IM952-A RETURN TO MAIN MENU AutoDrive 4R90 March, 2010 For use with machines having Code Number : 11492, 11722 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY 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.
vi TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...............................................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – AutoDrive 4R90 (K2685-2) INPUT VOLTAGE, CURRENT INPUT AMPERES 4A INPUT VOLTAGE ± 10% 0-40 VDC RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 100% rating 500 GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING K2685-2 WFS RANGE WIRE SIZES WFS RANGE WIRE SIZES 50 – 800 ipm (1.3 – 20.3m/min) .023 – .045" (0.6 – 1.2mm) 50 – 800 ipm (1.3 – 20.3m/min) .035 - .045” (0.9 – 1.2mm) PHYSICAL DIMENSIONS HEIGHT WIDTH 8.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.
A-3 A-3 INSTALLATION COAXIAL WELD CABLE Coaxial welding cables are specially designed welding cables for STT™ and pulse welding. Coaxial weld cables feature low inductance, allowing fast changes in the weld current. Regular cables have a higher inductance which may distort the STT™ waveshape. Inductance becomes more severe as the weld cables become longer.
A-4 A-4 INSTALLATION WIRE DRIVE CABLE, K1785-XX Wire drive cables are used to connect power sources and control boxes to remote wire drives. The cables have a 14 pin connector at each end. Both ends of the cable have a collar and the cables cannot be “daisy chained” to make a longer cable.
A-5 INSTALLATION SHIELDING GAS CONNECTION A-5 5. Attach one end of the inlet hose to the outlet fitting of the flow regulator. Attach the other end to the welding system shielding gas inlet. Tighten the union nuts with a wrench. WARNING CYLINDER may explode if damaged. 6. Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released. • Keep cylinder upright and chained to support.
A-6 A-6 INSTALLATION WIRE DRIVE CONFIGURATION (See Figure A.2) CHANGING BUSHING THE GUN RECEIVER WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.
A-7 A-7 INSTALLATION PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES 4. Open the idle arms. 5. Remove the drive rolls and inner wire guide. WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.
A-8 INSTALLATION CONDUIT INSTALLATION The K1546-xx series of conduits are compatible with K515-xx, K565-xx, Wire Wizard and Electron Beam Technologies conduits. To install conduit to the wire drive: 1. Slide the conduit bushing into the feed plate and secure with the set screw. 2. Slide the conduit into the bushing and lock in place with the thumb screw.
K884-5,-6 AutoDrive 4R90 Gas K1785-XX Wire Feeder Control Cable Air Wire Feeder (14 Pin) Electrode Connection * Work Cable (-) * Electrode Cable (+) Power Wave i400 K2669-1 * Refer to "Output Cable Guidelines" for recommended cable size Work Piece Optional Work Sense Lead (21) Robotic Torch Auto Drive 4R90 ArcLink (5 Pin) Wire Feeder Work (14 Pin) Sense ArcLink XT Connection Internal ArcLink XT Communication FANUC R-J30iA Controller with Integrated Op Box A-9 INSTALLATION A-9 SYSTEM SE
B-1 B-1 OPERATION SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL WARNING WIRE FEEDER • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.. • Do not touch electrically live part or electrode with skin or wet clothing.
B-2 OPERATION B-2 DEFINITION OF WELDING TERMS EQUIPMENT LIMITATIONS GMAW • Gas Metal Arc welding FCAW • Flux Core Arc Welding STT™ • Surface Tension Transfer K2685-2 AutoDrive 4R90: ß • Maximum GMAW gun length = 10’ (3.1m) ß • Maximum FCAW gun length = 10’ (3.1m) ß • Maximum wire drive control cable length = 100ft (31m) ß • Robot and power source software may need to be updated. ß • Drive rolls are not included with the feeder. ß • Mounts only to FANUC ArcMate100iC arms.
C-1 ACCESSORIES OPTIONAL KITS AND ACCESSORIES DRIVE ROLL KITS 4 ROLL DRIVE WIRE TYPE KITS Steel Wires: KP1505-030S KP1505-035S KP1505-040S KP1505-045S .023-.030 (0.6-0.8mm) .035 (0.9mm) .040 (1.0mm) .045 (1.2mm) Includes: 4 V groove drive rolls and inner wire guide. Cored Wires: KP1505-035C KP1505-045C .030-.035" (0.8-0.9mm) .040-.045" (1.0-1.2mm) Includes: 4 Knurled drive rolls and inner wire guide. 3/64" (1.
C-2 ACCESSORIES K1500-1 Gun Receiver Bushing (for guns with K466-1 Lincoln gun connectors; Innershield and Subarc guns) K1500-2 Gun Receiver Bushing (for guns with K466-2, K466-10 Lincoln gun Includes: Gun receiver bushconnectors; Magnum 200/300/400 ing with hose nipple, set screw guns and compatible with Tweco® and hex key wrench. #2-#4) K1500-3 K1500-4 Includes: Gun receiver bushing, set screw and hex key wrench.
C-3 ACCESSORIES K2175-1 500 lb Accu-Pak Box Payoff Kit K2175-2 1000 lb Accu-Pak Box Payoff Kit K895-2 Rotary Wire Dispenser K836-1 Dereeler Adapter K884-5 Accu-Trak Drum Payoff Kit – 20 inch diameter K884-6 Accu-Trak Drum Payoff Kit – 23 inch diameter K1796-xx Coaxial Cables K1785-xx Wire Drive Cables K1733-1 Wire Straightener K590-6 Water Connection Kit Includes: 1 cable of length “xx” feet. 14 pin connectors on both ends.
D-1 D-1 MAINTENANCE 6. When reassembling the feeder in the mounting bracket, make sure all of the studs fully are fully engaged in the slots. (See Figure D.2) SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION The wire feeder does not feed wire 1. Verify the power source is turned on. and the drive rolls do not spin. 2. Verify the circuit breaker for the wire feeder on the power source has not tripped. 3. Verify power is being supplied to the wire feeder. The wire feeds erratically. 1.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Variable or "hunting" arc. POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Output Problems 1. Check for proper size contact. Make sure the contact tip is not worn, free of spatter and not melted. 2. Clean and tighten all electrode and work connections. 3. Verify the proper polarity is being used for the weld procedure. 4. Make sure the proper electrode stick-out is being maintained. 5.
A B C D E F G H I J K L M N J2 GND AutoDrive 4R90 GAS SOLENOID RED BLACK WHITE 67A GREEN BLACK 551 550 552 553 BLACK W B BROWN RED MOTOR / ORANGE GEARBOX YELLOW TACH P4 1 2 3 4 550 551 537 534 531 535 551A 550A P3 1 2 3 4 5 6 7 8 553A 552A 1 2 3 4 5 6 7 8 BLACK RED GREEN BLACK 553 552 BLACK WHITE B W BR R Y O P1 550A 551A 843A 842A 515A 500A 553A 552A 845A 846A L2 L1 4 1 5 515A 843A 845A 842A 500A 846A 1 2 3 4 5 6 7 8 8 8 (J801) N.A.
AutoDrive 4R90 1.56” 1.00” 8.02” 0.62” 0.62” LINCOLN ELECTRIC 9.02” 1.97” 1.97” 1.46” 1.78” " 5 3 . 8.35”8 0.27” 4.72” 3.50” 7.50” 3.02” 6.02” F-2 DIMENSION PRINT F-2 " 6 4 . 1 " 7 9 . 1 " 2 6 .
NOTES AutoDrive 4R90
NOTES AutoDrive 4R90
NOTES AutoDrive 4R90
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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