Lincoln Electric LWF-22 User manual

IM7105-1
October, 2015
Export Rev. 02
LWF-22 & LWF-24 PLUS Wire Feeder
Product Number˖LWF-22 K60084-2 / 76202
LWF-24 PLUS K60086-2 / 76204
Shanghai Lincoln Electric Company
No195, Lane 5008, HuTai Road Shanghai 201907
Tel: [phone] Fax: [phone]
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
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.
OPERATOR’S MANUAL

i SAFETY i
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
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
1.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.
1.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult with their physician
before welding.
1.c. Exposure to EMF fields in welding may have other health effects which are now not known.
1.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding
circuit:
1.d.1. Route the electrode and work cables together. Secure them with tape when possible.
1.d.2. Never coil the electrode lead around your body.
1.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.
1.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
1.d.5. Do not work next to welding power source.
!
WARNING
ELECTRIC AND MAGNETIC FIELDS
May be dangerous

ii SAFETY ii
2.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.
2.b. Insulate yourself from work and ground using dry insula-
tion. 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:
xSemiautomatic DC Constant Voltage Wire
Welder.
xDC Manual (Stick) Welder.
xAC Welder with Reduced Voltage Control.
2.c. In semiautomatic or automatic wire welding, the electrode
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
2.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.
2.e. Ground the work or metal to be welded to a good electri-
cal (earth) ground.
2.f. Maintain the electrode holder, work clamp, welding cable
and welding machine in good, safe operating condition.
Replace damaged insulation.
2.g. Never dip the electrode in water for cooling.
2.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.
2.i. When working above floor level, use a safety belt to
protect yourself from a fall should you get a shock.
2.j. Also see items 5.c. and 8.
3.a. Use a shield with the proper filter and cover plates
to protect your eyes from sparks and the rays of the
arc welding or observing open arc welding.
The headshield and filter lens should conform to ANSI
Z87.I standards.
3.b. Use suitable clothing made from durable flame-
resistant material to protect your skin and that of your
helpers from the arc rays.
3.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.
4.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 with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors,
a respirator may be required. Additional precautions
are also required when welding on galvanized steel.
4.b. 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.
4.c. Shielding gases used for arc welding can displace air
and cause injury or death. Always use enough ventila-
tion, especially in confined areas, to insure breathing air
is safe.
4.d. Read and understand the manufacturer’s instruction for
this equipment and the consumables to be used,
including the material safety data sheet (MSDS) and
follow your employer’s safety practices. MSDS forms are
available from your welding distributor or from the
manufacturer.
ELECTRIC SHOCK can
Kill.
ARC RAYS can burn.
FUMES AND GASES
can be dangerous.

iii SAFETY iii
5.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.
5.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.
5.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.
5.d. Do not heat, cut or weld tanks, drums or containers until
the proper steps have been taken to insure that such pro-
cedures 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).
5.e. Vent hollow castings or containers before heating, cutting
or welding. They may explode.
5.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.
5.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.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.
6.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.c. Cylinders should be located:
xAway from areas where they may be struck or
subjected to physical damage.
xA safe distance from arc welding or cutting
operations and any other source of heat, sparks,
or flame.
6.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.e. Keep your head and face away from the cylinder valve
outlet when opening the cylinder valve.
6.f. Valve protection caps should always be in place and
hand tight except when the cylinder is in use or
connected for use.
6.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication
P-I, “Precautions for Safe Handling of Compressed
Gases in Cylinders,” available from the Compressed Gas
Association 1235 Jefferson Davis Highway, Arlington,
VA 22202.
7.a. Turn off input power using the
disconnect switch at the fuse box before working on the
equipment.
7.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
7.c. Ground the equipment in accordance with the U.S.
National Electrical Code and the manufacturer’s
recommendations.


CYLINDER may
explode if damaged.
WELDING SPARKS
can
cause fire or explosion.
FOR ELECTRICALLY
Powered Equipment.

iv SAFETY iv

7KDQN<RX
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.
Please record your equipment identification information below for future reference. This information
can be found on the nameplate of your machine.
Model Name & Number ______________________
Code & Serial Number ______________________
Date of Purchase ______________________
Whenever you request replacement parts for or information on this equipment always supply the
Information you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual
and keep it handy for quick reference. Pay particular attention to the safety instructions we have
provided for your protection. The level of seriousness to be applied to each is explained below:
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.
!
WARNING
!
CAUTION

iCONTENTS i
TABLE OF CONTENTS
Installation Section A
Technical Specification A-1
Safety Precautions A-1
Installation Instructions A-2
Welding Cable A-2
Gas Hose A-2
Control Cable A-2
Option Extension Cables A-2
Welding Gun A-2
Connection Diagram: LWF Feeder to Lincoln OPTIMARC A-2
Operation Section B
Installing Drive Rolls B-1
Loading the Wire Spool B-1
LWFTM-22 B-1
LWFTM-24 PLUS B-2
Maintenance Section C
Maintenance C-1
Schematic Diagram Section D
Schematic Diagram D-1

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS –LWFTM Wire Feeders
MODEL
LWFTM-22, LWFTM-24 PLUS
INPUT POWER
Supplied by power source
RECOMMENDED WIRE SIZES
0.8mm, 1.0mm, 1.2mm, 1.4mm, 1.6mm,2.0mm
WIRE FEED SPEED
1.5 to 18m/min
WELDING WIRE SPOOL (Max. load 20 kg)
SHAFT DIAMETER
OUTSIDE DIAMETER
WIDTH
50mm
280mm
105mm
DIMENSIONS & WEIGHT (Without Welding Wire Spool)
Specification
Model
HEIGHT WIDTH DEPTH WEIGHT
LWFTM-22 350mm 280mm 450mm 10.5kg
LWFTM-24 PLUS
350mm 280mm 450mm 12.5kg
Note: Please only use this wire feeder with specified power sources, otherwise no
output will be produced and the machine may be damaged.
SAFETY PRECAUTIONS
· Turn off the input power at the fuse box before working on other
equipment connected to the welding system at the disconnect
switch or fuse box before working on this equipment.
· Do not touch electrically hot parts.
!
WARNING
ELECTRIC SHOCK can kill.
· Only qualified personnel should perform this installation, mainte-
nance and troubleshooting work.

A-2 INSTALLATION A-2
INSTALLATION INSTRUCTION
WELDING CABLE
The needed cable assembly for the LWFTM feeders includes a control cable, welding cable and gas
hose. The lengths are made based on to the specific requirements from end users. The feeder has a
stud being used to connect the welding cable.
For self-shielded wire, the welding cable should be bolted to either the “+” or “-“output stud on power
source.
For Gas shielded wire, the power cable should be bolted to “+” output stud on power source.
GAS HOSE
The LWFTM interconnection cable assembly has a gas hose which connect to the rear panel in the
feeder. Another end of the hose connects to gas flow regulator with a clip for locking. Shielding gas
such as CO2, Ar, and blend gas can be used and the gas pressure cannot be more than 0.7 MPa).
CONTROL CABLE
The control cable is included in the interconnection cable assembly. When it is used with DURAWELD &
OPTIMARC, the 6-pin connector on the control cable will be linked to the rear panel of wire feeder and
6-pin connector on the power source.
OPTION EXTENSION CABLES
The LWFTM wire feeders can also be used with extension welding cables/ control cable /gas hoses if the
customers hope to get various length.
Notes: please fix the hose and cables into the holding bracket on the rear of the feeder after your
connection.
WELDING GUN
Loosen the hex screw on the gun block of the feeder with the hex wrench being provided by the feeder.
Install the gun into the feeder. Tighten the gun block with the hex wrench. A Euro adapter is an
available option for connecting Euro style guns.
CONNECTION DIAGRAM: LWFTM Feeder to Lincoln OPTIMARC

B-1 OPERATION B-1
INSTALLING DRIVE ROLLS
LWF™-22: One reversible drive roll needs to be installed on each LWFTM-22 wire feeder. Normally
each drive roll has two different size grooves for feeding different diameter wire. One groove is for
feeding 0.8/1.0/1.2mm and the other groove is for feeding 1.0/1.2/1.6mm. Ensure that the drive roll is
installed using the correct groove for the wire diameter being used.
LWF™-24 PLUS: Two reversible drive rolls need to be installed on each LWFTM-24 PLUS wire feeder.
Normally each drive roll has two different size grooves for feeding different diameter wire. One groove
is for feeding 1.0/1.2mm and the other groove is for feeding 1.2/1.6mm. Ensure that the drive roll is
installed using the correct groove for the wire diameter being used.
Notice: make sure the specifications of the 2 symmetrical feed rolls are same. And don’t make any
mistake about it!
LOADING THE WIRE SPOOL
xLWF™-22
Loosen the retainer on the spindle and put on the welding wire spool. Next, replace the retainer and
tighten the screw. Release the pressure handle and lift the pressure arm, then insert the welding wire
into the inlet straightening rolls 2-3cm (1/4 –1 inch). Now, replace the pressure arm and tighten with
the pressure handle noting that the pressure scale should suit the wire diameter. Using the cold-inch
button on the feeder, begin feeding wire. Release the cold-inch button when the wire comes out 1-2cm
(1/2-1 inch) from the contact tip. The installation of the welding wire is now completed.

B-2 OPERATION B-2
xLWF™-24 PLUS:
Loosen the retainer on the spindle and put on the welding wire spool. Next, replace the retainer and
tighten the screw. Release the pressure handle and lift the pressure arm, insert the welding wire into
conduit and V groove of feed roll, then insert it into the feedplate. Then insert the welding wire into V
groove of another feed roll and contact tip. Push down the pressure handle at last. Adjust the pressure
to feed wire smoothly. Then using the cold-inch button on the feeder, begin feeding wire. Release the
cold-inch button when the wire comes out 1-2cm (1/2-1 inch) from the contact tip. The installation of the
welding wire is now completed.

C-1 MAINTENANCE C-1
Note: Motor and gear box are maintenance free products, do not open them for maintaining, repairing or
oiling. Contact your nearest Lincoln Electric Service Center if a fault occurs.
Location
Inspection Points
Note
Wire Outlet
xCheck if there is any dust and
powder accumulated at the
entrance of the wire outlet and
on the surface of the feed rolls.
Clean the dust and powder
and find out the cause.
xCheck if the diameter of the
outlet suits the wire diameter.
If not suitable, erratic arc or
powder will occur.
xCheck if the end of the wire
outlet is lined up with the V
groove of the feed roll. (Visual
inspection)
If they are not lined up, erratic
arc or powder will occur.
Feed Rolls
xCheck if the diameter of the
feed roll is suitable for the
diameter of the wire used.
xCheck if there is any fragment
sticking in the groove.
xPowder and jam in liner
will cause erratic arc.
xReplace if abnormal.

D-1 SCHEMATIC DIAGRAM D-1

i BOTTOM i
Shanghai Lincoln Electric Company
No195, Lane 5008, HuTai Road Shanghai 201907
Tel: [phone] Fax: [phone]
The product performance data of this brochure and related attachments are from LINCOLN ELECTRIC application engineering laboratory.
Except for special instructions, experiments on welding machines are conducted in accordance with the general standard of IEC60974-1; experiments on welding consumables are conducted in accordance with
the general standard of AWS; for specic applicable standards on welding consumables please refer to the product page.
The product performance data of this website and related attachments are from LINCOLN ELECTRIC American application engineering laboratory.