Lincoln Electric pf40 User manual

IM3045
02/2016
REV06
PF40
OPERATOR’S MANUAL
ENGLISH
Lincoln Electric Bester Sp. z o.o.
ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
www.lincolnelectric.eu

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I
Declaration of conformity
Lincoln Electric Bester Sp. z o.o.
Declares that the welding machine:
PF40
conforms to the following directives:
2014/35/EU , 2014/30/EU
and has been designed in compliance with the
following standards:
EN 60974-5:2013, EN 60974-10:2014
20.04.2016
Piotr Spytek
Operations Director
Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland 07/11

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II
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......................................................................................................................................................................4
Installation and Operator Instructions..............................................................................................................................4
WEEE............................................................................................................................................................................12
Spare Parts....................................................................................................................................................................12
Electrical Schematic ......................................................................................................................................................12
Suggested Accessories.................................................................................................................................................13
Connection Diagram......................................................................................................................................................14

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1
Technical Specifications
NAME
INDEX
PF40
K14106-1
INPUT
Input Voltage U1
Input Amperes I1
EMC Class
40Vdc
4A
A
RATED OUTPUT
Duty Cycle 40°C
(based on a 10 min. period)
Output Current
100%
385A
60%
500A
OUTPUT RANGE
Welding Current Range
Peak Open Circuit Voltage
5 ÷ 500A
113Vdc or Vac peak
DIMENSION
Weight
Height
Width
Length
17 kg
460 mm
300 mm
640 mm
WIRE FEED SPEED RANGE / WIRE DIAMETER
WFS RANGE
Drive roll
Drive roll
diameter
Solid wires
Aluminum wires
Cored wires
1 ÷ 22 m/min
4
Ø37
0.8 ÷ 1.6 mm
1.0 ÷ 1.6 mm
0.9 ÷ 1.6 mm
Protection Rating
Maximum gas pressure
Operating Temperature
Storage Temperature
IP23
0,5MPa (5 bar)
from -10°C to +40°C
from -25°C to 55°C

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2
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.

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3
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.
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.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.

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4
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.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time
the operator’s manual.
Introduction
PF40 is digital wire feeder which has been designed to
work with all Lincoln Electric power sources using
ArcLink®protocol to communication.
Digital wire feeder allows the welding:
GMAW (MIG/MAG) –non-synergic process only.
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.
Location and Environment
This machine will operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation.
Do not place or operate this machine on a surface
with an incline greater 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.
Dirt and dust that can be drawn into the machine
should be kept to a minimum.
This machine has a protection rating of IP23. Keep
it dry when possible and do not place it on wet
ground or in puddles.
Locate the machine away from radio controlled
machinery. Normal operation may adversely affect
the operation of 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 allowable input voltage source is indicated on the
rating plate of the wire feeder. Verify the connection of
grounding wires from the power source to the input
source.

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5
Controls and Operational Features
3
1 2
5 4
6
Figure 1
1. Wire Feed Speed Control (WFS): Value
in percentage of nominal value wire feed
speed (also during welding).
2. Welding Load Voltage Control: The
welding load voltage and set by this
control (also during welding).
3. EURO Socket: For connecting a welding
gun (for GMAW, FCAW-GS, FCAW-SS).
4. Quick Connect Coupling: Coolant outlet
(supplies cool coolant to the gun).
5. Quick Connect Coupling: Coolant inlet
(takes warm coolant from the gun).
WARNING
Maximum coolant pressure is 5 bar.
6. Remote Control Connector Plug
(optional): To install Remote Control Kit.
It can be purchased separately. See
"Accessories" chapter.
7
8
9
10
11
Figure 2.
7. Gas Connector: Connection for gas line.
WARNING
The welding machine supports all suitable shielding
gases at a maximum pressure of 5,0 bar.
8. Control Receptacle: 5 pins receptacle for
wire feeder connection ( ArcLink®
protocol).
9. Current Socket: Input power connection.
10.Quick Connect Coupling: Coolant outlet
(takes warm coolant from welding
machines to cooler.)
11.Quick Connect Coupling: Coolant inlet
(supplies cool coolant from cooler to the
welding machines).
WARNING
Maximum coolant pressure is 5 bar.
To ensure failure-free work and right flow of coolant ,
use only coolant that is recommended by the
manufacturer of welding gun or cooler.
13 14
17
12 15 16
Figure 3.

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6
12.Gas Flow Regulator Plug: Gas Flow Regulator can
be purchased separately. See "Accessories" chapter.
13.Cold Inch / Gas Purge Switch: This switch enables
wire feeding or gas flow without turning on output
voltage.
14.Gun Mode Switch: It enables selection of 2-step or 4-
step gun mode. The functionality of 2T/4T mode is
shown in the Figure 4.
15.Wire Spool Support: Maximum 15kg spools. Accepts
plastic, steel and fiber spools onto 51mm spindle.
Also accepts Readi-Reel®type spools onto included
spindle adapter.
WARNING
Be sure that wire spool case has to be completely closed
during welding.
16.Spooled Wire: The machine does not include a
spooled wire.
17.Wire Drive: 4-Roll 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. See
"Accessories" chapter.
Wire Spool Loading
Wire spool type S300 and BS300 can be installed on the
wire spool support without adapter.
Wire spool type S200, B300 or Readi-Reel®can be
installed, but the applicable adapter must be purchased.
The applicable adapter can be purchased
separately(see "Accessories" chapter).
Wire Spool Type S300 & BS300 Loading
WARNING
Turn the input power OFF at the welding power source
before installation or changing a wire spool.
1819
20
21
Figure 5.
Turn the input power OFF.
Open the spool wire case.
Unscrew the Locking Nut [18] and remove it from
the Spindle [20].
Place the spool type S300 or BS300 [19] on the
Spindle [20] making certain the Spindle Brake Pin
[21] is put in the hole in back side of spool type
S300 or SB300.
WARNING
Position the spool type S300 or SB300 so that it will
rotate in a direction when feeding so as to be de-reeled
from bottom of the spool.
Re-install the locking nut [18]. Make sure that the
locking nut is tightened.
Trigger pressed
Trigger released
A
Welding current
B
Burnback time (fixed)
C
WFS
G
Gas
Figure 4.

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7
Wire Spool Type S200 Loading
WARNING
Turn the input power OFF at the welding power source
before installation or changing a wire spool.
18
20
21
22
23
24
Figure 6.
Turn the input power OFF.
Open the spool wire case.
Unscrew the Locking Nut [18] and remove it from
the Spindle [20].
Place the adapter of spool type S200 [22] on the
spindle [20] making certain the spindle brake pin
[21] is put in the hole in back side of the adapter
[22]. The adapter of spool type S200 can be
purchased separately (see "Accessories" chapter).
Place the spool type S200 [24] on the spindle [20]
making certain that the adapter brake pin [23] is put
in the hole in the back side of the spool.
WARNING
Position the spool type S200 so that it will rotate in a
direction when feeding so as to be de-reeled from
bottom of the spool.
Re-install the locking nut [18]. Make sure that the
locking nut is tightened.
Wire Spool Type B300 Loading
WARNING
Turn the input power OFF at the welding power source
before installation or changing a wire spool.
18
20
21
25
26
Figure 7.
Turn the input power OFF.
Open the spool wire case.
Unscrew the Locking Nut [18] and remove it from
the spindle [20].
Place the adapter of spool type B300 [25] on the
spindle [20].Make certain that the spindle brake pin
[21] is put in the hole in the back side of the adapter.
The adapter of spool type B300 can be purchased
separately (see "Accessories" chapter).
Re-install the locking nut [18]. Make sure that the
locking nut is tightened.
26
27
2825 29
Figure 8.
Rotate the spindle and adapter so the retaining
spring [26] is at the 12 o'clock position.
Place the spool type B300 [28] on the adapter [25].
Set one of the B300 inside cage wires [29] on the
slot [27] in the retaining spring tab [26] and slide the
spool onto the adapter.
WARNING
Position the spool type B300 so that it will rotate in a
direction when feeding so as to be de-reeled from
bottom of the spool.