Lincoln Electric POWER FEED 84 SINGLE User manual

Operator’s Manual
POWER FEED 84
Register your machine:
www.lincolnelectric.com/registration
Authorized Service and Distri utor Locator:
www.lincolnelectric.com/locator
IM10178-E | Issue D ate July-16
© Lincoln Glo al, Inc. All Rights Reserved.
For use with machines having Code Num ers:
Power Feed 84: 11986, 11987, 11988,
11989, 11990, 11991, 11993, 11994,
11996, 11997, 11998, 12274, 12275,
12276, 12277, 12278, 12279, 12280,
12281, 12282, 12283, 12284, 12517,
12520, 12521, 12522, 12523, 12524,
12525, 12526, 12527, 12528, 12529,
12530, 12578
Power Feed 84 Dual: 12108, 12109,
12110, 12111, 12112, 12113, 12115,
12116, 12285, 12286, 12287, 12288,
12289, 12290, 12291, 12292, 12518,
12578, 12531, 12532, 12533, 12534,
12535, 12536, 12537, 12538, 12579
Power Feed 84 U.I. Control Box:
12177, 12178, 12179
POWER FEED 84 SINGLE
POWER FEED 84 DUAL
POWER FEED 84 U.I. CONTROL BOX
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
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. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

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.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS 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 skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

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. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. 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. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
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. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

2
TABLE OF CONTENTS
POWER FEED 84, POWER FEED 84 DUAL
Page
Product Description..............................................................................................................................8
________________________________________________________________________
Installation...............................................................................................................................Section A
Technical Specifications...............................................................................................................A-1
Model umbers for Single, Dual Wire Feeders, Control Boxes and Boom Packages......................A-2
Safety Precaution.........................................................................................................................A-3
Location and 15° Tilt note ....................................................................................................A-3
Bench Configurations...........................................................................................................A-4
Boom Configurations............................................................................................................A-5
Boom Mounting....................................................................................................................A-6
Single/Dual User Interface Conversion ..................................................................................A-6
Bench to Boom Conversion...................................................................................................A-7
Control Box, Gas Flow Sensor...............................................................................................A-8
Installing Drive Rolls.............................................................................................................A-9
Wire Drive Pressure Settings..............................................................................................A-10
Lincoln, on Lincoln Equipment Adapters...........................................................A-11 thru A-16
Rotating the Wire Drive.......................................................................................................A-16
Pinion Gear Ratio......................................................................................................A-17, A-18
Shielding Gas Connection ...................................................................................................A-19
Water-Cooled Gun Connections ..........................................................................................A-20
Loading Spools of Wire .............................................................................................A-21, A-22
Wire Reel Stands ................................................................................................................A-23
Electrical Installation ..........................................................................................................A-24
Weld Cables, Standard .......................................................................................................A-25
Welding with Multiple Arcs .................................................................................................A-26
Control Cable and Connectors ...................................................................................A-27, A-28
________________________________________________________________________
Operation .................................................................................................................................Section B
Power Up Sequence.....................................................................................................................B-1
Graphic Symbols..........................................................................................................................B-1
Recommended Processes............................................................................................................B-2
Process Limitations......................................................................................................................B-2
Equipment Limitations .................................................................................................................B-2
Recommended Power Sources ....................................................................................................B-2
User Interface Layout...................................................................................................................B-3
Wire Feed Speed / Amps Display and Knob ..................................................................................B-4
Voltage Trim Display ....................................................................................................................B-5
Voltage / Trim Display and Knob, Shielding Gas ...........................................................................B-6
Selecting Weld Mode ...................................................................................................................B-7
Wave Control........................................................................................................................B-8, B-9
Trigger Selection........................................................................................................................B-10
2-Step Trigger ...........................................................................................................B-11 thru B-13
4-Step Trigger..................................................................................................................B-14, B-15
Spot Trigger...............................................................................................................................B-16
4-Step Special Consideration.....................................................................................................B-17
Start Options, End Options .........................................................................................................B-18
Wire Drive Selections, Cold Feed, Gas Purge..............................................................................B-19
Gouging Kit Operation ................................................................................................................B-20
Dual Procedure and Memory Operation, Procedure Memory vs. User Memory ...........................B-21
Using Procedure Memories ........................................................................................................B-21
User Memories ..........................................................................................................................B-22
Limits...............................................................................................................................B-23, B-24
USB Operation ...........................................................................................................................B-25
User Defined Parameters ...........................................................................................B-26 thru B-37
Gouging Kit, Gas Flow Sensor Kit ...............................................................................................B-38

3
TABLE OF CONTENTS
POWER FEED 84, POWER FEED 84 DUAL
Page
________________________________________________________________________
Accessories.............................................................................................................................Section C
Optional Kits and Accessories ......................................................................................................C-1
Gun Adapter Kits ..................................................................................................................C-2
Cables .................................................................................................................................................
C-2
General Accessories...........................................................................................................................
C-2, C-3
________________________________________________________________________
Maintenance.............................................................................................................................Section D
WFS Calibration...........................................................................................................D-1
________________________________________________________________________
Troubleshooting.......................................................................................................................Section E
Safety Precautions.......................................................................................................................E-1
How to Use Troubleshooting Guide...............................................................................................E-1
Troubleshooting Guide..........................................................................................................E-2, E-3
________________________________________________________________________
Wiring Diagrams and Dimension Prints..................................................................................Section F
________________________________________________________________________
Parts List ........................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.

4
PRODUCT DESCRIPTION
General Physical Description
The Power Feed 84 is an industrial, modular wire feeder. At the heart
of the feeder is the proven wire drive and motor, capable of feeding
large diameter electrodes and pulling through long conduits.
The modular platform allows the Power Feed 84 to be used in many
applications. The user interface may be separated from the wire
drive for “boom” applications. The feed plate may be located on
either the left or right hand side of the wire drive housing. Two single
Power Feed 84 wire drives may be connected to one user interface.
A dual wire drive is offered for a compact set-up. The same user
interface is used for both single and dual wire drive systems.
General Functional Description
The Power Feed 84 is ideal for applications requiring display of preset
voltage at the wire feeder. In addition, the feeder has digital display
of the wire feed speed and for amperage.
Included with the wire drive is a pinion gear for high speed operation.
The wire drive easily rotates to any angle.
A new series of gun adapters has been created for better reliability
and lower voltage drop.
POWER FEED 84, POWER FEED 84 DUAL

A-1
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
TECH ICAL SPECIFICATIO S – POWER FEED 84, POWER FEED 84 DUAL
K3328-xx, K3330-xx, K3336-xx
TEMPERATURE RANGE
OPERATIO : -40°F to 104°F (-40°C to 40°C)
STORAGE: -40°F to 185°F (-40°C to 85°C)
INPUT VOLTAGE nd CURRENT
PHYSICAL DIMENSIONS
VOLTAGE
40 VDC
OTES
Wire Drive
User Interface
IPUT AMPERES
9A
1A
RATED OUTPUT @ 104°F (40°C)
Wire Drive Only
With Gouging Kit
With Contactors
Wire Drive
Wire Drive
Gouging Stud
Wire Drive
DUTY CYCLE
60%
60%
30%
60%
I PUT AMPERES
600 Amps
500 Amps
600 Amps
500 Amps
GEARING - WIRE FEED SPEED RANGE-WIRE SIZE
WFS RA GE
50 – 700 inch/min
(1.3 – 19.0 m/min)
50 – 1200 inch/min
(1.3 – 30.4 m/min)
.025” – 1/16”
(0.6 – 1.6 mm)
.025” – .045”
(0.6 – 1.2 mm)
.035” – 5/64”
(0.9 – 2.0 mm)
.035” – 1/16”
(0.9 – 1.6 mm)
PI IO
GEAR
20 tooth*
30 tooth
GEARBOX
GEARI G
22.57:1
GMAW FCAW
Thermal tests have been performed at ambient temperature. The Duty Cycle (duty factor) @ 40ºC (104°F) has
been determined by simulation.
*= gearing installed in the wire drive as equipped from the factory.
WIRE SIZES
Power Feed 84
Wire Drive, Single
MODEL HEIGHT WIDTH DEPTH WEIGHT
Power Feed 84
Wire Drive, Dual
Power Feed 84
Control Box
Standard Duty
Wire Reel Stand
11.6 Inches
(257 mm)
11.9 Inches
(302 mm)
11.0 Inches
(279 mm)
13.6 Inches
(345 mm)
17.2 Inches
(437 mm)
15.9 Inches
(404 mm)
3.6 Inches
(31 mm)
8.7 Inches
(221 mm)
13.3 Inches
(338 mm)
10.3 Inches
(31 mm)
11.0 Inches
(279 mm)
13.3 Inches
(338 mm)
37 lbs.
(16.8 kg.)
59 lbs.
(26.8 kg.)
6.5 lbs.
(2.9 kg.)
11 lbs.
(5.0 kg.)
Heavy Duty
Wire Reel Stand
25.2 Inches
(640 mm)
14.6 Inches
(371 mm)
11.0 Inches
(279 mm)
19 lbs.
(8.6 kg.)

A-2
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
MODEL K#
K3328-1
K3328-2
K3328-3
K3328-4
K3328-5
K3328-6
K3328-7
K3328-8
K3328-9
K3328-11
K3328-12
K3328-13
User Interface
Blank Panel
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Wire Reel
Stand
N
N
N
N
N
Std Duty
Std Duty
Std Duty
Std Duty
N
N
Hvy Dty
Control
Cable
N
N
N
N
N
K1543-8'
K1543-8'
K1543-8'
K1543-8'
N
N
K1543-8'
USB
N
N
Y
N
Y
N
Y
N
Y
N
Y
Y
Gun
Adapter
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Gouging
Kit
N
N
N
N
N
N
N
N
N
Y
Y
N
Inlet
Bushing
K3929-1
K3929-1
K3929-1
K3929-1
K3929-1
N
N
N
N
K3929-1
K3929-1
N
Contactor
N
N
N
Y
Y
N
N
Y
Y
N
N
N
SI GLE WIRE DRIVE FEEDERS
MODEL K#
K3330-1
K3330-2
K3330-3
K3330-4
K3330-5
K3330-6
K3330-8
K3330-9
K3330-10
User Interface
Blank Panel
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Full display with memories
Wire Reel
Stand
N
N
N
N
Hvy Dty
Std Duty
Std Duty
Std Duty
Hvy Dty
Control
Cable
N
N
N
N
K1543-8'
K1543-8'
K1543-8'
K1543-8'
K1543-8'
USB
N
N
Y
N
Y
N
N
Y
Y
Gun
Adapter
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Std #2-#4
Inlet
Bushing
K3929-1
K3929-1
K3929-1
K3929-1
N
N
N
N
N
Contactor
N
N
N
Y
Y
N
Y
Y
N
DUAL WIRE DRIVE FEEDERS
CO TROL BOXES
MODEL K#
K3336-2
K3336-3
User Interface
Full display with memories
Blank Panel
USB
Y
N

A-3
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
SAFETY PRECAUTIONS
ELECTRIC SHOCK CAN KILL.
• ONLY QUALIFIED PERSONNEL
SHOULD PERFORM THIS
INSTALLATION.
• Turn the input power OFF at the
disconnect switch or fuse box before
attemptin to connect or disconnect
input power lines, output cables or
control cables.
• Do not touch the wire drive, drive rolls, wire coil or
electrode when weldin output is ON.
• Wire feeder may be connected to a piece of automatic
equipment that may be remotely controlled.
• Do not operate with covers, panels or uards removed.
• Do not let the electrode or wire spool touch the wire
feeder housin .
• Insulate yourself from the work and round.
• Always wear dry insulatin loves.
• The lift bail is insulated from the wire feeder
enclosure. If an alternate han in device is used, it
must be insulated from the wire feeder enclosure.
MOVING PARTS can injure.
• Keep away from movin parts.
• Wear Eye Protection
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LOCATION
For best wire feeding performance, place the Power Feed 84 on a
stable and dry surface.
This equipment is for industrial use only and it 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 residential locations due to conducted as well as
radiated radio-frequency disturbances. The EMC or RF classification
of this equipment is Class A.
o not submerge the Power Feed 84.
The Power Feed 84 is rated IP2X and is suitable for indoor use.
When suspending a wire feeder, insulate the hanging device from
the wire feeder enclosure.
For bench models, do not angle spindle for the wire spool or coil
more than 15 degrees downward. (See Figure A.A)
WAR I G
15 DEGREES MAXIMUM
FIGURE A.A

A-4
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
Bench Con igurations (See Figure A.1)
“Bench” configuration means the user interface is mounted
directly to the wire drive housing. Valid Bench configurations are:
• Single Wire rive
• ual Wire rive
• Two Single Wire rives
K1543-xx or K2683-xx
FIGURE A.1

A-5
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
Boom Con igurations (See Figure A.2)
“Boom” configuration means the user interface is located in a sepa-
rate control box. Valid Boom configurations are:
• 1 Control box + 1 Single Wire rive
• 1 Control box + 1 ual Wire rive
• 1 Control box + 2 Single Wire rives
The User Interface may be remotely located from the wire drive up
to 200 feet.
B M M UNTING
K1543-xx or K2683-xx
K1543-xx or K2683-xx
K1543-xx or K2683-xx
FIGURE A.2

A-6
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
(See Figure A.3)
When the wire drive is to be bolted to a boom or other
flat surface, first remove the (4) rubber mounting feet.
(3) screws secure each foot.
Mounting bolts securing the wire drive should not pro-
trude more than 1” into the wire feeder.
SINGLE/DUAL USER INTERFACE C NVERSI N
(See Figure A.4)
The Power Feed 84 uses the same user interface for
both single and dual models. A DIP switch on the back
side of the user interface board sets the board configu-
ration.
1. Turn power OFF at the welding power source.
2. Remove the (4) screws securing the user interface.
3. Set the DIP switch on the back side of the user inter-
face per the table.
Configuration DIP switch setting
Single On
Dual Off
4. Reassemble the user interface.
FIGURE A.3
FIGURE A.4

A-7
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
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(See Figure A.5)
Converting from a “Bench” feeder to a “Boom” feeder
means moving the user interface from the wire drive to a
control box.
Requires: K3336-3 User Interface.
1. Turn power OFF at the welding power source.
Wire Drive (See Figure A.6)
2. Remove the (4) screws securing the user interface to
the wire drive. Disconnect the harness from the 4 pin
connector on the back of the user interface.
3. If the wire drive has a USB interface installed:
a. Disconnect 10 pin connector from the USB board.
b. Remove the (2) screws securing the USB port from
the case front. Carefully remove the connector and
harness from the wire drive.
c. Remove the USB cover panel from the control box
and install on the wire drive.
d. Disconnect both 5 pin connectors from the USB
board. Remove both jumper harnesses from the
wire drive.
e. Remove the (4) screws securing the USB board and
lift out the USB board.
4. Remove the blank user interface panel from the
control box and install on the wire drive.
FIGURE A.5
FIGURE A.6
USB board
USB PORT
10 PIN
CONNECTOR
5 PIN
CONNECTOR

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INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
Control Box (See Figure A-7)
5. If the control box will have USB installed:
a. Install the USB board into the control box, oriented
with the 10 pin connector on the right-hand side.
b. Assemble the USB port to the case front. Connect
the harness to the USB board.
c. Connect one of the USB jumper harnesses to the
control box harness. Connect the other to the 4 pin
connector on the back of the User Interface.
6. Connect the Cold Feed/Gas Purge harness to the back
side of the user interface.
7. Connect the User Interface to the harness as shown.
8. Secure the User Interface to the Control box with (4)
screws.
Gas Flow Sensor
The gas flow sensor uses a mass flow sensor for
measuring gas flow in the range of 0 – 105 cfh (0 – 50
l/min).
The gas flow sensor kit is compatible with the following
gases:
• Air
• Argon
• CO2
• Helium
• 98Ar 2CO2
• 90Ar 10CO2
• 85Ar 15CO2
• 80Ar 20CO2
• 75A5 25CO2
• 90He 7.5Ar 2.5CO2
• 55He 42.5Ar 2.5CO2
• 98Ar 2O2
• 98Ar 2N2
Dual feeders require (2) gas flow sensors.
With USB
User Interface
Control Box
USB port
Jumper
Harness
10 pin connector
right hand side
4 pin connector
User Interface
Cold Feed/Gas Purge Harness
Without USB
Connect the
harness directly
to the board.
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A-9
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
Installing Drive Rolls

1. Turn power  at the welding power source.
2. Open the wire drive door by pulling on the top.
3. Remove the outer wire guide.
4. Remove drive rolls by pulling straight out. It may be
necessary to wiggle the drive roll to free it from the
snap ring.
5. Remove the inner wire guide.
6. Install the new inner wire guide, with the arrow
pointing in the direction of wire travel.
7. Install the drive rolls and outer wire guide.
8. Close the wire drive door and adjust the pressure
setting accordingly.
INNER WIRE DRIVE
DIVE ROLLS
OUTER WIRE DRIVE

A-10
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
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Most wires operate well with a pressure setting of “2”. The best
drive roll pressure varies with wire type, wire surface, lubrication and
hardness. Too much pressure may crush the wire or cause
"birdnesting", but too little pressure could cause slippage.
Set the drive roll pressure by:
1. Press the end of the gun against a solid object that is electrically
isolated from the welder output and press the gun trigger for
several seconds.
2. If the wire "birdnests" or jams, the drive roll pressure is too high.
Reduce the pressure by one turn of the knob, run new wire through
the gun, and repeat step 1.
3. If the only result is slippage, disconnect the gun and pull the gun
cable forward about 6" (150mm). There should be a slight
waviness in the exposed wire. If there is no waviness, increase the
pressure setting one turn, reconnect the gun and repeat the above
step electrode lead to the gun adapter.

PRESSURE
ADJUST KNOB

A-11
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
Lincoln, Standard #2-#4, Standard #5, Miller Gun
Adapter Installation
1. Turn power OFF at the welding power source.
2. Using a Phillips screw driver, remove the screw, lock washer and
washer securing the gun adapter cover. Remove the gun adapter
cover.
3. With a 3/4” wrench, remove the bolt holding the electrode lead to
the gun adapter.

SCREW
GUN
ADAPTER
COVER
ELECTRODE
LEAD
BOLT


A-12
INSTALLATIONPOWER FEED 84, POWER FEED 84 DUAL
4. Use a 1/8” hex key to loosen the set screw securing the gun
adapter.
5. Remove the sense lead with a Phillips screw driver.
6. If a gas hose is attached to the gun adapter, use pliers to remove
the hose clamp and remove the gas hose.
7. If the gun adapter requires guide tubes, install the correct size
guide tube and secure with the set screw.
8. Assemble the sense lead to the new gun adapter. Orient the lead
towards the rear of the gun adapter.
9. If required, assemble the gas hose to the gun adapter or the fitting
on the feed plate and secure with a hose clamp.
10. Assemble the gun adapter to the wire drive. Tighten the set
screw once the gun adapter is at a 90° angle.
Wire size Number o grooves in guide tube
.023-.045” ( 0.6 – 1.2mm) 1
.045 – 1/16” (1.2 – 1.6 mm) 2
1/16 – 5/64” (1.6 – 2.0 mm) 3
.068 – 7/64” (2.0 – 2.8 mm) 4
SET SCREW
GUN ADAPTER
SENSE
LEAD
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

SET SCREW
GUIDE TUBE