Lincoln Electric E-Cell Wire Drive System Mode d'emploi

Marque: Lincoln Electric

Modèle: E-Cell Wire Drive System

Catégorie: Système de soudage

Taper: Mode d'emploi

E-CELL

WIRE DRIVE

Operator’s Manual

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM876-A | Issue D ate 10-Mar

For use with machines having Code Numbers:

11240, 11721

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.

Stop the engine and allow it to cool before

refueling to prevent spilled fuel from vaporiz-

ing on contact with hot engine parts and

igniting. Do not spill fuel when filling tank. If

fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

guards only when necessary and replace them when the

maintenance requiring their removal is complete.

Always use the greatest care when working near moving

parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

SAFETY

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 ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.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

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.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.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

SAFETY

ARC RAYS can burn.

4.a. 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

open arc welding. Headshield and filter lens

should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

4.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.

ELECTRIC SHOCK can

kill.

3.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.

3.b. Insulate yourself from work and ground using dry insulation.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.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.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.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.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES

can be dangerous.

5.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 within applicable OSHA PEL and

ACGIH TLV limits using local exhaust or mechanical

ventilation. In confined spaces or in some circum-

stances, outdoors, a respirator may be required.

Additional precautions are also required when welding

on galvanized steel.

5. b. The operation of welding fume control equipment is affected

by various factors including proper use and positioning of

the equipment, maintenance of the equipment and the spe-

cific welding procedure and application involved. Worker

exposure level should be checked upon installation and

periodically thereafter to be certain it is within applicable

OSHA PEL and ACGIH TLV limits.

5.c.

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

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions 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.

5.f. Also see item 1.b.

Jan ‘09

iii

SAFETY

iii

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.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.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING and CUTTING

SPARKS can

cause fire or explosion.

6.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.

6.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.

6.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.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

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).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.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.

6.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 cir-

cuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention

During Welding, Cutting and Other Hot Work”, available

from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma

022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Jan ‘09

Refer to http://www.lincolnelectric.com/safety for additional safety information.

SAFETY

Mar. ‘93

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible

de la zone de travail qu’il est pratique de le faire. Si on place

la masse sur la charpente de la construction ou d’autres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

TThhaannkk YYoouu

for selecting a QUALITY product by Lincoln Electric. We want you

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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:

WARNING

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.

CAUTION

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 your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-

ment. 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 posses-

sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-

mation 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 responsive 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.

TABLE OF CONTENTS

Page

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Wire Drive Features and Components .................................................................................A-2

Safety Precautions ...............................................................................................................A-3

Mounting and Unit Dimensions ............................................................................................A-3

Safety Precautions ...............................................................................................................A-4

Weld Cable Sizes ........................................................................................................................A-4

Coaxial Weld Cables ............................................................................................................A-5

External Shut Down Signal...................................................................................................A-6

Digitial Control Cable Connection ........................................................................................A-6

Setting Electrode Polarity .....................................................................................................A-7

Wire Drive Configuration ......................................................................................................A-8

Assembly of Drive Rolls and Wire Guides............................................................................A-9

Pressure Arm Adjustment ..................................................................................................A-10

Shielding Gas Connection..................................................................................................A-10

Wire Reel Loading..............................................................................................................A-11

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Graphic Symbols, Common Welding Abbreviations.............................................................B-1

Product Description, Recommended Processes and Required Equipment .........................B-2

Front And Rear Controls and Connections ..........................................................................B-3

1. Status LED ................................................................................................................B-4

2. Cold Feed / Gas Purge Switch..................................................................................B-4

3. 5-pin Amphenol .........................................................................................................B-4

________________________________________________________________________________

Accessories.....................................................................................................Section C

General Options / Accessories...............................................................C-1 Thru C-3

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance.............................................................................................D-1

Periodic Maintenance............................................................................................D-1

Calibration Specification........................................................................................D-1

________________________________________________________________________

Troubleshooting............................................................................................................E

Safety Precautions.................................................................................................E-1

How To Use Troubleshooting Guide......................................................................E-1

Troubleshooting .............................................................................................E-2, E-3

Wiring Diagram ......................................................................................................F-1

________________________________________________________________________

Parts Lists................................................................................................................P522

________________________________________________________________________

A-1

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-1

TECHNICAL SPECIFICATIONS

eCELL

™

Wire Drive System

CODE. TYPE WIRE FEED SPEED RANGE

ITEMS INCLUDED WITH EACH PRODUCT

 Dimensions do not include wire reel.

CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS

CODE TYPE

INPUT POWER

PHYSICAL SIZE• TEMPERATURE RATING

Input Voltage Dimensions

and Current Height Width Depth Weight Operating Storage

9.5“ 9.1“ 11.3“ 19 Lbs 14°F to 104°F -40°F to 185°F

11240

eCELL™ 40 VDC ( 241mm) ( 231mm) ( 287mm) (8.6 Kg.) -10°C to 40°C -40°C to 85°C

4 Amps

WELDING CAPACITY RATING

Amp Rating Duty Cycle

600 A 60%

500 A 100%

11240

CODE

11240

Gearing

Normal Speed

Description

eCELL™

Wire Drive

System

Wire Feeder

eCELL™

Wire Drive

WFS Range

50 – 800 ipm

(1.3-20.3 m/min.)

Wire Reel Stand

------------

WFS Range

50 – 800 ipm

(1.3-20.3 m/min.)

Drive Roll Kit

----------

Gun Bushing

K1500-1

Wire Sizes

.023 – .045

(0.6 – 1.2mm)

Wire Sizes

.030 - .045

(0.8 - 1.2mm)

Control Cable

---------

GMAW FCAW

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

15°F to 104°F(-10°C to 40°C)

STORAGE TEMPERATURE RANGE

-40°F to 185°F(-40°C to 85°C)

eCELL™ WIRE DRIVE SYSTEM

A-2

INSTALLATION

A-2

4 DRIVE ROLLS

PLIT WIRE GUIDE

ADJUSTABLE

PRESSURE ARMS

AS OUTLET

GUN RECEIVER BUSHING

FOR GUN AND CABLE

ASSEMBLY

DOOR REMOVED

SEE INSTALLATION AND OPERATION SECTIONS FOR DETAILED INFORMATION

eCELL™ WIRE DRIVE FEATURES AND COMPONENTS

GAS PURGEGAS PURGE

COLD FEEDCOLD FEED

AS INGAS IN

L12529-2 VM

TIGHTENTIGHTEN

LOOSENLOOSEN

U U

0 VDC40 VDC

I I

4A 4A

60% 60%

100%100%

600A 600A

500A500A

ÆÆ

STATUSSTATUS

ELECTRIC

LINCOLN

ARCLINK STATUS LED

ARCLINK CONNECTION

(5 PIN AMPHENOL)

COLD FEED

GAS PURGE

TOGGLE SWITCH

GAS INLET

REAR VIEW

A-3

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-3

SAFETY PRECAUTION

MOUNTING AND UNIT DIMENSIONS

Mount the eCell™ Wire Drive System on the designat-

ed bracket of the eCell™ only.

(See Figure A.1).

Side View (Door not shown for clarity). (See Figure A.2)

Rear View. (See Figure A.3)

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the

welding power source before instal-

lation or changing drive rolls and/or

guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode

and drive mechanism are "hot" to work and

ground and could remain energized several

seconds after the gun trigger is released.

• Welding power source must be connected to

system ground per the National Electrical Code

or any applicable local codes.

• Only qualified personnel should perform main-

tenance work.

----------------------------------------------------------------------------------------

2.762.76

1.381.38

2.382.38

6.006.00

2.252.25

5/16 - 18 THREADS5/16 - 18 THREADS

(4 PLACES)(4 PLACES)

4.974.97

8.508.50

9.939.93

11.2511.25

4.974.97

1.391.39

8.828.82

5.085.08

8.508.50

FIGURE A.1

FIGURE A.2

FIGURE A.3

WARNING

A-4

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-4

SAFETY PRECAUTION

ELECTRIC SHOCK can kill.

• Only qualified personnel should

perform this installation.

• Turn off the input power to the

power source at the disconnect switch or fuse

box before working on this equipment. Turn off

the input power to any other equipment connect-

ed to the welding system at the disconnect

switch or fuse box before working on this equip-

ment.

• Do not touch electrically hot parts.

----------------------------------------------------------------------

** Tabled values are for operation at ambient temperatures of 40°C (104°F) and below. Applications above 40°C

(104°F) may require cables larger than recommended, or cables rated higher than 75°C (167°F).

Amperes

200

225

250

300

325

350

400

500

Percent

Duty

Cycle

100

40 & 30

100

200 to 250 Ft.

61 to 76 m

1/0

2/0

3/0

4/0

150 to 200 Ft.

48 to 61 m

1/0

2/0

3/0

100 to 150 Ft.

31 to 48 m

2/0

3/0

50 to 100Ft.

15 to 31 m

2/0

1/0

2/0

3/0

2/0

0 to 50 Ft.

0 to 15 m

4 or 5

2/0

1/0

2/0

3/0

2/0

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C [167°F] )**

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

WELD CABLE SIZES

Table A.1 has the copper cable sizes recommended

for different currents and duty cycles. Lengths stipu-

lated are the distance from the welder to work and

back to the welder again. Cable sizes are increased

for greater lengths primarily for the purpose of mini-

mizing voltage loss in the welding circuit.

TABLE A.1

A-5

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-5

COAXIAL WELD CABLES

Coaxial welding cables are specially designed welding

cables for pulse welding. Coaxial weld cables feature

low inductance, allowing fast changes in the weld cur-

rent. Regular cables have a higher inductance which

may distort the pulse wave shape. Inductance

becomes more severe as the weld cables become

longer.

Coaxial weld cables are recommended for all pulse

welding, especially when the total weld cable length

(electrode cable + work cable) exceeds 50 feet

(7.6m).

A coaxial weld cable is constructed by 8 small leads

wrapped around one large lead. The large inner lead

connects to the electrode stud on the power source

and the electrode connection on the wire feeder. The

small leads combine together to form the work lead,

one end attached to the power source and the other

end to the work piece.

(See Coaxial weld Cable below.)

WORK CONNECTION

Connect a work lead of sufficient size between the

proper output stud on the power source and the work.

Be sure the connection to the work makes tight metal

to metal electrical contact. Poor work lead connec-

tions can result in poor welding performance.

Electrode

Work

Power Source

Work

Electrode

Wire Feeder

Electrode

Work

Coaxial Weld Cable

A-6

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-6

EXTERNAL SHUTDOWN SIGNAL

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the dis-

connect switch before working on

this equipment.

• Do not touch electrically hot parts.

• Only qualified personnel should install, use or

service this equipment.

------------------------------------------------------------------------

The eCell™ Wire Drive includes one input for an

external shut-off circuit. The circuit interrupts the trig-

ger signal and stops the welding process in the event

of a fault. The most common use is for a flow switch

when using water cooled guns or torches.

The external device must have "normally closed" con-

tacts.

Do not use the external shut-off circuits for safety or

emergency stops.

To connect to the shutoff circuit:

1. Turn off power to the wire feeder at the disconnect

switch.

2. Remove the screws securing the wrap-around and

door assembly.

3. Locate leads 570 and 570A/570B in the harness

for external shut-off switch. (See Figure A.4)

4. Wire the external equipment to the leads. Route

the wiring for the external equipment through the

rear of the wire feeder.

5. Reassemble the wrap-around and door assembly.

6. Restore power.

FIGURE A.4

DIGITAL CONTROL CABLE, K1543-XX

ArcLink/LincNet control cables are special high quality

cables for digital communication. The cables are cop-

per 5 conductor cable in a SO-type rubber jacket.

There is one 20 gauge twisted pair for network com-

munications. This pair has an impedance of approxi-

mately 120 ohms and a propagation delay per foot of

less than 2.1 nanoseconds. There are two 12 gauge

conductors that are used to supply 40VDC to the net-

work. The fifth wire is 18 gauge and is used as an

electrode sense lead.

Use of non-standard cables may lead to system shut-

downs, poor arc starting and wire feeding problems.

The control cables connect the power source to the

wire feeder, and the wire feeder to other wire feeders.

PIN FUNCTION

A Digital I/O

B Digital I/O

C "67" voltage sense

D 40 VDC

E Common

Use a maximum of 250 feet (76.2m) of control cable

between components.

WARNING

EXTERNAL

DEVICE

570

570A/570B

OWER SOURCE

IRE FEEDER

A-7

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-7

SETTING ELECTRODE POLARITY

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the dis-

connect switch before working on

this equipment.

• Do not touch electrically hot parts.

• Only qualified personnel should install, use or

service this equipment.

When changing the electrode polarity, the weld

cables must be changed at the power source

studs and the DIP switches inside the eCell™ Wire

Drive System must be properly set. Operation

with the DIP switch in the wrong position will

cause erratic arc performance.

------------------------------------------------------------------------

The eCell™ Wire Drive is factory set for Electrode

Positive welding.

Most GMAW welding procedures use Electrode

Positive welding. Some Innershield procedures may

use Electrode Negative welding.

To change the DIP switch inside the eCell™ Wire

Drive for electrode polarity: (See Figure A.5)

1. Turn off power at the welding power source.

2. Remove the sheet metal wrap-around on the wire

drive.

3. Locate DIP switches on the Wire Drive Board.

4. Set DIP switch #7 to the desired polarity.

DIP Switch #7 Position Polarity

ON - (negative) polarity

OFF + (positive) polarity

5. Assemble the wrap-around to the wire drive.

6. Restore power.

1 2 3 4 5 6 7 8

- (Negative) Polarity

LOCATION DIP SWITCH

1 2 3 4 5 6 7 8

+ (Positive) Polarity

eCELL WIRE DRIVE BOARD

FIGURE A.5

CAUTION

WARNING

6. Remove the outer wire guide, and push the gun

bushing out of the wire drive. Because of the pre-

cision fit, light tapping may be required to remove

the gun bushing.

7. Disconnect the shielding gas hose from the gun

bushing, if required.

8. Connect the shielding gas hose to the new gun

bushing, if required.

9. Rotate the gun bushing until the thumb screw hole

aligns with the thumb screw hole in the feed plate.

Slide the gun receiver bushing into the wire drive

and verify the thumb screw holes are aligned.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun bushing and

tighten the thumb screw.

WIRE DRIVE CONFIGURATION

(See Figure A.6)

Changing the Gun Receiver Bushing

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the

welding power source before instal-

lation or changing drive rolls and/or

guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and

drive mechanism are "hot" to work and ground

and could remain energized several seconds

after the gun trigger is released.

• Only qualified personnel should perform mainte-

nance work.

------------------------------------------------------------------------

Tools required:

• 1/4" hex key wrench

Note: Some gun bushings do not require the use of

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

5. Loosen the socket head cap screw that holds the

connector bar against the gun bushing.

Important: Do not attempt to completely

remove the socket head cap screw.

A-8

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-8

WARNING

GUN RECEIVER BUSHING

CONNECTOR

BLOCK

SOCKET

HEAD CAP

SCREW

THUMB

SCREW

LOOSEN

CAP

SCREW

TIGHTEN

CAP

SCREW

FIGURE A.6

ASSEMBLY OF DRIVE ROLLS AND WIRE

GUIDES

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the

welding power source before instal-

lation or changing drive rolls and/or

guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode

and drive mechanism are "hot" to work and

ground and could remain energized several sec-

onds after the gun trigger is released.

• Only qualified personnel should perform mainte-

nance work.

------------------------------------------------------------------------

To remove drive rolls and wire guides:

(See Figure A.7)

1. Turn power off at the welding power source.

2. Remove the outer wire guide.

3. Rotate 4 triangular rings to the unlocked position.

4. Open the pressure arms.

5. Remove the drive rolls and inner wire guide.

To install drive rolls and wire guides:

(See Figure A.7 and A.7a)

1. Turn off power at the welding power source.

2. Open pressure arms.

3. Assemble the inner wire guide.

4. Slide the drive rolls onto the drive hubs.

(See figure A.8)

5. Close the pressure arms.

6. Rotate 4 triangular rings to the locked position.

(See figure A.8a)

7. Assemble the outer wire guide.

8. Adjust the pressure arms to the recommended set-

ting.

WARNING

OUTER WIRE GUIDE

4 TRIANGULAR RINGS

IN UNLOCKED POSITION

2 PRESSURE ARMS

ROTATE DOWN

INNER WIRE GUIDE

DRIVE ROLLS

DRIVE HUBS

PRESSURE ARMS

IN OPEN POSITION

SLIDE DRIVE ROLL

ON DRIVE HUB

TRIANGULAR RING IN

UNLOCKED POSITION

TRIANGULAR RING IN

LOCKED POSITION

FIGURE A.7

FIGURE A.8

FIGURE A.8a

A-9

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-9

SHIELDING GAS CONNECTION

CYLINDER may explode if damaged.

• Keep cylinder upright and chained to

support.

• Keep cylinder away from areas where

it may be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live elec-

trical circuits.

---------------------------------------------------------------------------

BUILD-UP OF SHIELDING GAS may

harm health or kill.

• Shut off shielding gas supply when

not in use.

SEE AMERICAN NATIONAL STANDARD Z-49.1,

"SAFETY IN WELDING AND CUTTING" PUB-

LISHED BY THE AMERICAN WELDING SOCIETY.

------------------------------------------------------------------------

Maximum inlet pressure is 100 psi. (6.9 bar.)

Install the shielding gas supply as follows:

1. Secure the cylinder to prevent it from falling.

2. Remove the cylinder cap. Inspect the cylinder

valves and regulator for damaged threads, dirt,

dust, oil or grease. Remove dust and dirt with a

clean cloth. DO NOT ATTACH THE REGULATOR

IF OIL, GREASE OR DAMAGE IS PRESENT!

Inform your gas supplier of this condition. Oil or

grease in the presence of high pressure oxygen is

explosive.

3. Stand to one side away from the outlet and open

the cylinder valve for an instant. This blows away

any dust or dirt which may have accumulated in the

valve outlet.

4. Attach the flow regulator to the cylinder valve and

tighten the union nut(s) securely with a wrench.

Note: if connecting to 100% CO

cylinder, insert

regulator adapter between regulator and cylinder

valve. If adapter is equipped with a plastic washer,

be sure it is seated for connection to the CO

cylin-

der.

5. Attach one end of the inlet hose to the outlet fitting

of the flow regulator. Attach the other end to the

welding system shielding gas inlet. Tighten the

union nuts with a wrench.

6. Before opening the cylinder valve, turn the regulator

adjusting knob counterclockwise until the adjusting

spring pressure is released.

7. Standing to one side, open the cylinder valve slowly

a fraction of a turn. When the cylinder pressure

gage stops moving, open the valve fully.

8. The flow regulator is adjustable. Adjust it to the flow

rate recommended for the procedure and process

being used before making a weld.

A-10

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-10

PRESSURE ARM ADJUSTMENT

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding power

source before installation or changing drive

rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode

and drive mechanism are "hot" to work and

ground and could remain energized several sec-

onds after the gun trigger is released.

• Only qualified personnel should perform mainte-

nance work.

------------------------------------------------------------------------

The pressure arm controls the amount of force the

drive rolls exert on the wire. Proper adjustment of

both pressure arms gives the best welding perfor-

mance.

Set the pressure arm as follows (See Figure A.9):

Aluminum wires between 1 and 3

Cored wires between 3 and 4

Steel, Stainless wires between 4 and 6

For best results, use the same setting on both pres-

sure arms. This maximizes traction of the drive rolls

while minimizing wire deformation.

FIGURE A.9

WARNING

ALUMINU M

OUTERSHIELD

METAL SHIELD

INNERS HIELD

STEEL

STAINLE SS

CORED WIRES

SOLID WIRES

WARNING

WIRE REEL LOADING

• Keep hands, hair, clothing and tools away from

rotating equipment.

• Do not wear gloves when threading wire or

changing wire spool.

• Only qualified personnel should install, use or

service this equipment.

-----------------------------------------------------------------------

The eCell™ Wire Drive is designed for use with bulk

packages of wire – reels, drums and boxes.

Connect the consumable package to the wire drive

using K515-xx wire conduit. For best results, locate

the wire near the wire drive and keep the conduit as

straight as possible.

A-11

INSTALLATION

eCELL™ WIRE DRIVE SYSTEM

A-11

WARNING

B-1

OPERATION

B-1

eCELL™ WIRE DRIVE SYSTEM

COLD FEED

POSITIVE OUTPUT

NEGATIVE OUTPUT

PROTECTIVE

GROUND

WARNING OR

CAUTION

DANGEROUS

VOLTAGE

SHOCK

HAZARD

WELDING

FUMES

EXPLOSION

GAS INPUT

WORK

CONNECTION

PURGE BY GAS

SAFETY PRECAUTIONS

Read this entire section of operating instructions

before operating the machine.

ELECTRIC SHOCK can kill.

• Unless using cold feed feature,

when feeding with the gun trigger,

the electrode and drive mechanism

are always electrically energized

and could remain energized several

seconds after welding ceases.

• Do not touch electrically live parts or electrodes

with your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

-------------------------------------------------------------

ONLY QUALIFIED PERSONS SHOULD INSTALL,

USE OR SERVICE THIS EQUIPMENT. READ AND

FOLLOW THE MANUFACTURER’S INSTRUC-

TIONS, EMPLOYER’S SAFETY PRACTICES AND

MATERIAL SAFETY DATA SHEETS (MSDS) FOR

CONSUMABLES.

-----------------------------------------------------------

READ THIS WARNING, PROTECT YOURSELF &

OTHERS.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust at the

arc, or both,to keep fumes and

gases from your breathing zone and

general area.

WELDING SPARKS can cause fire or

explosion.

• Do not weld near flammable material.

• Do not weld on containers which have

held flammable material.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

-----------------------------------------------------------

Observe additional guidelines detailed in the

beginning of this manual.

WARNING

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

COMMON WELDING ABBREVIATIONS

WFS

• Wire Feed Speed

• Constant Voltage

GMAW (MIG)

• Gas Metal Arc Welding

FCAW (Innershield or Outershield)

• Flux Core Arc Welding

B-2

OPERATION

B-2

eCELL™ WIRE DRIVE SYSTEM

RECOMMENDED PROCESSES

•

GMAW AND GMAW-STT

• FCAW

PROCESS LIMITATIONS

• The eCell™ Wire Drive is not recommended for

GTAW, CAG, SMAW, SAW

• The eCell™ Wire Drive is not compatible with push-

pull equipment.

REQUIRED EQUIPMENT

All power sources must be part of the eCell™ system.

These include:

• PowerWave 355M

• PowerWave 455M

• PowerWave 455M/STT

• PowerWave 455M Robotic

• PowerWave 455M/STT Robotic

EQUIPMENT LIMITATIONS

• Maximum GMAW gun length =25’ (7.6m)

• Maximum conduit length = 25' (7.6m)

• Maximum total control cable length = 100ft (31m)

• The eCell™ Wire Drive works only with ArcLink

equipment.

• Other gun bushings are required for welding guns

that do not have a "Lincoln" back-end.

PRODUCT DESCRIPTION

General Physical Description

The eCell™ Wire Drive System is the wire feeder for

the eCell™. It consists of a 4 roll wire drive with con-

nections for the torch, electrode conduit and shielding

gas. The small, lightweight feeder mounts at the rear

of the eCell™.

General Functional Description

The eCell™ Wire Drive System is a robotic wire drive

that operates only with the eCell™. All welding para-

meters (WFS, voltage, etc.) are set through the robot-

ic controller. Integrated in the wire drive is a robotic

wire drive module. The eCell™ Wire Drive module

communicates with the robotic control and Power

Wave power source via ArcLink.

The wire drive is capable of wire feed speeds of 50 –

800 ipm. Accurate speed control is obtained with a

tachometer integrated in the motor. The wire drive is

capable of feeding both forward and reverse.

The heart of the eCell™ Wire Drive is the MaxTrac™

4 roll wire drive.

This new 4 roll drive MaxTrac™ technology delivers

great feeding because:

• Patent pending drive rolls improve traction.

• The precision machined, rigid aluminum

alloy frame results in maximum drive roll

clamping pressure.

• Drive hubs with steel inner cores have 3 ball

bearings inside each hub.

• The drive hubs are supported by large, heat

treated and ground shafts for maximum

rigidity and accurate drive roll alignment.

• Patent pending dual spring pressure arms

have sensitivity for feeding soft wires without

crushing them, and have plenty of compres-

sion force for feeding solid or stiff wires.

Easy to configure, easy to service parts give

MaxTrac™ drives the edge in productivity.

• Patented split wire guides fully support the

wire and virtually eliminate birdnesting.

• No tools required to change the drive rolls

and wire guides.

• Changeable gun bushings easily accept

guns from many manufacturers.

• Brass-to-brass connections between the

electrode connection and the gun minimize

voltage drop variations, resulting in consis-

tent arc performance all day, every day.

Functions that can be operated without the robot con-

troller are gas purge and cold feed.

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Lincoln Electric E-Cell Wire Drive System Mode d'emploi

Marque: Lincoln Electric

Modèle: E-Cell Wire Drive System

Catégorie: Système de soudage

Taper: Mode d'emploi

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