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Lincoln Electric AUTODRIVE 4R90 manual

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Table of contents for the manual

  • Page 1

    OPERA TOR’S MANUAL • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • Copyright © Lincoln Global Inc. AutoDrive 4 R90 IM952-A March, 2010 For use with machines [...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 4.a. 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 open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

  • Page 4

    iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

  • Page 5

    iv SAFETY iv Mar. ‘93 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

  • Page 6

    v v T T h h a a n n k k Y Y o o u u 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy fo[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation ..................................................................[...]

  • Page 8

    A-1 INST ALLA TION A-1 AutoDrive 4R90 TEMPERA TURE RANGE OPERATION: -40°F to 104°F (-40°C to 40°C) STORAGE: -40°F to 185°F (-40°C to 85°C) INPUT VOL T AGE, CURRENT TECHNICAL SPECIFICA TIONS – AutoDrive 4R90 (K2685-2) HEIGHT WIDTH LENGTH WEIGHT 8.4 Inches 7.5 Inches 9.1 Inches 13.2 lbs (213 mm) ( 191 mm) (231 mm) (6.0 kg) PHYSICAL DIMENSIO[...]

  • Page 9

    WELD CABLE SIZE Table A.1 located below are copper cable sizes rec- ommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop. ** Tabled values are for operation at ambient[...]

  • Page 10

    A-3 INST ALLA TION AutoDrive 4R90 A-3 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 t[...]

  • Page 11

    A-4 INST ALLA TION AutoDrive 4R90 A-4 A B K H N L C D M G F E J I POWER SOURCE WIRE FEEDER A B K H N L C D M G F E J I Function Motor Power Motor Power Gas Solenoid Gas Solenoid Reserved Reserved “2A” Differential Tachometer “2B” Differential Tachometer Reserved Reserved “1A” Differential Tachometer “1B” Differential Tachometer Rese[...]

  • Page 12

    A-5 INST ALLA TION AutoDrive 4R90 A-5 SHIELDING GAS CONNECTION CYLINDER may explode if damaged. • Keep cylinder upright a nd chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other [...]

  • Page 13

    A-6 INST ALLA TION AutoDrive 4R90 A-6 WIRE DRIVE CONFIGURA TION (See Figure A.2) CHANGING THE GUN RECEIVER BUSHING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before instal- lation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode a[...]

  • Page 14

    A-7 INST ALLA TION AutoDrive 4R90 A-7 PROCEDURE TO INST ALL DRIVE ROLLS AND WIRE GUIDES ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- ing 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 &quo[...]

  • Page 15

    A-8 INST ALLA TION AutoDrive 4R90 A-8 CONDUIT INST ALLA TION 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 [...]

  • Page 16

    A-9 INST ALLA TION AutoDrive 4R90 A-9 SYSTEM SET -UP NEW ARMS Arc Link X T Co nne ctio n Arc Link (5 P in) Wo rk Se nse Wir e F eed er (14 Pi n) Ro bot ic Torc h Po wer W av e i 400 K2 669 -1 Wo rk Pi ece FA NU C R-J 30 iA C ont rol ler with In teg rate d O p Box Op tion al Wo rk Se nse Le ad (2 1) K1 785 -X X W ire Fee der K8 84 -5, -6 Co ntr ol C[...]

  • Page 17

    B-1 OPERA TION AutoDrive 4R90 B-1 • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri- cally energized and could remain energized several sec- onds after the welding ceases.. • Do not touch electrically live part or electrode with skin or wet clothing[...]

  • Page 18

    B-2 OPERA TION B-2 AutoDrive 4R90 DEFINITION OF WELDING TERMS GMAW • Gas Metal Arc welding FCAW • Flux Core Arc Welding STT™ • Surface Tension Transfer PRODUCT DESCRIPTION General Physical Description The AutoDrive 4R90 wire feeders are powerful yet compact wire drives for robotic and hard automation applications. The MAXTRAC 4 roll wire dr[...]

  • Page 19

    C-1 ACCESSORIES C-1 AutoDrive 4R90 WIRE TYPE Steel Wires: Cored Wires: Aluminum Wires: KITS ELECTRODE SIZE KP1505-030S .023-.030 (0.6-0.8mm) KP1505-035S .035 (0.9mm) KP1505-040S .040 (1.0mm) KP1505-045S .045 (1.2mm) KP1505-035C .030-.035" (0.8-0.9mm) KP1505-045C .040-.045" (1.0-1.2mm) KP1507-3/64A 3/64" (1.2mm) OPTIONAL KITS AND ACCE[...]

  • Page 20

    C-2 ACCESSORIES C-2 AutoDrive 4R90 K1500-4 K1500-5 K489-7 K515-xx K565-xx K1546-1 Gun Receiver Bushing (for gun with K466-3 Lincoln gun connec- tors; compatible with Miller® guns.) Gun Receiver Bushing (compatible with Oxo® guns.) Gun Receiver Bushing (for Lincoln Fast-Mate guns.) Wire Conduit Wire Conduit Incoming Bushing, for Lincoln Conduit .0[...]

  • Page 21

    C-3 ACCESSORIES C-3 AutoDrive 4R90 K2175-1 K2175-2 K895-2 K836-1 K884-5 K884-6 K1796-xx K1785-xx K1733-1 K590-6 500 lb Accu-Pak Box Payoff Kit 1000 lb Accu-Pak Box Payoff Kit Rotary Wire Dispenser Dereeler Adapter Accu-Trak Drum Payoff Kit – 20 inch diameter Accu-Trak Drum Payoff Kit – 23 inch diameter Coaxial Cables Wire Drive Cables Wire Stra[...]

  • Page 22

    D-1 MAINTENANCE D-1 AutoDrive 4R90 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 a n d d r i v e m e c h a n i s m a r e " h o t " t o w o r k a n d groun[...]

  • Page 23

    E-1 TROUBLESHOOTING E-1 AutoDrive 4R90 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair p[...]

  • Page 24

    E-2 TROUBLESHOOTING E-2 AutoDrive 4R90 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS[...]

  • Page 25

    E-3 TROUBLESHOOTING E-3 AutoDrive 4R90 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS[...]

  • Page 26

    F-1 DIAGRAMS F-1 AutoDrive 4R90 B M 2 1 56 2 55 2A TA C H IN TE R F A CE P C B D W IR ING DI A G RA M A UT OD RI V E 4 R90 /4 R 220 FE ED ER FE E D PL AT E P 1 8 M OT O R / G E A R BOX W TA CH 53 1 B B W B R 53 7 53 4 55 1 A 550 A 7 6 5 4 3 2 1 L2 L1 A J 2 B C D E F G H I J K L M N P 3 8 7 6 5 4 3 2 1 55 1 55 0A 55 2A 55 3 A 50 0 A 51 5 A 84 2 A 84[...]

  • Page 27

    F-2 DIMENSION PRINT F-2 AutoDrive 4R90 6.02” 4.72” 3.02” 7.50” 3.50” 8 . 3 5 " 1 . 4 6 " 1 . 9 7 " 0 . 6 2 " 8.35” 9.02” 8.02” 0.27” 0.62” 0.62” 1.97” 1.97” 1.78” 1.46” 1.00” 1.56” LINCOLN ELECTRIC[...]

  • Page 28

    NOTES AutoDrive 4R90[...]

  • Page 29

    NOTES AutoDrive 4R90[...]

  • Page 30

    NOTES AutoDrive 4R90[...]

  • Page 31

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL U[...]

  • Page 32

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep yo ur head ou t o f f umes . ● Use ven til atio n o r e xha ust to remo[...]

  • Page 33

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]