Lincoln Electric PF44 User manual

IM3053

02/2015

REV03

PF44 & PF46

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric ester Sp. z o.o.

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

www.lincolnelectric.eu

English English

Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the welding machine:

PF44

PF46

conforms to the following directives:

2006/95/CEE, 2004/10 /CEE

and has been designed in compliance with the

following standards:

EN 60974-5, EN 60974-10:2007

12.07.2013

Paweł Lipiński

Operations Director

Lincoln Electric ester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 ielawa, Poland

07/11

English English

12/05

THANKS!

For having chosen 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

Location and Environment ............................................................................................................................................... 4

Duty cycle and Overheating ............................................................................................................................................. 4

Input Supply Connection .................................................................................................................................................. 4

Controls and Operational Features .................................................................................................................................. 5

Guide’s Marking Interface ................................................................................................................................................ 7

Interface Description ........................................................................................................................................................ 9

Welding Parameters ar .................................................................................................................................................. 9

Welding Program Choice ............................................................................................................................................... 11

User Settings ................................................................................................................................................................. 12

The Settings and Configuration Menu ........................................................................................................................... 17

US Memory (PF46 only) .............................................................................................................................................. 27

Welding SMAW (MMA) Process .................................................................................................................................... 29

Gouging ......................................................................................................................................................................... 30

Welding GTAW / GTAW-PULSE Process ..................................................................................................................... 31

Welding GMAW, FCAW-GS and FCAW-SS Process in non-synergic mode ................................................................. 33

Welding GMAW and FCAW-GS Process in synergic mode CV .................................................................................... 35

Welding GMAW-P Process in synergic mode ................................................................................................................ 36

Aluminum Welding GMAW- PP Process in synergic mode ........................................................................................... 38

Welding STT

Process................................................................................................................................................... 40

Wire Spool Loading ....................................................................................................................................................... 42

Loading the Electrode Wire ........................................................................................................................................... 44

Adjustments of rake Torque of Sleeve ........................................................................................................................ 44

Adjusting Pressure Roll Force ....................................................................................................................................... 45

Inserting Electrode Wire into Welding Gun .................................................................................................................... 45

Changing Driving Rolls .................................................................................................................................................. 45

Gas Connection ............................................................................................................................................................. 46

Maintenance .................................................................................................................................................................. 46

Error’s Message ............................................................................................................................................................ 47

WEEE................................................................................................................................................................................ 48

Spare Parts ....................................................................................................................................................................... 48

Electrical Schematic .......................................................................................................................................................... 48

Suggested Accessories ..................................................................................................................................................... 49

Connection Diagram ......................................................................................................................................................... 50

English English

Technical Specifications

NAME INDEX

PF44 K14108-1

PF46 K14109-1

INPUT

Input Voltage U

Input Amperes I

EMC Class

40Vdc 4A A

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

18,5 kg 460 mm 300 mm 640 mm

WIRE FEED SPEED RANGE / WIRE DIAMETER

WFS Range Drive Rolls Drive roll

diameter Solid Wires Aluminum Wires Cored Wires

1 ÷ 22 m/min 4 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.

efore 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 may be potential difficulties in ensuring electromagnetic compatibility in those

locations, due to conducted as well as radiated disturbances.

English English

Safety

01/11

WARNING

This equipment must be used by qualified personnel. e 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 E 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 E 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 URN: 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 URN: 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

PF44 and PF46 are digital wire feeders which have been

designed to work with all Lincoln Electric power sources

using ArcLink

protocol to communication.

Digital wire feeders allow the welding:

• GMAW (MIG/MAG)

• FCAW-GS / FCAW-SS

• SMAW (MMA)

• GTAW (arc ignition using lift TIG)

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. reak 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

Figure 1

Figure 2.

1. EURO Socket: For connecting a welding

gun (for GMAW / FCAW-SS process).

2. Quick Connect Coupling: Coolant outlet

(supplies cool coolant to the gun).

3. Quick Connect Coupling: Coolant inlet

(takes warm coolant from the gun).

WARNING

Maximum coolant pressure is 5,0 bar.

4. Output Socket for the Welding Circuit: For

connecting an electrode holder with lead.

5. Remote Control Connector Plug (optional,

PF44 only): To install Remote Control Kit. It

can be purchased separately. See

"Accessories" chapter.

6. Remote Control Receptacle (PF46 only): To

connection Remote Control or Cross Switch

Gun.

7. Left utton:

•

••

• Cancel

•

••

• ack.

8. Display: Parameters of welding process are shown.

9. Left Control: The value of the parameter in the

upper left side of display [8] is adjusted.

10. Right Control: The value of the parameter in the

upper right side of display [8] is adjusted.

11. Set Control: Type of welding procedure and welding

settings is changed by this Control.

12. Right utton: Confirm change.

13. Gas Connector: Connection for gas line.

WARNING

The welding machine supports all suitable shielding

gases at a maximum pressure of 5,0 bar.

14. Control Receptacle: 5 pins receptacle for

wire feeder connection. To communication

wire feeder with power source is used

ArcLink

protocol.

Figure 3.

15. Current Socket: Input power connection.

16. Quick Connect Coupling: Coolant outlet

(takes warm coolant from welding machines

to cooler).

17. Quick Connect Coupling: Coolant inlet

(supplies cool coolant from cooler to the

welding machines).

English English

WARNING

Maximum coolant pressure is 5,0 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.

18. Gas Flow Regulator Plug: Gas Flow Regulator can

be purchased separately. See "Accessories"

chapter.

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

wire feeding or gas flow without turning on output

voltage.

20. Lighting Switch.

21. US Receptacle: To connection the US memory.

18 19 22

20 23

Figure 4.

18 19 20 21 22 23

Figure 5.

22. 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

e sure that wire spool case has to be completely

closed during welding.

23. Spooled Wire: The machine does not include a

spooled wire.

24. 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.

English English

Guide’s Marking Interface

Description of the abridged user interface in "Quick Guide" chapter. See "Spare Part".

Table 1. Symbols description

Select Welding Process

Soft

SMAW-Soft Process

Memory

(PF46 only)

...

Select Welding Program

Crisp

SMAW-Crisp Process

Save to the User

Memory

(PF46 only)

Non-synergic Programs

SMAW-Pipe Process

Recall from the User

Memory

(PF46 only)

Syner

Synergic Programs

Gouging

Arc Force

GMAW Process

(MIG/MAG)

Electrode Wire Type

Selection

Hot Start

MODE

POWER

GMAW Process –

POWER MODE

Wire Size (diameter)

Selection

Frequency Settings

(GTAW-PULSE)

FCAW Process

Gas Selection

Frequency

(GTAW-PULSE)

FCAW-S

FCAW-SS Process

User Settings

ackground Settings

(GTAW-PULSE)

FCAW-G

FCAW-GS Process

Pinch

ackground Current

(GTAW-PULSE)

GMAW-P Process

Select Function of Gun

Trigger (2-Step / 4-Step)

ackground Current

(STT

)

GMAW-P Process

RapidArc

Program

2-Step

Peak Current

(STT

)

GMAW-P Process

RapidX

Program

4-Step

TailOut

(STT

)

GMAW-P process

Precision Pulse™

Program

Preflow Time

UltimArc™

GMAW-P Process

Pulse-On-Pulse

Program

Postflow Time

Setting and

Configuration Menu

STT

Process

urnback Time

Memory Limits

(PF46 only)

GTAW Process

(TIG)

Run-in WFS

Display Configuration

Settings

GTAW Welding

Spot Welding Settings

ig Meters Menu

(factory default)

GTAW-PULSE Welding

Spot Timer

Standard Menu

GTAW Program

Start Procedure

Weld Score™ Menu

GTAW-PULSE Program

Crater Procedure

True Energy™ Menu

SMAW Process

(MMA)

A/B

A/ Procedure

(PF46 only)

Assign Function

to the Right utton

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