Lincoln Electric WELDYSTIFFENER Mounting instructions

PORTABLE WELDING CARRIAGE
WELDYSTIFFENER
SAFETY INSTRUCTION FOR USE AND MAINTENANCE
60 to 160 mm –120 to 320 mm
EDITION : EN Instructions for use REF : 8695 5876
REVISION : E
DATE : 10-2018 Original instructions

Thank for the trust you have expressed by purchasing this equipment, which
will give you full satisfaction if you follow its instructions for use and
maintenance.
Its design, component specifications and workmanship comply with
applicable European directives.
Please refer to the enclosed CE declaration to identify the directives
applicable to it.
The manufacturer will not be held responsible where items not recommended
by themselves are associated with this product.
For your safety,there follows a non-restrictive list of recommendations or
requirements, many of which appear in the employment code.
Finally we would ask you kindly to inform your supplier of any error which
you may find in this instruction manual.

8695 5876
WELDYSTIFFENER I
CONTENTS
A - IDENTIFICATION.........................................................................................................................1
B - SAFETY INSTRUCTIONS............................................................................................................2
1 - SERVICING.........................................................................................................................2
2 - PERSONAL PROTECTION................................................................................................2
C - DESCRIPTION .............................................................................................................................4
1 - DEFINITION........................................................................................................................4
2 - TECHNICAL SPECIFICATIONS.........................................................................................7
D - INSTRUCTIONS FOR USE..........................................................................................................8
1 - CARRIAGE..........................................................................................................................8
2 - OPERATING OF WELDYSTIFFENER.................................................................................10
3 - CONTROL PANEL.............................................................................................................10
4 - FUNCTIONAL SEQUENCE '' INTERMITTENT ''...............................................................11
5 - PARAMETER SETTING....................................................................................................12
E - MAINTENANCE............................................................................................................................14
1 - SERVICING.........................................................................................................................14
2 - SPARE PARTS...................................................................................................................15
3 - WIRING DIAGRAM.............................................................................................................18
4 - PC BOARD..........................................................................................................................19
5 - ELECTRICAL MAINTENANCE..........................................................................................21
PERSONAL NOTES ..........................................................................................................................22

8695 5876
II WELDYSTIFFENER
INFORMATIONS
DISPLAYS AND PRESSURE GAUGE
The measuring tools or displays for voltage, intensity and speed .... either analog or digital, must be considered
as indicators
REVISIONS
REVISION B 08/08
DESIGNATION
PAGE
Update photos
REVISION C 08/09
DESIGNATION
PAGE
Update
REVISION D 08/14
DESIGNATION
PAGE
Spare parts
REVISION E 10/18
DESIGNATION
PAGE
To change logo

8695 5876 / E
WELDYSTIFFENER A-1
A - IDENTIFICATION
Please enter the number of your machine in the following box.
Quote this information in all correspondence.

8695 5876 / E
B-2 WELDYSTIFFENER
B - SAFETY INSTRUCTIONS
ELECTROMECHANICAL EQUIPMENT USED AS THE SUBASSEMBLY OF AN
INSTALLATION.
- This equipment can be associated with a
welding installation, in which case it is
covered by safety instructions described in
the instructions for the welding installation
- If this equipment is used in other cases, a
minimum of instructions must be
respected, in particular :
1 - SERVICING
2 - PERSONAL PROTECTION
Check often that the insulation and
connections of the electrical equipment
and accessories are in good condition:
plugs, cables, flexible cables, sheaths,
connectors, extension cables,
workpiece clamps, electrode holders or
torches...
Maintenance and repair work on
insulating sheaths and covers should
never be carried out in a makeshift
manner.
Have defective accessories repaired by
a specialist or, better still, replace them.
Periodically check that electrical
connections are properly tightened and
do not overheat.
RISK OF EXTERNAL INJURY.
The operator must be properly dressed
and protected for the work he is
carrying out.
Ensure that no part of the operator's
body or of his assistant's body can come
in contact with metal parts and
workpieces which are energized or
which could accidentally become
energized and/or which are moving.
Do not wrap electrical cables around
your body.
WARNING !
Be careful not to crush your fingers
Make sure that no spray or water enters into the electrical box of the carriage.
IP23 PROTECTION

8695 5876 / EB - SAFETY INSTRUCTIONS
WELDYSTIFFENER B-3

8695 5876 / E
C-4 WELDYSTIFFENER
C - DESCRIPTION
1 - DEFINITION
WELDYSTIFFENER carriages are portable, with two driving wheels,
it supports 2 independent torches.
They are specially designed for semiautomatic welding of stiffener
named " holland –profile " of size :
- 60 to 160 mm
or
- 120 to 320 mm.
Light and robust, they offer the quality of automatic welding as well
as easy operation and fast commissioning.
A) MOTORIZATION
WELDYSTIFFENER is driven by a 14 VDC motor.
The carriage is autonomous. The battery ensures a continuous work during
6 hours.
Charger
Battery
Control panel

8695 5876 / EC - DESCRIPTION
WELDYSTIFFENER C-5
B) ELECTRIFICATION
Indication of battery low status by the red led M1.
Pre-display and real display of the speed by high-brightness LEDs and
adjustment via numerical encoder M3 (max. error at mid scale < +/-5%).
Manual starting up with pushbutton M2 or automatic starting up with arc
sensor with power source function in 2 stages.
C) GUIDANCE PRINCIPAL
The carriage takes place quickly and easily on the welded seam.
The tilted position of the carriage is done by setting the height of the rollers.
The troggle clamp allows to maintain the carriage against the profil to be
welded.

C - DESCRIPTION 8695 5876 / E
C-6 WELDYSTIFFENER
D) TORCH SETTING
The adjustment of the torch position is very
easy and precise with 2 crossed slides (M8)
which have different fixation steps.
A ball joint, coupled to an indexed handle,
allows to set the torch holder very precisely. The
torch holder enables an easy and quick setting,
and can be changed by a specific tool
E) CARRYING
Lightweight 16 kg and handy (M7) WELDYSTIFFENER can be held easily by an operator for a fast
commissioning..

8695 5876 / EC - DESCRIPTION
WELDYSTIFFENER C-7
2 - TECHNICAL SPECIFICATIONS
FUNCTIONS
Ultra bright preview of the advance speed in cm/min.
Setting of the advance speed by digital encoder (Precision +/- 5%)
moving manually controlled by pushbutton or automatically by the welding arc sensor.
=> the generator must be set to the "2 cycle" mode
CHARACTERISTICS
Size "A"
60 to 160 mm
120 to 320 mm
Weight
16 kg
16 kg
Supply
Battery 14 VDC
Battery 14 VDC
Work autonomy
6 hours
6 hours
Movement speed
15 to 180 cm/mn
15 to 180 cm/mn
Protection index
IP 23
IP 23
Trigger control
1 contact 1T/2A
1 contact 1T/2A
Operating temperature
-5°C to +45°C
-5°C to +45°C
Storage temperature
-10°C to +60°C
-10°C to +60°C
Relative humidity
<90%
<90%
Dimensions in mm L x l x h
500 x 500 x 500
500 x 500 x 600

8695 5876 / E
D-8 WELDYSTIFFENER
D - INSTRUCTIONS FOR USE
REMARK : the battery is delivered flat. The
battery must be charged before the first use
1 - CARRIAGE
A) CONTROL BOX
The basic control box is used for the following functions :
M2
Starting up
M4
Cycle start/stop..
- selection of the displacement direction (left)
- selection of the displacement direction (right)
M9
Menu
M13
Scroll through menu , confirm and save a selection or setting
M1
Indication of battery
M5
Display.
M3
Numerical incrementing/decrementing potentiometer
M10
Switch "arc 1"
M14
Switch "arc 2"

8695 5876 / ED - INSTRUCTIONS FOR USE
WELDYSTIFFENER D-9
B) BATTERY
The battery autonomy is 6 hours in continuous work.
The display flashes to indicate that the battery charge level is too low to
power the carriage and its optional features.
Connect the charger to a main connector 220-240V / 50-60 Hz.
When the battery is well connected, according to the polarities, green
warning light goes red and the charge begins. The light remains red during all
the charging time.
When the charge is over, the light turns green.

D - INSTRUCTIONS FOR USE 8695 5876 / E
D-10 WELDYSTIFFENER
2 - OPERATING OF WELDYSTIFFENER
When power is turned on with M2
- The direction is automatically set to the right 
- To connect the cable "TRIGGER" on the touch.
Movement of the carraige by push on the touch start / stop M4.
3 - CONTROL PANEL
To access to level 2 :
To exit the level 2 :
Push the touch 3
seconds.
Push the touch 3
seconds.
PARAMETER
MINI VALUE
MAXI VALUE
UNIT
LEVEL
1
VITESSE / SPEED
0000
0180
CM/mn
PRE SOUDAGE / CAR
000,1
005,0
SECOND
LONGUEUR /S / WELD
0001
9999
MILLIMETER
LONGUEUR /NS / NO WELD
0000
9999
MILLIMETER
POST SOUDAGE / ARC
000,1
005,0
SECOND
LEVEL
2
NUMEROUS of masking program ( PG )
00
01
INTEGER
NUMBER of steps in mode intermittent ( PA )
00
99
INTEGER
SELECTION of DISPLAY ( AF )
0(speed)
1 (distance)
CM/mn or
millimèter
Legende :
PG : Hide program
LS : Low speed
HD : High speed
X… : Entered value
PA : Number of steps
PG
WELD
NO WELD
CARRIAGE
SPEED
AUTOMATIC STOP
CARRIAGE
00
0
0
PV
Without
0
X….
GV
With
X….
0
PV
With
X….
X….
PV / GV
Without

8695 5876 / ED - INSTRUCTIONS FOR USE
WELDYSTIFFENER D-11
With PG = 01 :
- WELD = X…
Carriage LS / HS
and automatic stop
after PAsteps.
- NO WELD = X…
- PA = X…
4 - FUNCTIONAL SEQUENCE '' INTERMITTENT ''
WELDING
SPEED CARRAIGE
Pre-welding
Post welding
STEPS (PA)
Run
sequence
WELD
NO WELD
LS
HS
STEPS (PA)

D - INSTRUCTIONS FOR USE 8695 5876 / E
D-12 WELDYSTIFFENER
5 - PARAMETER SETTING
PUSH ON THE
KEY< 3s
SPEED
CAR
------ WELD
---- NO WELD
ARC










A push on the key
displays the
next parameter and
saves the
preceding 
returns to the
preceding
parameter and
saves the actual
parameter.paramet
er.
A push on the key
returns to the
preceding
parameter and
saves the actual
parameter.
The value of
parameter can be
modified by a
rotation of button 
A slow rotation of button
means a slow
increasing or decreasing .
A fast rotation of button 
means a fast increasing or
decreasing .
TO MAKE A SEQUENCE
IT'S NECESSARY TO
MOVE THE PARAMETER
ON SPEED
PARAMETERS CAN ONLY
BE MODIFIED WHEN THE
CAR IS AT STANDSTILL ;
ONLY SPEED
PARAMETER

8695 5876 / ED - INSTRUCTIONS FOR USE
WELDYSTIFFENER D-13
PUSH ON THE
KEY > 3s
SPEED
( PG ) 00 ou
01
( PA ) 1 à 99
( AF ) 0 ou 1








A push on the key
displays the next
parameter and
saves the
preceding
parameter.
A push on the key
returns to the
preceding
parameter and
saves the actual
parameter.
The value of
parameter can be
modified by a
rotation of button 
A slow rotation of button
means a low increasing
or decreasing .
A fast rotation of button 
means a ast increasing or
decreasing .
TO MAKE A SEQUENCE
IT'S NECESSARY TO
MOVE THE PARAMETER
ON SPEED
PARAMETERS CAN ONLY
BE MODIFIED WHEN THE
CAR IS AT STANDSTILL .

8695 5876 / E
E-14 WELDYSTIFFENER
E - MAINTENANCE
1 - SERVICING
So that the machine continues to provide good service for as long as possible, a certain minimum of care and
maintenance is necessary
The frequency of this maintenance work is given on the basis of the production of one work station per day.
Maintenance should be more frequent if production is greater.
Your maintenance department may photocopy these pages so that it can follow up maintenance dates and
operations (tick as appropriate)
Daily
Remove regularly welding projection on protection lenses of the photo cell, protection casing and
support roller.
Regularly clean the outside of the carriage and the welding torch support adjusting elements.
Every 100 hours
Date of maintenance : / /
- Grease manœuvre screw
- Dismount and clean the support rollers.
Annually or after every 500 hours
Date of maintenance : / /
- check up the transmission system
- adjust the clearance of guiding shims on the slides
- adjust the clearance of the geared motor on the large sprocket wheel.
- wash and grease the wheels.
- blow very carefully the electronic card, speed regulator, electric rack.

8695 5876 / EE - MAINTENANCE
WELDYSTIFFENER E-15
2 - SPARE PARTS
How to order
The photos or sketches identify nearly every part in a machine or an installation
The descriptive tables include 3 kinds of items:
thosenormallyheldinstock: 
articlesnotheld in stock: 
thoseavailable onrequest: nomarks
(For these, we recommend that you send us acopyof the page with the list of parts duly
completed. Please specify in the Ordercolumn the number of parts desired and indicate the type and
the serial number of your equipment.)
For items noted on the photos or sketches but not in the tables, send a copy of the page
concerned, highlighting the particular mark.
For example:

normally in stock

not in stock
on request
Item
Ref.
Stock
Order
Designation
1
W000XXXXXX


Machine interface board
2
W000XXXXXX


Flowmeter
3
9357 XXXX


Silk-screen printed front panel
For parts order, give the quantity required and put the number of your machine in the box below.
TYPE:
Number:

E - MAINTENANCE 8695 5876 / E
E-16 WELDYSTIFFENER