Lincoln Electric WF 52D User manual

IM3166
06/2021
REV01
WF 52D
OPERATOR’S MANUAL
ENGLISH
Lincoln Electric Bester Sp. z o.o.
ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

English English
I
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 ......................................................................................................................................................................... 5
Installation and Operator Instructions.................................................................................................................................. 5
WEEE ............................................................................................................................................................................... 24
Spare Parts ....................................................................................................................................................................... 24
REACh .............................................................................................................................................................................. 24
Authorized Service Shops Location .................................................................................................................................. 24
Electrical Schematic.......................................................................................................................................................... 24
Suggested Accessories..................................................................................................................................................... 25
Connection configuration................................................................................................................................................... 27

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1
Technical Specifications
NAME INDEX
WF 52D W100000176
INPUT
Input Voltage U1Input Amperes I1EMC Class
40Vdc 4Adc A
RATED OUTPUT
Duty Cycle 40°C (based on a 10 min. period) Output Current
100% 420A
60% 500A
OUTPUT RANGE
Welding Current Range Peak Open Circuit Voltage
5 ÷ 500A 113Vdc or Vac peak
DIMENSION
Weight Height Width Length
17 kg 516 mm 302 mm 642 mm
WIRE FEED SPEED RANGE / WIRE DIAMETER
WFS Range Drive Rolls Drive roll diameter
1.5 ÷ 22 m/min 4 Ø37
Solid Wires Aluminum Wires Cored Wires
0.8 ÷ 1.6 mm 1.0 ÷ 1.6 mm 0.9 ÷ 1.6 mm
OTHERS
Protection Rating Maximum Gas Pressure
IP23 0,5 MPa (5 bar)
Operating Temperature Storage Temperature
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.

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4
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.
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.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time
the operator’s manual.

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5
Introduction
WF 52D is digital wire feeder which has been designed
to work with Lincoln Electric power sources:
DIGISTEEL 355S,
DIGISTEEL 425S,
DIGISTEEL 505S,
CITOSTEEL 355S,
CITOSTEEL 425S,
CITOSTEEL 505S.
The CAN protocol is used for communication between the
power source and the wire feeder. All signals from the
power source are displayed on the User Interface located
in the wire feeder machine.
Set of power source and wire feeder allow welding in
listed processes:
GMAW (MIG/MAG),
FCAW,
SMAW (MMA),
CAG.
The complete package contains:
Wire feeder.
USB memory with operator’s manual.
Easy Start.
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.
Exploitation conditions
This machine can operate in harsh environments.
However, it is important to use the following simple
preventive measures that will ensure its long life and
reliable operation:
Do not place or operate this machine on a surface
with an incline higher 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. Do not cover the machine with paper,
cloth or rags when switched on.
Dirt and dust that can be drawn into the machine
should be kept away from the item.
This machine has a protection rating of IP23. Keep it
dry when possible and do not place it on a wet
ground or in puddles.
Locate the machine away from a radio controlled
machinery. Normal operation may adversely affect
the operation of a 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 acceptable level of input voltage is indicated in the
section „Technical Specificationsʺand on the rating plate
of the power source. Verify the connection of grounding
wires from the power source to the input source.

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6
Controls and Operational Features
1
23
4
5
Figure 1
6
7
8
9
10
Figure 2
1. EURO Socket: For connecting a welding gun
(for GMAW, FCAW process).
2. Quick Coupling Socket: Coolant outlet
(supplies cool coolant to the welding gun).
3. Quick Coupling Socket: Coolant inlet (takes
warm coolant from the welding gun).
WARNING
Maximum coolant pressure is 5 bar.
4. Output Socket for SMAW and CAG welding:
For connecting welding cable with an
electrode holder.
5. U22 User Interface: See „User Interface” section.
6. Gas Quick Coupling Socket: For connecting a
gas pipe.
WARNING
The welding machine supports all suitable shielding
gases at a maximum pressure of 5,0 bar.
7. Control Socket: 5 pins socket for connecting
a control cable. The CAN protocol is used for
communication between the power source
and wire feeder.
8. Current Socket: For connecting a welding
cable.
9. Quick Coupling Socket: Coolant inlet
(supplies cool coolant from cooler to the
welding machine).
10. Quick Coupling Socket: Coolant outlet (takes
warm coolant from welding machine to
cooler).
11 12
13
14 15
16
Figure 3
11. Gas Flow Regulator Plug: Gas Flow Regulator can
be purchased separately. See "Accessories"
section.
12. Switch: Cold Inch / Gas Purge: This switch allows
wire feeding (wire test) and gas flow (gas test)
without switching on the output voltage.
13. Transport Holder: For the feeder lifting and
transporting using a crane.
14. Wire Spool Holder: For wire spool with maximum
16kg weight. Holder allows mounting plastic, steel
and fiber spools on the 51mm spindle.

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7
WARNING
Be sure that wire spool case has to be completely closed
during welding.
15. Spool with Wire: Not supplied as standard.
16. Wire Drive: 4-rolls 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.
User Interface
The WF 52D wire feeder uses the U22 interface based
on two separate LED displays for operation.
Interface U22
17 18 19 20 21
22
23
24
25
26
272829
30
31
32
Figure 4
17. Left Display: Shows wire feed speed or welding
current. During welding shows the actual welding
current value.
18. Status LED: A two color light that indicates system
errors. Normal operation is steady green light. Error
conditions are indicated, per Table 1.
Note: The status light will flash green for up to one
minute when the machine is turned on for the first time.
When the power source is powered it can take as long
as up to 60 seconds for the machine to be ready to weld.
This is a normal situation as the machine goes through
the initialization.
Table 1
LED Light
Condition
Meaning
Only machines which using
protocol for communication
Steady Green Power source is operational, and is
communicating normally with all
healthy peripheral equipment.
Blinking Green Occurs during power up or a system
reset, and indicates the power source
is mapping (identifying) each
component connect to the system.
This behavior occurs for first after
power is turned on, or if the system
configuration is changed during
operation.
Alternating Green
and Red
If the status lights are flashing any
combination of red and green color, it
means that errors are present in the
power source.
Each digit of the code corresponds to
the number of red flashes of the
indicator lamp.
Individual code digits are flashed in
red with a long pause between digits.
If more than one code is present, the
codes will be separated by green
light. Read the error code before the
machine is turned off.
To clear the errors try to turn off the
machine and wait for a few seconds,
then turn on again. If the error
remains, a it maintenance is required.
Please contact the nearest
authorized technical service center or
Lincoln Electric and report the error
code.
Steady Red Indicate no communication between
the power source and device which
has been connected to this power
source.
19. Thermal Overload Indicator: It indicates that the
machine is overloaded or that the cooling is not
sufficient.
20. Right Display: Depending on the source welding and
the welding program shows the welding voltage in
volts or Trim value. During welding shows the actual
welding voltage value.
21. LED Indicator: Informs that the value on the right
display is in volts unit and during welding, it blinks
and the display shows the measured voltage.
22. LED Indicator: Informs that the value on the right
display is Trim. Trim is adjustable from 0.50 to 1.50.
1.00 is the nominal setting.
23. Right Control: Adjusts values on the right display.
24. LED Indicator: Quick Access Menu.

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8
25. Right Button: Enables selecting, changing and setting
welding parameters. Quick Access Menu.
26. LED Indicator: Indicates that the Settings and
Configuration Menu is activated.
27. Left Button: Enables:
Checking the active program number. To check
the program number, press the left button once.
Changing the Welding Process.
28. Welding Programs Indicators (changeable): In the
user memory can be stored four user programs.
Shine LED indicates that the program is active.
29. Welding Programs Indicators (unchangeable): LED
indicates the program for non-synergic process is
active. See the table 2.
30. Left Control: Adjusts values on the left display.
31. LED Indicator: Informs that the value on the left
display is in ampere units, blinks during welding and
the display shows current measured. .
32. LED Indicator: Informs that the wire feed speed is
on the left display.