Lincoln Electric Power Feed 10R User manual

Description
Output Input
MIG Pulsed STT Flux-Cored
Power Feed™ 10R
Compact Wire Drive System for Automation
AUTOMATIC WIRE FEEDERS
The Power Feed 10R is a high performance, digitally controlled wire feeder designed to
be a part of a modular, multi-process welding system. It is specifically designed to mount to a
robot arm or to use in hard automation applications. Modular systems can be arranged in a
variety of ways for optimum, customized performance and easy maintenance. This four drive roll
feeder operates on 40VDC input power and is designed to be used with ArcLink™ Robotic
Power Wave™ power sources. Close integration of the feeder, power source and existing
equipment creates the foundation for a system with superior welding performance and reliability.
Publication E9.160 4/03
Web Update 1/07
www.lincolnelectric.com
Processes
Advantage Lincoln
Recommended Power Sources
Order
TECHNICAL SPECIFICATIONS
•Digitally controlled by the Power Wave power source, yielding
the best performance in the industry.
•Use with Lincoln power sources featuring ArcLink, the leading
digital communications protocol for welding, making it the best
choice for seamless integration with the power source and
networked equipment.
•Tachometer feedback provides calibration and precise control
of wire feed speed.
•Feeder brakes from maximum speed to zero in milliseconds,
minimizing the chance of wire sticking in the puddle.
•Select standard or high speed gears for wide wire feed speed
range.
•Split wire guides provide trouble-free feeding and offer fast,
tool-less wire installation, changeover and maintenance.
•Easy-to-read gauge for accurate drive roll tension.
•Brass-to-brass connections for good connectivity between
feeder and gun.
•Modular construction for easy servicing.
•Self loading wire feature for easy set-up.
Recommended General Options
Power Wave F355i, Power Wave 455M Robotic,
Power Wave 455M/STT Robotic, Power Wave 655R
Water Connection Kit, 14-Pin to 14-Pin Control Cable, 4 Drive Rolls
and Split Wire Guide, Torch Bushings, Incoming Conduit Bushings,
Wire Straightener, Magnum Low Drag Wire Conduit, Accu-Trak™
Drum Payoff Kit
K1780-2 Power Feed 10R
Call the Lincoln Electric Automation Division at 216.383.2667 for
more information.
Wire Size Range Wire Size Range Dimensions Net
Product Product Wire Feed Speed Range Solid Cored H x W x D Weight
Name Number inches/min (m/min) inches (mm) inches (mm) inches (mm) lbs (kg)
Power Feed 10R K1780-2 50-800 in/min (1.3-20.3m/min) .025-3/32 in (0.6-2.4mm) .035-.120 in. (0.9-3.0mm) 8.9 x 10.3 x 8.1 22.4 lbs
75-1200 in/min (2.0-30.5 m/min) .025-1/16 in (0.6-1.6mm) .035-5/64 in (0.9-2.0mm) (226 x 261 x 206) (10.2 kg)
Power Feed 10R mounted
on FANUC Robot Arm.
Power Wave F355i shown integrated with
FANUC Arc-Mate RJ3iB controller.
Power Wave 455M Robotic.
40
VDC

Power Feed 10R
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[2]
A CLOSER LOOK
PERFORMANCE
•Designed for robotic and hard automation for the automotive,
transportation, fabrication, furniture, lawn and garden, and agri-
cultural industries, among others.
•Digital communication between the power source and the wire
feeder for demanding robotic applications.
•Braking system minimizes wire sticking in the puddle for smooth
finishes.
Nextweld incorporates Lincoln's technologies,
processes and products to create a technologically
advanced arc welding platform. Waveform Control
Technology™, power electronics and digital
communications provide the foundation for
Nextweld innovations, including Surface Tension
Transfer®, Pulse-On-Pulse™, Chopper
Technology™, ArcLink™ and many more. Try
Nextweld products for ultimate arc control, high
efficiency/reliability, and seamless system
integration.
WHAT IS NEXTWELD™?
ArcLink™ and FANUC Robotics
ArcLink is a digital communications protocol for sharing information
between intelligent components in an arc welding system. Power
Wave products and FANUC robotic systems interfaced with ArcLink™
provide the following benefits over Analog-Digital Interface:
•Common user interface on Teach Pendant eliminates the
requirement for any user panel on the power source.
•Teach Pendant can display actual volts, wire feed speed, etc. in
process specific units.
•No setup function is required. The Robot is an ArcLink device and
recognizes which power source is connected.
•Process procedures reside in the power source database and can
be searched by process and material type directly on the Teach
Pendant.
•High speed CAN 2.0B interface provides robust industrial network
with collision detection and active/general connection states.
•Switch among eight modes (CV, Pulse, Pulse-On-Pulse, etc.)
dynamically on the fly based on weld requirements.
•Arc start response time of 5/10 msec or less.
•FANUC’s FAStart provides 300 msec arc start improvement over
other systems, 100 msec arc end improvement resulting in time
savings of 400 msec per weld.
•Touch Sensing Performance of 100 mm/sec search speed with
.045 steel wire.
•Touch Sensing does not require additional hardware.
•ArcTool Control software enables true weld sequencer commands
motion and weld procedures.
•Detailed power source Fault & Alarm information available on the
Teach Pendant.
•Ability to monitor and download software to the power source
through the Ethernet connection on FANUC’s R-J3iB controller.
New procedures can be sent to any and all machines over the
network.
•Full support of Lincoln diagnostic packages through R-J3iB
Ethernet port.
•FANUC TAST performance is available with no additional
hardware to provide updates of actual weld current and voltage
at 250 Hz for improved seam tracking performance.
•Calibration between robot and power source is not required.

Power Feed 10R
www.lincolnelectric.com
[3]
A CLOSER LOOK
DESIGN
•Easy-to-read gauge for accurate drive roll tension producing a
reference point for the operator to set tension on the wire more accu-
rately.
Patented Drive Roll System
•The Power Feed 10R is a basic wire feeder with an optimized design,
which consists of an industrial motor driving the feeder mecha-
nism in a sheet metal frame. The logic for controlling the wire feeder
resides in a PC board inside the robotic power source.
•Lower section contains gas solenoid and differential tachometer
amplifier allowing accurate motor speed control up to 100 ft. from
power source.
•Split wire guide provides easy wire loading and accessibility for
maintenance.
•Variety of drive rolls for any application.
•Tool-less access to routine maintenance points.
•High speed gear for most fine wire applications. Low speed gear for
applications requiring higher torque such as welding with
Innershield® electrode.
•Brass-to-brass electrode pairing connections for good connectivity
between welding torch and torch bushing.
•The feeder is self-threading for easy wire loading enabling operator
to feed wire without the need to remove drive rolls.
4-Drive Roll and Split Wire Guide System
QUALITY AND RELIABILITY
•Electronically protected from overloads.
•Feeder can be easily disassembled for servicing.
•Modular construction for easy servicing of individual units.
•Rugged steel and cast aluminum construction.
•Storage temperature for the Power Feed 10R is -40°C to +40°C.
•Operating temperature for the Power Feed 10R is -20°C to
+40°C.
•Three year warranty on parts and labor.
•Manufactured under a quality system certified to ISO 9001
requirements.
Brass Connector
4-Drive Roll
Split Wire Guide
1. Drive Roll Tension Gauge
2. Drive Roll Tension Adjustment Knob
3. 14-Pin Receptacle for Control Cable (Amphenol)
4. CGA Gas Connection
5. Wire Inlet Guide
6. Optional Water Kit (Not Shown)
7. Drive Roll Cover
8. Gun Bushings (K1500-1)
12
34
5
6
7
8
Key Controls

Power Feed 10R
[4]
RECOMMENDED OPTIONS
4 DRIVE ROLLS AND SPLIT WIRE GUIDE
Description Order Number
Solid Steel Wire, Smooth V Groove .023-.030 (0.6-0.8mm) Solid KP1505-030S
.035 (0.9mm) Solid KP1505-035S
.040-.045 (1.0-1.2mm) Solid KP1505-045S
.052 (1.4mm) Solid KP1505-052S
Cored Steel Wire, Knurled V Groove .030-.035 (0.8-0.9mm) Cored KP1505-035C
.040-.045 (1.0-1.2mm) Cored KP1505-045C
.052 (1.4mm) Cored KP1505-052C
1/16” (1.6mm) Cored KP1505-1/16C
7/64” (2.8mm) Hardfacing (Smooth U Groove) KP1505-7/64H
Cored or Solid Steel Wire, Knurled V Groove .068-.072 (1.8mm) KP1505-068
5/64” (2.0mm) KP1505-5/64
3/32” (2.4mm) KP1505-3/32
7/64” (2.8mm) Cored only KP1505-7/64
Aluminum Wire, Smooth U Groove .035 (0.9mm) KP1507-035A
.040 (1.0mm) KP1507-040A
3/64” (1.2mm) KP1507-3/64A
1/16” (1.6mm) KP1507-1/16A
3/32” (2.4mm) KP1507-3/32A
18 in. (0.45m)
12 ft. (3.6m)
16 ft. (4.8m)
25 ft. (7.6m)
50 ft. (15.2m)
100 ft. (30.4m)
K1785-2
K1785-12
K1785-16
K1785-25
K1785-50
K1785-100
Description Product
Number
14-PIN TO 14-PIN CONTROL CABLES
22-pin to 14-pin
14-pin to 22-pin
10 ft. (3m)
18 in. (0.45m)
18 in. (0.45m)
K1804-1
K1804-2
K1805-1
Cable Cable Product
Adapter Length Number
CABLE ADAPTERS
KP1505-XX
Drive Rolls for Solid and Cored Wires
KP1507-XX
Drive Rolls for Aluminum Wires
14
K1785-X
K1805-1
K1795-X
14
K1804-X
POWERWAVE455M
PIN PIN
14
PIN
22
PIN
POWER FEED 10R
K1780-1
K1805-1
ROBOT
22
PIN
POWER WAVE 455M Robotic K2262-3
OR
POWER WAVE 455M/STT Robotic K2263-1
22
PIN
14
POWER FEED 10R
K1780-2
OR
14
PIN
K1785-2
POWERWAVE455M
POWER WAVE 455M Robotic K2262-3
OR
POWER WAVE 455M/STT Robotic K2263-1
K1805-1
K1785-X
K1795-X
POWER FEED 10R
K1780-1
14
PIN
14
PIN
OR
POWER FEED 10R
K1780-2
22
PIN
14
PIN
K1795-X K1804-2
K1795-X
POWERWAVE455M
POWERFEED 10R
K1780-2
POWERFEED 10R
K1780-1
POWERWAVE 455R
K1761-X
POWERWAVE 655R
K1519-1
OR
22
PIN
22
PIN
14
PIN
22
PIN
22
PIN
K1795-X
K1804-2
22
22
14
POWERWAVE455M
14
PIN
22
PIN
POWERFEED 10R
K1780-1
K1805-1
POWERWAVE 455R
K1761-X
POWERWAVE 655R
K1519-1
ROBOT
PIN
PIN
PIN
K1804-1
K1785-2
14
PIN
POWERFEED 10R
K1780-2
OR
K1785-2
OR
CABLE SELECTION
(1)
(1)
(1)
(1) Obsolete product.
Hard Automation Robotic (1)
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Power Feed 10R
www.lincolnelectric.com
[5]
RECOMMENDED OPTIONS
GENERAL OPTIONS
Water Connection Kit
Consists of quick disconnect inlet
and outlet fittings with water hose
and clamps to be mounted on
Power Feed10R.
Order K590-7
Gun Bushings
Convert feedplate on Power Feed
10R to accommodate specific
torches.
Order:
K1500-2 (Optional) Tweco® or
Tregaskiss® Torches (standard on
PowerFeed 10R)
K1500-1 Lincoln or D&F® Torches
K489-7 Binzel® or Lincoln Fast-
Mate Torches
Incoming Conduit Bushings
Bushings connect directly to wire
conduit for use in boom system,
long distances or large payoff
packages. Fits Lincoln Electric K515
conduit.
Order:
K1546-1 for .025-1/16” (0.6-1.6mm)
K1546-2 for 1/16-3/32” (1.6-2.4mm)
GENERAL OPTIONS CONT.
Wire Straightener
For Lincoln Electric 10 series wire
feeders.
Order K1733-1
Magnum Low Drag Wire Conduit
Plastic wire conduits are for use
with the Accu-Trak Drum Payoff Kit.
Order:
K515-15 for 15ft. (5m)
K515-25 for 25ft. (7.6m)
K515-50 for 50ft. (15m)
Accu-Trak Drum Payoff Kit
A payoff kit must be used with
Accu-Trak drums to insure precise
feeding.
Order:
K884-5 (20 in. drum)
K884-6 (23 in. drum)

THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
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. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers
based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such
information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice.
As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision
of information or advice create, expand or alter any warranty with respect to the sale of our products.
Lincoln Electric is a responsible manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the
customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change — This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
POWER FEED 10R K1780-2
RECOMMENDED EQUIPMENT
Power Wave F355i Contact Lincoln Automation at 216.383.2667 for information
Power Wave 455M Robotic K2262-3
Power Wave 455M/STT Robotic K2263-1
Power Wave 655R K1519-1
RECOMMENDED GENERAL OPTIONS
Water Connection Kit K590-7
4 Drive Rolls and Split Wire Guide See Chart on Page 4
14-Pin to 14-Pin Control Cables See Chart on Page 4
Cable Adapters See Chart on Page 4
Gun Bushings
Tweco®or Tregaskiss®K1500-2 (Optional)
Lincoln or D&F®K1500-1
Binzel or Lincoln Fast-Mate K489-7
Incoming Conduit Bushings
.025-1/16 in. (0.6-1.6mm) K1546-1
1/16-3/32 in. (1.6-2.4mm) K1546-2
Wire Straightener K1733-1
Magnum Low Drag Wire Conduit
15 ft. (5m) K515-15
25 ft. (7.6m) K515-25
50 ft. (15m) K515-50
Accu-Trak™ Drum Payoff Kit
20 in. drum K884-5
23 in. drum K884-6
TOTAL:
POWER FEED 10R ORDER FORM
PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE