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A good user manual
The rules should oblige the seller to give the purchaser an operating instrucion of Lincoln Electric IM916, along with an item. The lack of an instruction or false information given to customer shall constitute grounds to apply for a complaint because of nonconformity of goods with the contract. In accordance with the law, a customer can receive an instruction in non-paper form; lately graphic and electronic forms of the manuals, as well as instructional videos have been majorly used. A necessary precondition for this is the unmistakable, legible character of an instruction.
What is an instruction?
The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Lincoln Electric IM916 one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.
Unfortunately, only a few customers devote their time to read an instruction of Lincoln Electric IM916. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.
What should a perfect user manual contain?
First and foremost, an user manual of Lincoln Electric IM916 should contain:
- informations concerning technical data of Lincoln Electric IM916
- name of the manufacturer and a year of construction of the Lincoln Electric IM916 item
- rules of operation, control and maintenance of the Lincoln Electric IM916 item
- safety signs and mark certificates which confirm compatibility with appropriate standards
Why don't we read the manuals?
Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Lincoln Electric IM916 alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Lincoln Electric IM916, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Lincoln Electric service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Lincoln Electric IM916.
Why one should read the manuals?
It is mostly in the manuals where we will find the details concerning construction and possibility of the Lincoln Electric IM916 item, and its use of respective accessory, as well as information concerning all the functions and facilities.
After a successful purchase of an item one should find a moment and get to know with every part of an instruction. Currently the manuals are carefully prearranged and translated, so they could be fully understood by its users. The manuals will serve as an informational aid.
Table of contents for the manual
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Page 1
Po wer F eed ™ 10M Dual W ire Feeder %&( * %(Z)Y#$+" IM91 6 July, 2010 )498GL8C8A7FBA/BH 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. % $%* $)*"[...]
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Page 2
%($$ CBJ8E878DH<C@8AG 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. _____________________________[...]
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Page 3
<< )*/ << ARC R A Y S can b urn. 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 materi[...]
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Page 4
<<< )*/ <<< FOR ELECTRIC ALL Y pow er ed 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 a[...]
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Page 5
<I )*/ <I &(N+*%$))W(*N 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: )PE8GO&BHE)BH74:8"ZE6 1. Protegez-vous con[...]
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Page 6
I I Thank Y ou for selecting a '+"*/ 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! (847G;<F%C8E4GBEF #4AH4?6B@C?8G8?L before attempting to use this equipment. Save this manual and keep it han[...]
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Page 7
I< I< * "%%$*$*) Page AFG4??4G<BA ?[...]
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Page 8
I<< I<< * "%%$*$*) #4<AG8A4A68 ?[...]
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Page 9
&%-(R#+"-(( $)* "" *%$ *$" )& *%$)T&BJ8E887R#H4?-<E88878E -((,%(-((,)*%$?[...]
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Page 10
$)* "" *%$ &%-(R#+"-(( )*/ &(+*%$ "*(%(%+*$ The electrode supply may be either from reels, Readi- R e e l s , s p o o l s , o r b u l k p a c k a g e d d r u m s o r r e [...]
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Page 11
$)* "" *%$ &%-(R#+"-(( $ *,"*(%&%"(*/ When negative electrode polarity is required, such as in some Innershield applications, reverse the output connections at the power s[...]
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Page 12
$)* "" *%$ &%-(R#+"-(( ,%" * )$)$ T he b es t a rc p er fo r ma nc e o c cu rs w he n t h e P ow e r Waves® have accurate data about the arc conditions. Depending upon the process, inductance within t[...]
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Page 13
$)* "" *%$ &%-(R#+"-(( -( (, ( ( *% %("%-)& The speed range capability and drive torque of the Power Feed™ wire drives can be easily and qui[...]
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Page 14
$)* "" *%$ &%-(R#+"-(( (( *%(%$*%$ 1. Remove the rear access door from the wire feeder case. 2. Locate the dip switch bank on the P.C. board (refer to table A.3) 3. Locate dip switch # 8 a[...]
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Page 15
$)* "" *%$ &%-(R#+"-(( &(%+( *% $)* "" (, (%"") $-(+) E<I8(B??!<GAFG4??4G<BA!&12?[...]
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Page 16
$)* "" *%$ &%-(R#+"-(( #4:AH@HAF The easiest and least expensive way to use the Magnum 550 guns with Power Feed™ 10 Dual wire feeders is to order the gun with the K613-7 connector kit, and install a K1500-3 [...]
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Page 17
$)* "" *%$ &%-(R#+"-(( ?BJ)8AFBE!<G<AFG4??4G<BA<F4F9B??BJF 1. Remove rear access door of the wire feeder case. 2 . Locate the shutdown circuit leads inside feeder case cavity (refer to table [...]
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Page 18
$)* "" *%$ &%-(R#+"-(( Shown with • K2230-2 Power Feed™ 10M Single Wire Feeder • K1780-2 PF™-10/R • K2203-1 Power Wave® 455M/STT • K2205-1 Wire Drive Module 4E7HGB@4G<BA)LFG8@ Shown with • Co[...]
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Page 19
%&( *%$ &%-(R#+"-(( %##%$-"$ (, *%$) -) • Wire Feed Speed Q Constant Current , Q Constant Voltage #-# • Gas Metal Arc welding #-&#?[...]
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Page 20
%&( *%$ &%-(R#+"-(( &(%+*)(&*%$ The Power Feed™ 10M Dual Wire Feeder unit con- sists of a user interface and two wire drives. This unit will be available as a bench model or a boom model. The Power Feed™ 10M D[...]
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Page 21
+( %&( *%$ %&( *%$" *+() $ %$*(%") &%-( R# )() )/)*# %$+( *%$ The specific system component function of the pc board will be configurable by dip switch or by softwar[...]
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Page 22
%+*&+*%$*(%") • The Power Feed™ 10M Dual Wire Feeder has 2 encoder knobs to adjust weld parameters. • Each encoder changes the displayed value of the meter located directly above that encoder. • In CC-GTAW modes when equipped with a foot or hand amptrol, the left encoder sets the maximum welding current. Full depr[...]
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Page 23
%&( *%$ &%-(R#+"-(( "/%+*%$*(%") )+( The MSP4 panel controls (Items 7 and 9) set consist of an encoder knob Item 8 and two push buttons. The encoder is primarily used to change the value [...]
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Page 24
%&( *%$ &%-(R#+"-(( Once “Weld Mode Search” is displayed, pressing the right pushbutton labeled “Begin” will start the search process. During the search process, pressing the right pushbut- ton typically acts as a “next” button and t[...]
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Page 25
%&( *%$ &%-(R#+"-(( )* +& *+()#$+ (See Figure B.3a) 1. To access the set-up menu, press the (<:;G and "89G buttons of the #)& panel simultaneously. $BG8 that the set-up menu cannot be accessed if the[...]
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Page 26
%&( *%$ &%-(R#+"-(( +)($& (#*() &4E4@8G8E 89<A<G<BA K<G)8GHC#8AH & This setup menu parameter can be used to exit the setup menu. When & is displayed, pre[...]
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Page 27
%&( *%$ &%-(R#+"-(( +)($& (#*() &4E4@8G8E 89<A<G<BA & &EB687HE8;4A:8#8G;B7 This option selects how remote procedure selection (A/B) will be made. The selected pro[...]
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Page 28
%&( *%$ &%-(R#+"-(( +)($& (#*() &4E4@8G8E 89<A<G<BA & HA%99F8G 7=HFG@8AG This option adjusts the wire feed speed calibration of the pull motor of a push-pull[...]
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Page 29
%&( *%$ &%-(R#+"-(( +)($& (#*() &4E4@8G8E 89<A<G<BA & &HF;&H??HA!AB58;4I<BE This option determines how the potentiometer on the Push/Pull[...]
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Page 30
%&( *%$ &%-(R#+"-(( +)($& (#*() &4E4@8G8E 89<A<G<BA & );BJ* 8FG#B78F Most power sources contain weld modes used for calibration and test purposes. By default, t[...]
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Page 31
%&( *%$ &%-(R#+"-(( &4E4@8G8E 89<A<G<BA & A6B78E"B6>BHG Locks one or both of the upper knobs (encoders), preventing the operator from changing wire feed speed, amps, volts or trim. The functio[...]
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Page 32
%&( *%$ &%-(R#+"-(( &4E4@8G8E 89<A<G<BA & )8G+F8EAG8E9468&4FF6B78 Prevents unauthorized changes to the equipment. The default passcode is zero which allows full access. A nonzero passcode wi[...]
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Page 33
%&( *%$ &%-(R#+"-(( Memory#4 Memory#5 Memory#6 Memory #1 -Weld Parameters -Mode -Preflow/Postflow -Run in -Start Parameters -Arc Control -Crater Parameters Memory#2 Memory#3 ProcedureB -Weld Parameters -Mode -Preflow/Postflow -Run in -Star[...]
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Page 34
%&( *%$ Each procedure contains/stores the following informa- tion: • Basic weld parameters as applicable - WFS, Volts, Trim, Amps • Weld Mode - Mode Number • Preflow/Postflow - Time in Seconds • Run in - WFS Only (work point determined by next active sequence state) • Start Parameters - Status, Slop[...]
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Page 35
%&( *%$ (864??<A:9EB@#8@BEL To recall the contents of a memory into the active proce- dure, momentarily push the desired memory button (for less than 2 seconds). The saved parameters will be copied into the active procedure, and the LED of the memory button will light indicating the source of the info[...]
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Page 36
%&( *%$ )G8C)LA8E:<6%C8E4G<BA -<G;BHG)G4EGE4G8EHEA546>9HA6G<BAF46G<I8 -4I89BE@HA6G<BA4?<GL 1. Trigger is pulled and released; Preflow sequence begins and runs until Preflow timer expires. 2. Run-In sequence begins and runs until Arc is estab-[...]
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Page 37
-( (" "%$ ((") )&%%")%(%") * B #BHAG 4 "5 >: (847<(88? &46>4:8 +F<A: G;8 #B?787 &?4FG<6 !& (847<(88? 74CG8E The Sp[...]
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Page 38
%&( *%$ +( * B #BHAG GB "5 >: )CBB?F @@ <4@8G8E BE "5 !: AA8EF;<8?7B<?F The Spindle should be located in the "%-(?[...]
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Page 39
%&( *%$ $ "*(%$(! +)*#$* 1) Turn the Reel or spool until the free end of the electrode is accessible. 2) While tightly holding the electrode, cut off the bent end and straighten the first 6" (150 mm). Cut off the first 1" (25 mm)[...]
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Page 40
%&( *%$ #!$ -" 1) Use only a network compatible power source. 2) Properly connect the electrode and work leads for the correct electrode polarity. 3) Set all desired parameters such as trigger logic, Run-in Speed, Acceleration, Electrode polarity, etc. per “DIP SWITCH SETUP?[...]
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Page 41
%&( *%$ %#&%$$*)* *+)"*) Each network component has a single status light. The light is a bicolor, Green/Red, LED. The purpose of the status light is to allow the operator to quickly identify that the system is working properly or, if not, which component is causing the proble[...]
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Page 42
%&( *%$ &%-(R#+"-(( )* *+)"*)* *)%$Z* ")G4G8 Red LED blinking at a fast rate Red LED ON and steady Green LED ON and steady &BJ8E)BHE68" Power source needs to be [...]
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Page 43
%&( *%$ &%-(R#+"-(( "#*)**$ Each user memory can be optionally configured to limit the user’s range of control over some user interface set- tings. By default, user limits are not enabled. To set lim- its for a sel[...]
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Page 44
))%() &%-(R#+"-(( *"T(,(%""$+*+!*) -<E8)<M8 (B?? E<I8 E<I8A )B?<7)G88??86GEB78 0.023”[...]
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Page 45
• Readi-Reel Adapters - Adapts 22-30 lb. Readi-Reels to a 2" Spindle K363P - Adapts 50-60 lb. Readi-Reels to a 2" Spindle K438 • Coil Adapter - Adapts 50-60 lb. Lincoln coils to a 2" Spindle K1504-1 • Plastic Wire Cover for 30-44 lb. Wire Packages K1634-3 • Plastic Wire Cover for up to 60 lb. Wire Packages K1634-2 • Water C[...]
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Page 46
))%() &%-(R#+"-(( ! %" &*( Permits 14 lb. (6 kg) Innershield coils to be mounted on 2” (51 mm) O.D. spindles. !& ((" &*( Adap[...]
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Page 47
))%() &%-(R#+"-(( !#""(%$$*%$ For any gun having a newer style Miller connector. Install gun adapters per the instructions shipped with it. !%.%%$$?[...]
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Page 48
))%() &%-(R#+"-(( !-()*(*$( Install per the Instructions shipped with the Kit. ! &+)&+"" !* $ ! %%* #&[...]
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Page 49
#$*$$ &%-(R#+"-(( IB<7<A:-<E8887<A:&EB5?8@F Wire feeding problems can be avoided by observing the following gun handling and feeder set up proce- dures: a) Do not kink or pull cable around sharp corners. b) K[...]
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Page 50
*(%+")%%*$ &%-(R#+"-(( If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "B64?"<A6B?AHG;BE<M87<8?7)8EI<6846<?<[...]
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Page 51
*(%+")%%*$ &%-(R#+"-(( 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 "B64?"<A6B[...]
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Page 52
*(%+")%%*$ &%-(R#+"-(( 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 "B64?"<A6B[...]
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Page 53
*(%+")%%*$ &%-(R#+"-(( 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 "B64?"<A6B[...]
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Page 54
*(%+")%%*$ &%-(R#+"-(( 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 "B64?"<A6B[...]
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Page 55
*(%+")%%*$ &%-(R#+"-(( 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 "B64?"<A6B[...]
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Page 56
*(%+")%%*$ &%-(R#+"-(( Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455: Code 10555 and below $BG8 For any Err # listed below write down the error number for reference and try cycli[...]
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Page 57
*(%+")%%*$ &%-(R#+"-(( If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "B64?"<A6B?AHG;BE<M87<8?7)8EI<6846<?<[...]
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Page 58
*(%+")%%*$ &%-(R#+"-(( If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "B64?"<A6B?AHG;BE<M87<8?7)8EI<6846<?<[...]
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Page 59
*(%+")%%*$ &%-(R#+"-(( If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "B64?"<A6B?AHG;BE<M87<8?7)8EI<6846&l[...]
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Page 60
*(%+")%%*$ &%-(R#+"-(( If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "B64?"<A6B?AHG;BE<M87<8?7)8EI<6846&l[...]
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Page 61
*(%+")%%*$ &%-(R#+"-(( If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "B64?"<A6B?AHG;BE<M87<8?7)8EI<6846&l[...]
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Page 62
(#) &%-(R#+"-(( $%* This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagra[...]
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Page 63
(#) &%-(R#+"-(( 6.88 .218 4.25 .75 .75 .81 .90 12.07 12.96 18963 3.06 8.50 M 4.08 3.86 (4 KEYHOLE SLOTS) 10-17-97 CONTROL BOX DIMENSION PRINT 6 . 8 8 . 2 1 8 4 . 2 5 . 7 5 . 7 5 . 8 1 . 9 0 1 2 . 0 7 1 2 . 9 6 18963 3 . 0 6 8 . 5 0 M 4 . 0 8 3[...]
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Page 64
(#) &%-(R#+"-(( 19.89 A A 19.91 A A 15.41 A A 30.61 A A L11044 7-21-2000C 19.8 9 A A 19.9 1 A A 15.4 1 A A 30.6 1 A A L 11 0 4 4 7-21-2000C -(($#%"#$)%$&($*[...]
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Page 65
(#) &%-(R#+"-(( 8.56 A A 14.10 A A 15.55 A A 6.00 A A DOOR OPEN TYP. 5.25 A A 19.43 A A 11.12 A A 2.54TYP. A A 4.43 A A 2.25 A A 2.93 A A 4.25TYP. A A WIRE DRIVE DIMENSION PRINT 7-2000 M19304 8.56 A A 14.10 A A 15.55 A A 6.00 A A DOOR OPEN TY [...]
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Page 66
W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INSTR UCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LA S INSTR UCCIONES DEL F ABRIC [...]
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Page 67
W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A AS INS TRUÇÕES DO F ABRICANTE P ARA ES TE EQUIP AMENT O E AS P ARTES DE USO , E SIGA AS PRÁTIC A S DE SEGUR ANÇA DO EMPREG ADOR. • Kee p yo ur he ad o ut o f fu mes. • Use ven tilat ion or e xhau [...]
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Page 68
• 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 •[...]