Lincoln Electric PF44, Operator'S Manual

Page 1: ...IM3053 02 2015 REV03 PF44 PF46 OPERATOR S MANUAL ENGLISH Lincoln Electric Bester Sp z o o ul Jana III Sobieskiego 19A 58 263 Bielawa Poland www lincolnelectric eu ...

Page 2: ...machine PF44 PF46 conforms to the following directives 2006 95 CEE 2004 108 CEE and has been designed in compliance with the following standards EN 60974 5 EN 60974 10 2007 12 07 2013 Paweł Lipiński Operations Director Lincoln Electric Bester Sp z o o ul Jana III Sobieskiego 19A 58 263 Bielawa Poland 07 11 ...

Page 3: ...ls and Operational Features 5 Guide s Marking Interface 7 Interface Description 9 Welding Parameters Bar 9 Welding Program Choice 11 User Settings 12 The Settings and Configuration Menu 17 USB Memory PF46 only 27 Welding SMAW MMA Process 29 Gouging 30 Welding GTAW GTAW PULSE Process 31 Welding GMAW FCAW GS and FCAW SS Process in non synergic mode 33 Welding GMAW and FCAW GS Process in synergic mod...

Page 4: ... Welding Current Range Peak Open Circuit Voltage 5 500A 113Vdc or Vac peak DIMENSION Weight Height Width Length 18 5 kg 460 mm 300 mm 640 mm WIRE FEED SPEED RANGE WIRE DIAMETER WFS Range Drive Rolls Drive roll diameter Solid Wires Aluminum Wires Cored Wires 1 22 m min 4 Ø37 0 8 1 6 mm 1 0 1 6 mm 0 9 1 6 mm Protection Rating Maximum Gas Pressure Operating Temperature Storage Temperature IP23 0 5MPa...

Page 5: ...d 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 ...

Page 6: ...tor 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...

Page 7: ...n of the machine Location and Environment This machine will operate in harsh environments However it is important that simple preventative measures are followed to assure long life and reliable operation Do not place or operate this machine on a surface with an incline greater than 15 from horizontal Do not use this machine for pipe thawing This machine must be located where there is free circulat...

Page 8: ... Cancel Back 8 Display Parameters of welding process are shown 9 Left Control The value of the parameter in the upper left side of display 8 is adjusted 10 Right Control The value of the parameter in the upper right side of display 8 is adjusted 11 Set Control Type of welding procedure and welding settings is changed by this Control 12 Right Button Confirm change 13 Gas Connector Connection for ga...

Page 9: ...Switch 21 USB Receptacle To connection the USB memory 18 19 22 24 20 23 Figure 4 18 19 20 21 22 23 24 Figure 5 22 Wire Spool Support Maximum 15kg spools Accepts plastic steel and fiber spools onto 51mm spindle Also accepts Readi Reel type spools onto included spindle adapter WARNING Be sure that wire spool case has to be completely closed during welding 23 Spooled Wire The machine does not include...

Page 10: ...s User Settings Background Settings GTAW PULSE FCAW G FCAW GS Process Pinch Background Current GTAW PULSE GMAW P Process Select Function of Gun Trigger 2 Step 4 Step Background Current STT GMAW P Process RapidArc Program 2 Step Peak Current STT X GMAW P Process RapidX Program 4 Step TailOut STT GMAW P process Precision Pulse Program t1 Preflow Time UltimArc GMAW P Process Pulse On Pulse Program t2...

Page 11: ...Cold Feed Wave Controls Switch Off Output Voltage MMA TIG only Gas Purge Brightness Level Switch On Output Voltage MMA TIG only Error Lock Unlock A Welding Current USB Memory PF46 only Locked min m Wire Feed Speed in m min USB Memory is connected PF46 only Unlocked min in Wire Feed Speed in in min ESCape Button Set Passcode V Welding Voltage Confirm Button ...

Page 12: ...ters Bar enables Welding Program change Wave Control Value change The gun s trigger function change GMAW GMAW P FCAW STT GTAW only Add or hide functions and welding parameters User Settings Table 3 SMAW Welding Parameters Bar factory default Welding Process Choice Arc Force A Hot Start SMAW Soft and SMAW Crisp only User Settings Table 4 Gouging Welding Parameters Bar factory default Welding Proces...

Page 13: ...Pulse On Pulse only UltimArc except for Pulse On Pulse The function of the gun s trigger change User Settings Table 9 Non synergic STT Welding Parameters Bar factory settings Welding Process Choice Peak Current Background Current TailOut A Hot Start The function of the gun s trigger change User Settings Table 10 Synergic STT Welding Parameters Bar factory settings Welding Process Choice UltimArc A...

Page 14: ...ighlight the Welding Program Number Note The list of available programs depends on the power source 123 4 5 6 7 8 GMAW CV Figure 9 Confirm the select press the Right Button 12 If a user does not know the Welding Program Number it can be searched In that case in subsequent steps are given The Welding Process 123 MIG GMAW Synergic Non synergic Process MODE POWER Syner The Electrode Wire Type GMAW St...

Page 15: ...ons had to be added to the Welding Parameters Bar 27 To add the Parameter or Function to the Welding Parameters Bar 27 Access to the User Settings see the Figure 11 Use the Set Control 11 to highlight the parameter or function icon which will be added to the Welding Parameters Bar 27 for example Run in WFS t1 t2 A B M OFF Figure 12 Press the Set Button 11 Run in WFS icon will drop t1 t2 A B M OFF ...

Page 16: ...he User Settings Menu is closed The Selected parameters or function was disappeared from the Welding Parameters Bar 27 v 28 6 125A 22 5V 1 2 Steel ArCO2 21 min m 5 51 Figure 17 Preflow Time adjusts the time that shielding gas flows after the trigger is pulled and prior to feeding Factory default Preflow Time is set at 0 2 seconds Adjust range from 0 seconds OFF to 25 seconds M OFF 25 0 M 0 2s t1 t...

Page 17: ...Spot Timer is OFF Adjust range from 0 second OFF to 120 seconds Note Spot Timer has no effect in 4 Step Trigger Mode OFF 120 t2 t1 OFF t Figure 21 Run in WFS sets the wire feed speed from the time the trigger is pulled until an arc is established Factory default Run in is turned off Adjust range from minimum to maximum WFS OFF 17 78 OFF M t1 t2 Figure 22 The Start Procedure controls the WFS and Vo...

Page 18: ...re the Welding Program to the User Memory Add the User Memory icon to the Welding Parameters Bar 27 Use the Set Control 11 to highlight the User Memory icon 125A 22 5V 1 2 Steel ArCO2 21 M M v 28 6 min m 5 51 Figure 27 Press the Set Control 11 the User Memory Menu is shown on the display Use the Set Control 11 to highlight the Save to the Memory icon M M Figure 28 Press the Set Control 11 Use the ...

Page 19: ...iances enter to Setup Menu and set the parameters P 28 and or P 20 accordingly M v 20 0 min m 7 62 1 2 3 4 5 6 7 8 9 94 ArCO2 Steel 0 8 Figure 30 Additionally the Setting and Configuration Menu can be also entered from the User Settings Menu Full description the Setting and Configuration Menu in Section 3 10 Note The Setting and Configuration Menu icon cannot add to the Welding Parameters Bar 27 T...

Page 20: ...s to the Configuration Menu Memory Limits PF46 only Note The Limits can be set only for the programs stored in the user memory The limits can be set for Welding Current Wire Feed Speed WFS Welding Voltage Wave Controls Display Configuration Four Display Configuration are available True Energy Menu Weld Score Menu A V Big Meters Menu factory default Standard Menu To set the Display Configuration Ac...

Page 21: ...Function to the Right Button To the Right Button 12 can assign Icon Description PF44 PF46 Disabled OFF factory default Crater Procedure Rub in WFS Wave Controls Recall the Program stored in the User Memory Note To use the assigned functions Recall the Program stored in the User Memory Crater Procedure Run in WFS icons of these functions must be added to the Welding Parameters Bar 27 To assign the ...

Page 22: ...n 12 is pressed the Crater Interface Settings will be shown on the display The Brightness Level Enables the Brightness Level Adjust range from 0 to 10 Lock Unlock Can lock unlock Icon Description PF44 PF46 All Interface Components The Left 9 and or Right 10 Control The Welding Parameters Bar 27 The Set Control 11 and the Left 7 and the Right 12 button Configuration Menu M User Memory To set the lo...

Page 23: ...cess to the Lock Menu In that case to change the Lock Settings the User Passcode needs to be set The default passcode is 0000 It enables free access to Lock Menu Restore Factory Settings Note After Factory Settings restore the settings stored in user memory are deleted To restore Factory Settings Access to the Settings and Configuration Menu Use the Set Control 11 to highlight the Restore Factory ...

Page 24: ...re 49 Press the Set Control 11 The Configuration Menu is shown on the display Use the Set Control 11 to highlight the Parameter Number which will be changed for example P 1 allows change WFS units factory default Metric m min P 0 P 1 P 2 P 4 Wire Feed Speed Units Metric P 5 Figure 50 Press The Set Control 11 Use the Set Control 11 to highlight the English in min P 0 P 1 P 2 P 4 P 5 Wire Feed Speed...

Page 25: ...procedure A settings The procedure can be changed as many times as needed during the weld Release the trigger to stop welding When the next weld is made the system will start again with procedure A IntegralTrigProc Allows switching between Procedure A and procedure B while welding with 4 stroke mode When in 2 step the system operates identical to the External Switch selection To operate in 4 step ...

Page 26: ...on the push pull gun The Left Control 9 is only used to adjust Start and Crater wire feed speed Gun Pot Disabled The wire feed speed is always controlled by the Left Control 9 This setting is useful when the operator wishes to have wire feed speed settings recalled from memories and not have the potentiometer overwrite the setting Gun Pot Proc A When in procedure A the welding wire feed speed is c...

Page 27: ... STT weld mode is selected the left and right joystick positions will adjust Background Current When a Power mode is selected the left and right joystick positions will adjust the Power kW WFS Job memory The left and right joystick positions will Select a user memory while not welding Adjust Trim Voltage Power STT Background Current while welding WFS Proced A B The left and right joystick position...

Page 28: ...tivate the Welding Parameters Bar 27 press the Set Control 11 Standard On the Display is shown preset information during and after a weld P 501 Encoder Lockout Locks one or both of the upper Controls 9 and 10 preventing the operator from changing wire feed speed amps volts or trim The function of each upper Control depends on the selected weld mode Both Encoders Unlocked factory default The Left 9...

Page 29: ...meter can only be accessed using PowerWave Manager software P 505 Setup Menu Lock Determines if the setup parameters can be modified by the operator without entering a passcode No factory default The operator can change any set menu parameter without first entering the passcode even if the passcode is non zero 0000 Yes The operator must enter the passcode if the passcode is non zero in order to ch...

Page 30: ...l 11 to highlight the Check Mark icon Figure 53 Press the Right Button 12 to confirm the USB Memory Stick selectrion Use the Set Control 11 to highlight the Save icon Figure 54 Press the Right Button 12 to confirm the save on a USB Memory Stick Create or chose a file in which will be saved copies of the data mark means a new file Figure 55 The display shows the Save Data Menu on a USB Memory Stick...

Page 31: ...m the USB Memory selection Use the Set Control 11 to highlight the load data icon from the USB Memory Stick Figure 60 Select the file name with the data to be loaded into interface Highlight the file icon use Set Control 11 LEB1 WMB LEB2 WMB Figure 61 Press the Right Button 12 to confirm the file selection The display shows the Load Data Menu from a USB Memory Stick to User Interface Use the Set C...

Page 32: ... the input power ON Set the SMAW welding program 1 2 or 4 Note The list of available programs depends on the power source Set the welding parameters The welding machine is now ready to weld By applying the principle of occupational health and safety at welding welding can be begun For 1 or 2 program can set Welding current 9 Switch on switch off the output voltage on the output lead 10 Wave Contro...

Page 33: ...elding Program gouging Process Program Gouging 9 Note The list of available programs depends on the power source For 9 program can set Gouging current 9 Switch on switch off the output voltage on the output lead 10 0A 0 0V 9 237 A V Figure 66 ...

Page 34: ...llimeters contact ignition and lift ignition By applying the principle of occupational health and safety at welding welding can be begun For 3 program can set Welding current 9 Switch on switch off the output voltage on the output lead 10 Note It does not work in the 4 Step Postflow Time 2 Step 4 Step Crater 27 Wave Control 27 HOT START For 8 program can set Welding current 9 Switch on switch off ...

Page 35: ...rc is narrower more stable Reduces the amount of heat input to the weld Reduces distortions Increases welding speed Note Adjust range depend on the power source A 0 3 35 0 0 3 Figure 69 Background Current value in percentage of nominal value welding current Adjusts the overall heat input into the weld Changing the background current changes the shape of the back bead A 20 100 20 Figure 70 ...

Page 36: ...traight as possible when loading electrode through cable WARNING Never use defected gun Check gas flow with Gas Purge Switch 19 GMAW and FCAW GS process Close the wire drive door Close the spool wire case Select the right welding program Non synergic programs are described in the Table 17 Note The list of available programs depends on the power source Set the welding parameters The welding machine...

Page 37: ...rt arc welding Increasing Pinch Control greater than 0 0 results in a crisper arc more spatter while decreasing the Pinch Control to less than 0 0 provides a softer arc less spatter Adjust range from 10 to 10 Factory default Pinch is OFF M 10 0 10 0 OFF OFF Figure 72 ...

Page 38: ...es if the voltage is above or below the ideal voltage Preset voltage above ideal voltage v 23 5 Preset voltage at ideal voltage v 25 9 Preset voltage below ideal voltage v 27 8 Additionally can manually set Burnback Run In WFS Preflow Time Postflow Time Spot Time 2 Step 4 Step Crater Wave Control Pinch The 2 Step 4 Step changes the function of the gun s trigger 2 Step trigger operation turns weldi...

Page 39: ...he waveform parameters to maintain good welding characteristics Trim 10 is used as a secondary control the value of parameter in the upper right side of display 26 The Trim setting adjusts the arc length Trim is adjustable from 0 50 to 1 50 1 00 is the nominal setting Increasing the Trim value increases the arc length Decreasing the Trim value decreases the arc length 1 00 0 50 1 50 Figure 75 When...

Page 40: ...Arc Control value the arc is tight stiff for high speed sheet metal welding Adjust range from 10 to 10 Factory default UltimArc is OFF M 10 0 10 0 OFF OFF Figure 77 1 2 3 Figure 78 1 UltimArc Control 10 0 Low Frequency Wide 2 UltimArc Control OFF Medium Frequency and Width 3 UltimArc Control 10 0 High Frequency Focused ...

Page 41: ...ht side of display 26 The Trim setting adjusts the arc length Trim is adjustable from 0 50 to 1 50 1 00 is the nominal setting Increasing the Trim value increases the arc length Decreasing the Trim value decreases the arc length 1 00 0 50 1 50 Figure 80 When Trim is adjusted the power source automatically recalculates the voltage current and time of each part of the pulse waveform for the best res...

Page 42: ...ld Reduces distortions Increases welding speed Note Adjust range from 10 to 10 The frequency controls the spacing of the ripples in the weld Frequency less than 0 0 Wide weld and ripple spacing slow travel speed Figure 82 shows the spacing weld when the frequency is 10 10 0 10 0 OFF 10 0 Figure 82 Frequency greater then 0 0 Narrow weld and ripple spacing fast travel speed Figure 83 shows the spaci...

Page 43: ...eat input much easier without overheating or burning through and distortion is minimized STT is also ideal for Open root welding Welding on thin materials Welding on parts with poor fit up During STT welding sense lead has to be connected to the workpiece Welding STT in non synergic mode Manually can set Wire Feed Speed WFS 9 Burnback Time Run in WFS Preflow Time Postflow Time Spot Time 2 Step 4 S...

Page 44: ...range from 0 to 10 A OFF 10 0 OFF A Figure 86 TailOut provides additional heat into the weld without increasing the arc length or the droplet size Higher tailout values improve wetting and may give faster travel speeds Adjust Range from 0 to 10 A OFF 10 0 OFF Figure 87 Background Current adjusts the overall heat input into the weld Changing the background current changes the shape of the back bead...

Page 45: ...el can be installed but the applicable adapter must be purchased The applicable adapter can be purchased separately see Accessories chapter Wire Spool Type S300 BS300 Loading WARNING Turn the input power OFF at the welding power source before installation or changing a wire spool 28 29 30 31 Figure 92 Turn the input power OFF Open the spool wire case Unscrew the Locking Nut 28 and remove it from t...

Page 46: ...re that the locking nut is tightened Wire Spool Type B300 Loading WARNING Turn the input power OFF at the welding power source before installation or changing a wire spool 28 30 31 36 35 Figure 94 Turn the input power OFF Open the spool wire case Unscrew the Locking Nut 28 and remove it from the Spindle 30 Place the adapter of spool type B300 35 on the spindle 30 Make certain that the spindle brak...

Page 47: ...l wire case Unscrew the locking nut of the sleeve Load the spooled wire on the sleeve such that the spool turns clockwise when the wire is fed into the wire feeder Make sure that the spindle brake pin 38 goes into the fitting hole on the spool Screw in the locking nut of the sleeve Open the wire drive door Put on the wire roll using the correct groove corresponding to the wire diameter Free the en...

Page 48: ...ded end Or the Cold Inch Gas Purge Switch 19 can be used keep in Cold Inch position until the wire comes out of the threaded end When trigger or the Cold Inch Gas Purge Switch 19 is released spool of wire should not unwind Adjust wire spool brake accordingly Turn the welding machine off Install a proper contact tip Depending on the welding process and the type of the gun install the nozzle GMAW pr...

Page 49: ...d Maintenance WARNING For any repair operations modifications or maintenance it is recommended to contact the nearest Technical Service Center or Lincoln Electric Repairs and modifications performed by unauthorized service or personnel will cause the manufacturer s warranty to become null and void Any noticeable damage should be reported immediately and repaired Routine maintenance everyday Check ...

Page 50: ...does not exceed duty cycle limit of the machine Check the setup for proper air flow around and through the system Check that the system has been properly maintained including removal of accumulated dust and dirt from the intake and outlet louvers 81 Motor overload long term The wire drive motor has overheated Check that the electrode slides easily through the gun and cable Remove tight bends from ...

Page 51: ... will protect the environment and human health Spare Parts 12 05 Part List reading instructions Do not use this part list for a machine if its code number is not listed Contact the Lincoln Electric Service Department for any code number not listed Use the illustration of assembly page and the table below to determine where the part is located for your particular code machine Use only the parts mar...

Page 52: ...M Source wire feeder cable gas and water Available in 5 10 or 15m Speedtec Power Wave S350 S500 CE K10348 PG xxM Source wire feeder cable gas Available in 5 10 or 15m Power Wave 455M Power Wave 455M STT Power Wave 405M K10348 PGW xxM Source wire feeder cable gas and water Available in 5 10 or 15m Power Wave 455M Power Wave 455M STT Power Wave 405M KP10519 8 TIG Euro adapter K10315 26 4 TIG Torch F...

Page 53: ...nection Diagram K14 1 091 K1412 1 3 K14121 1 K14108 1 PF44 K1412 1 5 K2909 1 K10095 1 K14121 1 K1412 1 2 K1412 1 3 K1412 1 4 K1412 1 2 K14121 1 K14109 1 PF46 K14 1 091 K2909 1 K10095 1 K14121 1 K1412 1 2 K1412 1 3 K1412 1 4 ...

Page 54: ...English English 51 K10348 PGW XXM 9 K10348 PG XXM K1034 PGW XXM K1034 PG XXM 9 K14108 1 PF44 K14109 1 PF46 ...

Page 55: ...English English 52 K10348 PGW XXM 9 K10348 PG XXM K1034 PGW XXM K1034 PG XXM 9 K14121 1 K1412 1 2 K1412 1 3 K1412 1 4 K141 1 32 K141 1 31 K14108 1 PF44 K14109 1 PF46 ...

Page 56: ...English English 53 K10348 PGW XXM 9 K10348 PG XXM K1034 PGW XXM K1034 PG XXM 9 K141 1 31 K14108 1 PF44 K14109 1 PF46 K14121 1 K1412 1 2 K1412 1 3 K1412 1 4 K141 1 32 ...