Lincoln Electric WF 52D User manual

IM3166

06/2021

REV01

WF 52D

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

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

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 ......................................................................................................................................................................... 5

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

WEEE ............................................................................................................................................................................... 24

Spare Parts ....................................................................................................................................................................... 24

REACh .............................................................................................................................................................................. 24

Authorized Service Shops Location .................................................................................................................................. 24

Electrical Schematic.......................................................................................................................................................... 24

Suggested Accessories..................................................................................................................................................... 25

Connection configuration................................................................................................................................................... 27

English English

Technical Specifications

NAME INDEX

WF 52D W100000176

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

OUTPUT RANGE

Welding Current Range Peak Open Circuit Voltage

5 ÷ 500A 113Vdc or Vac peak

DIMENSION

Weight Height Width Length

17 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 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.

English English

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.

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.

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

an environment with increased hazard 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 English

Introduction

WF 52D is digital wire feeder which has been designed

to work with Lincoln Electric power sources:

DIGISTEEL 355S,

DIGISTEEL 425S,

DIGISTEEL 505S,

CITOSTEEL 355S,

CITOSTEEL 425S,

CITOSTEEL 505S.

The CAN 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),

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 operation

of 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 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. U22 User Interface: See „User Interface” section.

6. Gas Quick Coupling Socket: For connecting a

gas pipe.

WARNING

The welding machine supports all suitable shielding

gases at a maximum pressure of 5,0 bar.

7. Control Socket: 5 pins socket for connecting

a control cable. The CAN 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 12

14 15

Figure 3

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.

English English

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 wire drive door and wire spool case have to be

completely closed during welding.

WARNING

Not use handle to move the machine during work.

User Interface

The WF 52D wire feeder uses the U22 interface based

on two separate LED displays for operation.

Interface U22

17 18 19 20 21

272829

Figure 4

17. Left Display: Shows wire feed speed or welding

current. During welding shows the actual welding

current value.

18. Status LED: A two color light that indicates system

errors. Normal operation is steady green light. Error

conditions are indicated, per Table 1.

Note: The status light will flash green for up to one

minute when the machine is turned on for the first time.

When the power source is powered it can take as long

as up to 60 seconds for the machine to be ready to weld.

This is a normal situation as the machine goes through

the initialization.

Table 1

LED Light

Condition

Meaning

Only machines which using

protocol for communication

Steady Green Power source is operational, and is

communicating normally with all

healthy peripheral equipment.

Blinking Green Occurs during power up or a system

reset, and indicates the power source

is mapping (identifying) each

component connect to the system.

This behavior occurs for first after

power is turned on, or if the system

configuration is changed during

operation.

Alternating Green

and Red

If the status lights are flashing any

combination of red and green color, it

means that errors are present in the

power source.

Each digit of the code corresponds to

the number of red flashes of the

indicator lamp.

Individual code digits are flashed in

red with a long pause between digits.

If more than one code is present, the

codes will be separated by green

light. Read the error code before the

machine is turned off.

To clear the errors try to turn off the

machine and wait for a few seconds,

then turn on again. If the error

remains, a it maintenance is required.

Please contact the nearest

authorized technical service center or

Lincoln Electric and report the error

code.

Steady Red Indicate no communication between

the power source and device which

has been connected to this power

source.

19. Thermal Overload Indicator: It indicates that the

machine is overloaded or that the cooling is not

sufficient.

20. Right Display: Depending on the source welding and

the welding program shows the welding voltage in

volts or Trim value. During welding shows the actual

welding voltage value.

21. LED Indicator: Informs that the value on the right

display is in volts unit and during welding, it blinks

and the display shows the measured voltage.

22. LED Indicator: Informs that the value on the right

display is Trim. Trim is adjustable from 0.50 to 1.50.

1.00 is the nominal setting.

23. Right Control: Adjusts values on the right display.

24. LED Indicator: Quick Access Menu.

English English

25. Right Button: Enables selecting, changing and setting

welding parameters. Quick Access Menu.

26. LED Indicator: Indicates that the Settings and

Configuration Menu is activated.

27. Left Button: Enables:

Checking the active program number. To check

the program number, press the left button once.

Changing the Welding Process.

28. Welding Programs Indicators (changeable): In the

user memory can be stored four user programs.

Shine LED indicates that the program is active.

29. Welding Programs Indicators (unchangeable): LED

indicates the program for non-synergic process is

active. See the table 2.

30. Left Control: Adjusts values on the left display.

31. LED Indicator: Informs that the value on the left

display is in ampere units, blinks during welding and

the display shows current measured. .

32. LED Indicator: Informs that the wire feed speed is

on the left display.

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