 bar)

from -10°C to +40°C

from -25°C to 55°C

English English

Electromagnetic Compatibility (EMC) 01/11

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

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

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

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

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

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

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

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

with, if necessary, assistance from Lincoln Electric.

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

electromagnetic disturbances. Consider the following.

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

machine.

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

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

Personal medical devices like pacemakers and hearing aids.

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

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

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

taking place.

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

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

additional precautions such as filtering the input supply.

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

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

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

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

applications.

WARNING

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

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

WARNING

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

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

due to conducted as well as radio-frequency disturbances.

English English

Safety 01/11

WARNING

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

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

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

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

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

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

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

death.

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

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

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

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

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

the electrode, work clamp, and connected work pieces.

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

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

regulations.

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

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

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

risk of accidental arc ignition.

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

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

pacemakers, and welders having a pacemaker shall consult their physician before operating this

equipment.

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

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

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

Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as

required by EN169 Standard.

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

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

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

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

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

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

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

the arc.

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

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

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

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

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

vapors or liquid combustibles are present.

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

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

materials in the work area.

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

an environment with increased hazard of electric shock.

English English

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

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

pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do

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

electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders

must be located away from areas where they may be subjected to physical damage or the welding

process including sparks and heat sources.

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

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

starting, operating and servicing.

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

the operator’s manual.

Introduction

PF40 is digital wire feeder which has been designed to

work with all Lincoln Electric power sources using

ArcLink®protocol to communication.

Digital wire feeder allows the welding:

GMAW (MIG/MAG) –non-synergic process only.

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 operation

of the machine.

Location and Environment

This machine will operate in harsh environments.

However, it is important that simple preventative

measures are followed to assure long life and reliable

operation.

Do not place or operate this machine on a surface

with an incline greater than 15° from horizontal.

Do not use this machine for pipe thawing.

This machine must be located where there is free

circulation of clean air without restrictions for air

movement.

Dirt and dust that can be drawn into the machine

should be kept to a minimum.

This machine has a protection rating of IP23. Keep

it dry when possible and do not place it on wet

ground or in puddles.

Locate the machine away from radio controlled

machinery. Normal operation may adversely affect

the operation of nearby radio controlled machinery,

which may result in injury or equipment damage.

Read the section on electromagnetic compatibility in

this manual.

Do not operate in areas with an ambient

temperature greater than 40°C.

Duty cycle and Overheating

The duty cycle of a welding machine is the percentage of

time in a 10 minute cycle at which the welder can

operate the machine at rated welding current.

Example: 60% duty cycle

Welding for 6 minutes.

Break for 4 minutes.

Excessive extension of the duty cycle will cause the

thermal protection circuit to activate.

Minutes

or decrease

Duty Cycle

Input Supply Connection

Check the input voltage, phase, and frequency of the

power source that will be connected to this wire feeder.

The allowable input voltage source is indicated on the

rating plate of the wire feeder. Verify the connection of

grounding wires from the power source to the input

source.

English English

Controls and Operational Features

1 2

5 4

Figure 1

1. Wire Feed Speed Control (WFS): Value

in percentage of nominal value wire feed

speed (also during welding).

2. Welding Load Voltage Control: The

welding load voltage and set by this

control (also during welding).

3. EURO Socket: For connecting a welding

gun (for GMAW, FCAW-GS, FCAW-SS).

4. Quick Connect Coupling: Coolant outlet

(supplies cool coolant to the gun).

5. Quick Connect Coupling: Coolant inlet

(takes warm coolant from the gun).

WARNING

Maximum coolant pressure is 5 bar.

6. Remote Control Connector Plug

(optional): To install Remote Control Kit.

It can be purchased separately. See

"Accessories" chapter.

Figure 2.

7. Gas Connector: Connection for gas line.

WARNING

The welding machine supports all suitable shielding

gases at a maximum pressure of 5,0 bar.

8. Control Receptacle: 5 pins receptacle for

wire feeder connection ( ArcLink®

protocol).

9. Current Socket: Input power connection.

10.Quick Connect Coupling: Coolant outlet

(takes warm coolant from welding

machines to cooler.)

11.Quick Connect Coupling: Coolant inlet

(supplies cool coolant from cooler to the

welding machines).

WARNING

Maximum coolant pressure is 5 bar.

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

use only coolant that is recommended by the

manufacturer of welding gun or cooler.

13 14

12 15 16

Figure 3.

English English

12.Gas Flow Regulator Plug: Gas Flow Regulator can

be purchased separately. See "Accessories" chapter.

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

wire feeding or gas flow without turning on output

voltage.

14.Gun Mode Switch: It enables selection of 2-step or 4-

step gun mode. The functionality of 2T/4T mode is

shown in the Figure 4.

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

plastic, steel and fiber spools onto 51mm spindle.

Also accepts Readi-Reel®type spools onto included

spindle adapter.

WARNING

Be sure that wire spool case has to be completely closed

during welding.

16.Spooled Wire: The machine does not include a

spooled wire.

17.Wire Drive: 4-Roll wire drive.

WARNING

The wire drive door and wire spool case have to be

completely closed during welding.

WARNING

Not use handle to move the machine during work. See

"Accessories" chapter.

Wire Spool Loading

Wire spool type S300 and BS300 can be installed on the

wire spool support without adapter.

Wire spool type S200, B300 or Readi-Reel®can be

installed, but the applicable adapter must be purchased.

The applicable adapter can be purchased

separately(see "Accessories" chapter).

Wire Spool Type S300 & BS300 Loading

WARNING

Turn the input power OFF at the welding power source

before installation or changing a wire spool.

1819

Figure 5.

Turn the input power OFF.

Open the spool wire case.

Unscrew the Locking Nut [18] and remove it from

the Spindle [20].

Place the spool type S300 or BS300 [19] on the

Spindle [20] making certain the Spindle Brake Pin

[21] is put in the hole in back side of spool type

S300 or SB300.

WARNING

Position the spool type S300 or SB300 so that it will

rotate in a direction when feeding so as to be de-reeled

from bottom of the spool.

Re-install the locking nut [18]. Make sure that the

locking nut is tightened.

Trigger pressed

Trigger released

Welding current

Burnback time (fixed)

WFS

Gas

Figure 4.

English English

Wire Spool Type S200 Loading

WARNING

Turn the input power OFF at the welding power source

before installation or changing a wire spool.

Figure 6.

Turn the input power OFF.

Open the spool wire case.

Unscrew the Locking Nut [18] and remove it from

the Spindle [20].

Place the adapter of spool type S200 [22] on the

spindle [20] making certain the spindle brake pin

[21] is put in the hole in back side of the adapter

[22]. The adapter of spool type S200 can be

purchased separately (see "Accessories" chapter).

Place the spool type S200 [24] on the spindle [20]

making certain that the adapter brake pin [23] is put

in the hole in the back side of the spool.

WARNING

Position the spool type S200 so that it will rotate in a

direction when feeding so as to be de-reeled from

bottom of the spool.

Re-install the locking nut [18]. Make sure that the

locking nut is tightened.

Wire Spool Type B300 Loading

WARNING

Turn the input power OFF at the welding power source

before installation or changing a wire spool.

Figure 7.

Turn the input power OFF.

Open the spool wire case.

Unscrew the Locking Nut [18] and remove it from

the spindle [20].

Place the adapter of spool type B300 [25] on the

spindle [20].Make certain that the spindle brake pin

[21] is put in the hole in the back side of the adapter.

The adapter of spool type B300 can be purchased

separately (see "Accessories" chapter).

Re-install the locking nut [18]. Make sure that the

locking nut is tightened.

2825 29

Figure 8.

Rotate the spindle and adapter so the retaining

spring [26] is at the 12 o'clock position.

Place the spool type B300 [28] on the adapter [25].

Set one of the B300 inside cage wires [29] on the

slot [27] in the retaining spring tab [26] and slide the

spool onto the adapter.

WARNING

Position the spool type B300 so that it will rotate in a

direction when feeding so as to be de-reeled from

bottom of the spool.

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