Operator’s Manual

AutoDrive 4R220 ®

For use with machines having Code Numbers:

12789

Register your machine:

www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10471 | Issue Date Mar-18

© Lincoln Global, Inc. All Rights Reserved.
 THANK YOU FOR SELECTING
A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES.
LINCOLN ELECTRIC. DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label
DAMAGE IMMEDIATELY that appears on all containers of
When this equipment is shipped, title passes to the purchaser welding materials.
upon receipt by the carrier. Consequently, claims for material USE ENOUGH VENTILATION or
damaged in shipment must be made by the purchaser against the exhaust at the arc, or both, to
transportation company at the time the shipment is received. keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
SAFETY DEPENDS ON YOU
USE NATURAL DRAFTS or fans to keep the fumes away
Lincoln arc welding and cutting equipment is designed and built
from your face.
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part. If you develop unusual symptoms, see your supervisor.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT Perhaps the welding atmosphere and ventilation system
WITHOUT READING THIS MANUAL AND THE SAFETY should be checked.
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
WARNING PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life. PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
CAUTION leggings, and high boots.
PROTECT others from splatter, flash, and glare
This statement appears where the information must be followed with protective screens or barriers.
to avoid minor personal injury or damage to this equipment.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.

SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 5/16/2018
 SAFETY

SECTION A: 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

WARNINGS
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
CALIFORNIA PROPOSITION 65 WARNINGS Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
WARNING: Breathing diesel engine exhaust repairing equipment.
exposes you to chemicals known to the State 1.e. In some cases it may be necessary to remove safety guards to
of California to cause cancer and birth defects, perform required maintenance. Remove guards only when
or other reproductive harm. necessary and replace them when the maintenance requiring
• Always start and operate the engine in a their removal is complete. Always use the greatest care when
well-ventilated area. working near moving parts.
• If in an exposed area, vent the exhaust to the outside. 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
• Do not modify or tamper with the exhaust system.
rods while the engine is running.
• Do not idle the engine except as necessary.
1.g. To prevent accidentally starting gasoline engines while turning
For more information go to the engine or welding generator during maintenance work,
www.P65 warnings.ca.gov/diesel disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
WARNING: This product, when used for welding or 1.h. To avoid scalding, do not remove the radiator
cutting, produces fumes or gases which contain pressure cap when the engine is hot.
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm ELECTRIC AND

www.P65warnings.ca.gov MAGNETIC FIELDS MAY
BE DANGEROUS
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS 2.a. Electric current flowing through any conductor
INJURY OR DEATH. KEEP CHILDREN AWAY. causes localized Electric and Magnetic Fields (EMF).
PACEMAKER WEARERS SHOULD CONSULT WITH Welding current creates EMF fields around welding cables
THEIR DOCTOR BEFORE OPERATING. and welding machines
Read and understand the following safety highlights. For 2.b. EMF fields may interfere with some pacemakers, and
additional safety information, it is strongly recommended welders having a pacemaker should consult their physician
that you purchase a copy of “Safety in Welding & Cutting - before welding.
ANSI Standard Z49.1” from the American Welding Society,
2.c. Exposure to EMF fields in welding may have other health effects
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
which are now not known.
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. minimize exposure to EMF fields from the welding circuit:
BE SURE THAT ALL INSTALLATION, OPERATION, 2.d.1. Route the electrode and work cables together - Secure
MAINTENANCE AND REPAIR PROCEDURES ARE them with tape when possible.
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. 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
FOR ENGINE POWERED work cable should also be on your right side.

EQUIPMENT. 2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
1.a. Turn the engine off before troubleshooting 2.d.5. Do not work next to welding power source.
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 vaporizing on contact Safety 02 of 04 - 5/16/2018
 SAFETY

ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your
electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or
not touch these “hot” parts with your bare skin or wet clothing. observing open arc welding. Headshield and filter lens should
Wear dry, hole-free gloves to insulate hands. conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped FUMES AND GASES
positions such as sitting, kneeling or lying, if there CAN BE DANGEROUS.
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following 5.a. Welding may produce fumes and gases
equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep your head out of the fume.
• DC Manual (Stick) Welder. Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
• AC Welder with Reduced Voltage Control.
hardfacing (see instructions on container or SDS)
3.c. In semiautomatic or automatic wire welding, the electrode, or on lead or cadmium plated steel and other
electrode reel, welding head, nozzle or semiautomatic welding metals or coatings which produce highly toxic
gun are also electrically “hot”. fumes, keep exposure as low as possible and
3.d. Always be sure the work cable makes a good electrical within applicable OSHA PEL and ACGIH TLV limits
connection with the metal being welded. The connection should using local exhaust or mechanical ventilation
be as close as possible to the area being welded. unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
3.e. Ground the work or metal to be welded to a good electrical (earth) outdoors, a respirator may also be required.
ground. Additional precautions are also required when
3.f. Maintain the electrode holder, work clamp, welding cable and welding
welding machine in good, safe operating condition. Replace on galvanized steel.
damaged insulation. 5. b. The operation of welding fume control equipment is affected by
3.g. Never dip the electrode in water for cooling. various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.h. Never simultaneously touch electrically “hot” parts of electrode welding procedure and application involved. Worker exposure
holders connected to two welders because voltage between the level should be checked upon installation and periodically
two can be the total of the open circuit voltage of both thereafter to be certain it is within applicable OSHA PEL and
welders. ACGIH TLV limits.
3.i. When working above floor level, use a safety belt to protect 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
yourself from a fall should you get a shock. coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
3.j. Also see Items 6.c. and 8.
phosgene, a highly toxic gas, and other irritating products.
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
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.

Safety 03 of 04 - 5/16/2018
 SAFETY

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. If the correct shielding gas for the process used
this is not possible, cover them to prevent the welding sparks and properly operating regulators designed for
from starting a fire. Remember that welding sparks and hot the gas and pressure used. All hoses, fittings,
materials from welding can easily go through small cracks and etc. should be suitable for the application and
openings to adjacent areas. Avoid welding near hydraulic lines. maintained in good condition.
Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. 7.c. Cylinders should be located:
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
• Away from areas where they may be struck or subjected
and the operating information for the equipment being used.
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit is • A safe distance from arc welding or cutting operations
touching the work or ground. Accidental contact can cause and any other source of heat, sparks, or flame.
overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside. 7.e. Keep your head and face away from the cylinder valve outlet
They can cause an explosion even though they have been when opening the cylinder valve.
“cleaned”. For information, purchase “Recommended Safe 7.f. Valve protection caps should always be in place and hand tight
Practices for the Preparation for Welding and Cutting of except when the cylinder is in use or connected for use.
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society 7.g. Read and follow the instructions on compressed gas cylinders,
(see address above). associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
6.e. Vent hollow castings or containers before heating, cutting or the Compressed Gas Association, 14501 George Carter Way
welding. They may explode.
Chantilly, VA 20151.
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. FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area POWERED EQUIPMENT.
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on
crane cables or other alternate circuits. This can create fire the equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.

Safety 04 of 04 - 5/16/2018
AUTODRIVE 4R220 TABLE OF CONTENTS

INSTALLATION............................................................................................................................................. SECTION A
TECHNICAL SPECIFICATIONS..................................................................................................................................... A-1
PRODUCT DESCRIPTION............................................................................................................................................ A-1
RECOMMENDED PROCESSES.................................................................................................................................... A-1
PROCESS LIMITATIONS..............................................................................................................................................A-1
EQUIPMENT LIMITATIONS.......................................................................................................................................... A-1
RECOMMENDED POWER SOURCES............................................................................................................................A-1
DUTY CYCLE ............................................................................................................................................................ A-2
SELECT SUITABLE LOCATION.....................................................................................................................................A-2
SOFTWARE: ............................................................................................................................................................ A-2
WELD CABLE SIZE..................................................................................................................................................... A-2
COAXIAL WELD CABLE...............................................................................................................................................A-3
WIRE DRIVE CABLE, K1785-XX.................................................................................................................................. A-4
SHIELDING GAS CONNECTION....................................................................................................................................A-5
PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES........................................................................................ A-6
PRESSURE ARM ADJUSTMENT.................................................................................................................................. A-7
LOADING WIRE.......................................................................................................................................................... A-7
CONDUIT INSTALLATION............................................................................................................................................A-7

OPERATION.................................................................................................................................................. SECTION B
DEFINITION OF WELDING TERMS............................................................................................................................... B-1
GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL............................................................... B-1

OPTIONAL KITS AND ACCESSORIES............................................................................................................ SECTION C

MAINTENANCE............................................................................................................................................. SECTION D
ROUTINE MAINTENANCE............................................................................................................................................D-1
BRUSHES ............................................................................................................................................................ D-1

TROUBLESHOOTING......................................................................................................................................SECTION E

WIRING DIAGRAM & DIMENSION PRINTS.................................................................................................... SECTION F

PARTS LIST................................................................................................................. PARTS.LINCOLNELECTRIC.COM

CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION MANUALS,
GO TO PARTS.LINCOLNELECTRIC.COM.

2
AUTODRIVE 4R220 INSTALLATION

INSTALLATION
ProDuCt DesCriPtion
TECHNICAL SPECIFICATIONS - The AutoDrive® 4R220 wire feeder is fully controlled and operated
AutoDrive® 4r220 (K3561-1) by a robot, control box or user interface on the power source.

General Physical Description

INPUT VOLTAGE, CURRENT Refer to the appropriate manual for operating the wire drive.
Input Voltage ± 10% Input Amperes
0-40 VDC 7A The AutoDrive® 4R220 wire feeder is powerful yet compact wire
drive for robotic and hard automation applications.
RATED OUTPUT @ 104°F (40°C) The MAXTRAC 4 roll wire drive gives steady feeding of all wire
DUTY CYCLE INPUT AMPERES sizes and types. The drive features split wire guides, tool-less
100% RATING 500 drive roll changing, dual spring pressure arms and changeable
gun bushings all mounted in a precision die cast aluminum frame.
A right angle gear box efficiently transfers motor power for both
GEARING - WIRE FEED SPEED RANGE-WIRE SIZE high torque and high speed.
GMAW FCAW The AutoDrive® 4R220 features a powerful motor with an efficient
WFS Range Wire Sizes WFS Range Wire Sizes two stage gearbox. This feeder is best for feeding larger diameter
wires, pulling wire through long conduits, and in applications
50 – 1200 IPM .023 – 1/16" 50 – 1200 IPM .035 - 5/64” requiring extra ruggedness. A door covers the wire drive,
(1.3 – 30.5M/MIN) (0.6 – 1.2MM) (1.3 – 30.5M/MIN) (0.9 – 2.0MM) protecting it from dust.
Robotic mounting brackets are not included. Necessary
PHYSICAL DIMENSIONS
mounting brackets can be found on the Robotic Compatibility
Height
General Functional Description
10.22 INCHES (260 MM) Chart - Table A.1
Width 10.48 INCHES (266 MM)
Depth 9.92 INCHES (252 MM) The AutoDrive® 4R220 features a dual channel, high resolution
tachometer for precision wire feeding both forwards and in
Weight 22.0 LBS (10.0 KG) reverse.

TEMPERATURE RANGES reCoMMenDeD ProCesses

Operating -40°F TO 104°F (-40°C TO 40°C) • GMAW
Storage -40°F TO 185°F (-40°C TO 85°C) • FCAW
• STT®

WARNING
SAFETY PRECAUTIONS
ProCess LiMitAtions
• Maximum wire size = 1/16 (1.6mm)
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the
welding power source before eQuiPMent LiMitAtions
installation or changing drive rolls • Maximum GMAW gun length = 10’ (3.1m)
and/or guides.
• Maximum FCAW gun length = 15’ (4.6m)
• Do not touch electrically live parts.
• Maximum wire drive control cable length = 100ft. (31m)
• When inching with the gun trigger,
• Robot and power source software may need to be updated.
electrode and drive mechanism are "hot" to work and
ground and could remain energized several seconds • Drive rolls are not included with the feeder.
after the gun trigger is released. • Maximum Conduit Length 50 Ft. (15m).
• Welding power source must be connected to system
ground per the National Electrical Code or any
reCoMMenDeD PoWer sourCes
applicable local codes.
• Power Wave® R450
• Only qualified personnel should perform maintenance
work. • Power Wave® i400

A-1
AUTODRIVE 4R220 INSTALLATION

seLeCt suitABLe LoCAtion soFtWAre:

Firmly secure the AutoDrive® 4R220 wire feeder to a robot arm or When the feeder is installed in a Power Wave® or Robotic system,
fixture. select “AutoDrive® 4R220” from the list of feeders. Refer to the
Feeder installation instructions are included with the robotic Power Wave® or Robotic manual.
mounting bracket. For the mounting bracket specific to your robot,

TABLE A.1
see the Robot Compatibility Chart - Table A.1. DutY CYCLe
• The duty cycle is based upon the amount of welding
ROBOT COMPATABILITY CHART
performed in a 10 minute period.
Robot Mounting Bracket K#
• Thermal test have been performed at ambient temperature.
FANUC The duty cycle (duty factory) @ 40°C (104ºF) has been
FANUC iD K3562-1 determined by simulation.
FANUC iC K3562-2
ABB
WeLD CABLe siZe
IRB1520ID K3573-1
Table A.2 located below are copper cable sizes recommended for
IRB1660ID K3573-2 different currents and duty cycles. Lengths stipulated are the
IRB2600ID K3573-3 distance from the welder to work and back to the welder again.
IRB1600 K3573-4 Cable sizes are increased for greater lengths primarily for the
IRB2600 K3573-5 purpose of minimizing cable drop.
IRB4600 K3573-6
YASKAWA
MA1440 K3572-1
MA2010 K3572-2
KUKA
Kuka Thru-Arm K3574-1
Kuka Over-Arm K3574-2
Mount only in a dry environment.
This equipment is for industrial use only and it 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 residential locations due to conducted as well as
radiated radio-frequency disturbances. The EMC or RF classi-
fication of this equipment is Class A.

TABLE A.2
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES PERCENT
DUTY 0 to 50Ft. 50 to 100Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.
(0 to15m) (15 to 30m) (30 to 46m) (46 to 61m) (61 to 76m)
CYCLE

200 60 2 2 2 1 1/0
200 100 2 2 2 1 1/0
225 20 4 or 5 3 2 1 1/0
225 40 & 30 3 3 2 1 1/0
250 30 3 3 2 1 1/0
250 40 2 2 1 1 1/0
250 60 1 1 1 1 1/0
250 100 1 1 1 1 1/0
300 60 1 1 1 1/0 2/0
325 100 2/0 2/0 2/0 2/0 3/0
350 60 1/0 1/0 2/0 2/0 3/0
400 60 2/0 2/0 2/0 3/0 4/0
400 100 3/0 3/0 3/0 3/0 4/0
500 60 2/0 2/0 3/0 3/0 4/0

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).

A-2
AUTODRIVE 4R220 INSTALLATION

CoAXiAL WeLD CABLe TABLE A.3

Coaxial welding cables are specially designed welding cables for RECOMMENDED CABLE SIZES
STT® and pulse welding. Coaxial weld cables feature low (RUBBER COVERED COPPER - RATED 75°C)**
inductance, allowing fast changes in the weld current. Regular COAXIAL CABLE LENGTH
cables have a higher inductance which may distort the STT® Duty 0 to 25 to 50 to 75 to
Amperes
waveshape. Inductance becomes more severe as the weld cables Cycle 25 Ft. 50 Ft. 75 Ft. 100 Ft.
become longer.
250 100% 1 1 1 1
Coaxial weld cables are recommended for STT® welding,
especially when the total weld cable length (electrode cable + 300 60% 1 1 1 1/0
work cable) exceeds 50 feet (7.6m). See Table A.3.
350 60% 1/0 1/0 -- --
A coaxial weld cable is constructed with multiple small leads
wrapped around one large lead. The large inner lead connects to ** Tabled values are for operation at ambient temperatures of 104°F(40°C) and
below. Applications above 104°F(40°C) may require cables larger than
recommended, or cables rated higher than 167°F(75°C).
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.
To install:
1. Turn the input power off at the welding power source.
2. Connect one end of the center lead to the power source
electrode connection, and the other end to the wire feeder
electrode connection.
3. Connect the outer lead bundle to the power source work
connection, and the other end to the work piece. Minimize the
length of any work lead extension for best results.
4. Insulate all connections.

Figure A.1

Power Source Wire Feeder

Electrode

Electrode
Work
– +
Work Electrode

Coaxial Weld Cable

K1796-XX (XX is length in feet)

Work

A-3
AUTODRIVE 4R220 INSTALLATION

Wire Drive CABLe, K1785-XX

Wire drive cables are used to connect power sources and control
boxes to remote wire drives.
The cables have a 14-pin connector at each end. Both ends of
the cable have a collar and the cables cannot be “daisy chained”
to make a longer cable.

POWER SOURCE WIRE FEEDER

J A A J
I K B B K I

H N L C C L N H

G M D M G
D
F E E F

POWER SOURCE WIRE FEEDER

Pin Function Pin Function

A Motor Power A Motor Power

B Motor Power B Motor Power
C Gas Solenoid C Gas Solenoid
D Gas Solenoid D Gas Solenoid
E Reserved E “2A” Differential Tachometer
F Reserved F Reserved
G “2A” Differential Tachometer G +15VDC Tech Supply
H “2B” Differential Tachometer H Tachometer Common
I Reserved I Reserved
J Reserved J Reserved
K “1A” Differential Tachometer K “1A” Differential Tachometer
L “1B” Differential Tachometer L “1B” Differential Tachometer
M Reserved M “2B” Differential Tachometer
N “67” Electrode Sense Lead N “67” Electrode Sense Lead

A-4
AUTODRIVE 4R220 INSTALLATION

4. Attach the flow regulator to the cylinder valve and tighten the
union nut(s) securely with a wrench. Note: if connecting to
sHieLDinG GAs ConneCtion 100% CO2 cylinder, insert regulator adapter between

WARNING
regulator and cylinder valve. If adapter is equipped with a
plastic washer, be sure it is seated for connection to the CO2
cylinder.
CYLINDER may explode 5. Attach one end of the inlet hose to the outlet fitting of the flow
if damaged. regulator. Attach the other end to the welding system
• Keep cylinder upright and chained to shielding gas inlet. Tighten the union nuts with a wrench.
support. 6. Before opening the cylinder valve, turn the regulator adjusting
• Keep cylinder away from areas where it knob counterclockwise until the adjusting spring pressure is
may be damaged. released.
• Never lift welder with cylinder attached. 7. Standing to one side, open the cylinder valve slowly a fraction
of a turn. When the cylinder pressure gage stops moving,
• Never allow welding electrode to touch cylinder. open the valve fully.
• Keep cylinder away from welding or other live electrical 8. The flow regulator is adjustable. Adjust it to the flow rate
circuits. recommended for the procedure and process being used
before making a weld.

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” Published by
the American Welding Society.

----------------------------------------------------------------------
Maximum inlet pressure is 100 psi. (6.9 bar.)
Install the shielding gas supply as follows:

FIGURE A.2
1. Secure the cylinder to prevent it from falling.

Cylinder Cap

Regulator

Chained to
Support

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.

A-5
AUTODRIVE 4R220 INSTALLATION

To remove drive rolls and wire guides:

ProCeDure to instALL Drive roLLs AnD Wire 1. Turn power off at the welding power source.

WARNING
GuiDes
2. Remove the outer wire guide.
3. To unlock Drive Hub, lift up on the Leaf Spring tab 1/8”. Twist
the Twist Lock Ring (while the Leaf Spring tab is lifted) until
ELECTRIC SHOCK can kill. the spline of the Twist Lock Ring is aligned with the spline of
• Turn the input power OFF at the welding the Drive Hub Assembly. See Figure A.3 (drive roll not shown
power source before installation or for clarity).
changing drive rolls and/or guides.
4. Move Pressure Arm down open the Idler Arms.
• Do not touch electrically live parts.
5. Remove the drive rolls and inner wire guide.
• When inching with the gun trigger, electrode and drive

To install drive rolls and wire guides:

mechanism are "hot" to work and ground and could
remain energized several seconds after the gun trigger
is released.
1. Turn off power at the welding power source.
• Do not operate with covers, panels or guards removed
or open.
2. Move Pressure Arm down open the Idler Arms.
• Only qualified personnel should perform maintenance
3. Assemble the inner wire guide.
work. 4. Slide the drive rolls onto the drive hubs.
5. Close the Idler Arms. Move Pressure Arm up.
6. Rotate all Twist Lock Rings to the locked position.
7. Assemble the outer wire guide.
8. Adjust the Pressure Arms to the recommended setting.
FIGURE A.3

Twist Lock
Ring Spline Twist Lock Ring

Drive Roll
Spline

Leaf Spring Tab

Idler Arm open

Pressure Arm down

Wire Guide

A-6
AUTODRIVE 4R220 INSTALLATION

WARNING WARNING
Pressure ArM ADJustMent LoADinG Wire

ELECTRIC SHOCK can kill. • Keep hands, hair, clothing and tools
• Turn the input power OFF at the welding away from rotating equipment.
power source before installation or • Do not wear gloves when threading
changing drive rolls and/or guides. wire or changing wire spool.
• Do not touch electrically live parts. • Only qualified personnel should install,
• When inching with the gun trigger, electrode and drive use or service this equipment.
mechanism are "hot" to work and ground and could
remain energized several seconds after the gun trigger
is released.
• Do not operate with covers, panels or guards removed
ConDuit instALLAtion
or open.
The K1546-xx series of conduits are compatible with K515-xx,
• Only qualified personnel should perform maintenance
K565-xx, Wire Wizard and Electron Beam Technologies conduits.
work.
To install conduit to the wire drive:
1. Slide the conduit bushing into the feed plate and secure with

FIGURE A.5
The pressure arm controls the amount of force the drive rolls exert the set screw.
on the wire. Proper adjustment of the pressure arm gives the best
welding performance.
Set the pressure arm as follows:
(See Figure A.3)
Aluminum wires between 1 and 3
Cored wires between 3 and 4

FIGURE A.4
Steel, Stainless wires between 4 and 6

Conduit
Bushing Set Screw

A-7
 K1505-XX
K1507-XX
AUTODRIVE 4R220

Electrode
SYSTEM SET-UP

Connection

AutoDrive® 4R100
(Without Cover Shown)
ArcMate 100iC

FANUC R-J30iA Controller

with Integrated Op Box

Wire Feeder
(14 Pin)

Gas Internal ArcLink XT

Communication
Robotic ArcLink XT
Torch Connection

A-8
Power Wave® i400
K2669-1

Air

* Electrode
Optional Work Cable (+)
Sense Lead (21)
K884-5,-6

K1785-XX Wire Feeder Wire Feeder

Control Cable
ArcLink Work (14 Pin)
(5 Pin) Sense
Work Piece
SYSTEM SET-UP (SINGLE ARM)

* Work
Cable (-)

* Refer to "Output Cable Guidelines" for recommended cable size

INSTALLATION
AUTODRIVE 4R220 OPERATION

OPERATION GrAPHiC sYMBoLs tHAt APPeAr on tHis

MACHine or in tHis MAnuAL
Safety Precautions

WIRE FEEDER
Read and understand this entire section before operating
your machine.

WARNING POSITIVE OUTPUT

ELECTRIC SHOCK can kill.

NEGATIVE OUTPUT
• Unless using COLD FEED feature, when
feeding with gun trigger, the electrode
and drive mechanism are always
electrically energized and could remain

INPUT POWER
energized several seconds after the
welding ceases..
• Do not touch electrically live part or electrode with skin

DIRECT CURRENT
or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.

U0 OPEN CIRCUIT
• Do not operate with covers, panels or guards removed

VOLTAGE
or open.

U1 INPUT VOLTAGE
FUMES AND GASSES can be
dangerous.
• Keep your head out of fumes.

U2 OUTPUT VOLTAGE
• Use ventilation or exhaust to remove
fumes from breathing zone.

I1 INPUT CURRENT
WELDING SPARKS can cause fire
or explosion.
• Keep flammable material away.

ARC RAYS can burn. I2 OUTPUT CURRENT

• Wear eye, ear and body protection.

PROTECTIVE
SEE ADDITIONAL WARNING INFORMATION UNDER ARC
WELDING SAFETY PRECAUTIONS AND in the FRONT
GROUND

--------------------------------------------------------------------- WARNING OR
OF THIS OPERATING MANUAL.

CAUTION

DeFinition oF WeLDinG terMs

GMAW - Gas Metal Arc welding
FCAW - Flux Core Arc Welding
STT® - Surface Tension Transfer

B-1
AUTODRIVE 4R220 ACCESSORIES

OPTIONAL KITS AND

ACCESSORIES
DRIVE ROLL KITS 4 ROLL DRIVE
WIRE TYPE KITS ELECTRODE SIZE

Steel Wires: KP1505-030S .023-.030 (0.6-0.8mm) Includes: 4 V groove

KP1505-035S .035 (0.9mm) drive rolls and inner
KP1505-040S .040 (1.0mm) wire guide.
KP1505-045S .045 (1.2mm)

Cored Wires: KP1505-035C .030-.035" (0.8-0.9mm) Includes: 4 Knurled

KP1505-045C .040-.045" (1.0-1.2mm) drive rolls and inner
wire guide.

Aluminum Wires: KP1507-3/64A 3/64" (1.2mm) Includes: 4 polished

U groove drive rolls,
outer wire guide and
inner wire guide.

C-1
AUTODRIVE 4R220 ACCESSORIES

Gun Receiver Bushing (for guns Includes: Gun receiver bush-

K1500-1 with K466-1 Lincoln gun connec- ing, set screw and hex key
tors; Innershield® and Subarc wrench.
guns)

Gun Receiver Bushing (for guns Includes: Gun receiver bush-

K1500-2 with K466-2, K466-10 Lincoln gun ing with hose nipple, set screw
connectors; Magnum® and hex key wrench.
200/300/400 guns and compatible
with Tweco® #2-#4)

Gun Receiver Bushing (for guns Includes: Gun receiver bush-

K1500-3 with K613-7 Lincoln gun connec- ing with hose nipple, set screw
tors; Magnum® 550 guns and com- and hex key wrench.
patible with Tweco® #5)

Gun Receiver Bushing (for gun Includes: Gun receiver bush-

K1500-4 with K466-3 Lincoln gun connec- ing with hose nipple, set screw
tors; compatible with Miller® guns.) and hex key wrench.

Includes: Gun receiver bushing

K1500-5 Gun Receiver Bushing (compatible with hose nipple, 4 guide tubes,
with Oxo® guns.) set screw and hex key wrench.

K489-7 Gun Receiver Bushing (for Lincoln Includes: Gun receiver bushing
Fast-Mate guns.) with trigger connector.

K515-xx Wire Conduit Requires K1546-1

K565-xx Wire Conduit Requires K1546-1

Incoming Bushing, for Lincoln

K1546-1 Conduit .025- 1/16" (0.6 - 1.6mm) Includes: Incoming bushing and
wire. Compatible with Electron hex key wrench.
Beam Conduit.

C-2
AUTODRIVE 4R220 ACCESSORIES

K2175-1 500 lb Accu-Pak® Box Payoff Kit

K2175-2 1000 lb Accu-Pak® Box Payoff Kit

K895-2 Rotary Wire Dispenser

K836-1 Dereeler Adapter

K884-5 Accu-Trak® Drum Payoff Kit – 20

inch diameter

K884-6 Accu-Trak® Drum Payoff Kit – 23

inch diameter

K1796-xx Coaxial Cables Includes: 1 cable of length

“xx” feet. 14-pin connectors on
both ends. Cable length can-
not be extended by connecting
K1785 cables together.

K2593-xx Coaxial Cables

K1785-xx Wire Drive Cables Includes: 1 cable of length

“xx” feet. 14-pin connectors on
both ends. Has collars at both
ends. Used with FANUC arms
that have an integrated cable.

K2709-xx Wire Drive Cables Includes: 1 cable of length “xx”

feet. 14-pin connectors on
both ends. May be daisy
chained to make a longer
cable. Used with FANUC arms
that do not have an integrated
cable.

K1733-1 Wire Straightener Includes: 1 wire straightener

C-3
AUTODRIVE 4R220 MAINTENANCE

MAINTENANCE TROUBLESHOOTING
WARNING
WARNING
HoW to use trouBLesHootinG GuiDe

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding Service and Repair should only be performed by Lincoln
power source before installation or Electric Factory Trained Personnel. Unauthorized repairs
changing drive rolls and/or guides. performed on this equipment may result in danger to the
technician and machine operator and will invalidate your
• Do not touch electrically live parts. factory warranty. For your safety and to avoid Electrical
• When inching with the gun trigger, electrode and drive Shock, please observe all safety notes and precautions
mechanism are "hot" to work and ground and could detailed throughout this manual.
remain energized several seconds after the gun trigger
is released. This Troubleshooting Guide is provided to help you locate and
repair possible machine malfunctions. Simply follow the three-
• Do not operate with covers, panels or guards removed step procedure listed below.
or open.
• Only qualified personnel should perform maintenance Step 1. LOCATE PROBLEM (SYMPTOM).
work.
Look under the column labeled “PROBLEM (SYMPTOMS).” This
column describes possible symptoms that the machine may
routine MAintenAnCe exhibit. Find the listing that best describes the symptom that the
machine is exhibiting.
To Install or remove the AutoDrive® 4R220 for servicing:
Step 2. POSSIBLE CAUSE.
See Installation Section of this Instruction Manual.
The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symptom.
BrusHes:
Step 3. RECOMMENDED COURSE OF ACTION
Every 6 months or every 2.5 million arc starts (which ever comes This column provides a course of action for the Possible Cause,
first), inspect the motor brushes. Replace if shorter than 0.5” generally it states to contact you local Lincoln Authorized Field
(12.7mm). Service Facility.

WARNING
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your local
Lincoln Authorized Field Service Facility.

WARNING
Do not open this machine and do not intro-
duce anything into its openings. Power supply E
must be disconnected from the machine
before each maintenance and service. After
each repair, perform proper tests to ensure ELECTRIC SHOCK can kill.
safety. • Turn off machine at the disconnect switch

WARNING
on the rear of the machine and remove
main power supply connections before
doing any troubleshooting.
Power supply must be disconnected from the
machine before each maintenance and ser-
vice. Always use gloves in compliance with
the safety standards.

D-1
AUTODRIVE 4R220 TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

PROBLEM POSSIBLE AREAS OF RECOMMENDED COURSE
(SYMPTOMS) MISADJUSTMENT(S) OF ACTION

WELDING PROBLEMS
The wire feeder does not 1. Verify the power source is turned on.
feed wire and the drive rolls
do not spin. 2. Verify the circuit breaker for the wire feeder on the power
source has not tripped.
3. Verify power is being supplied to the wire feeder.
The wire feeds erratically. 1. Verify the correct drive rolls and inner wire guide are installed
in the wire drive.
2. Check for sharp bends in the gun liner or conduit.
3. Examine the contact tip for wear and proper size. Replace as
necessary.
4. Check the gun liner and conduit. The welding electrode
should slide easily through both.
5. Verify the proper gun liner is installed.
6. Verify the pressure arms are set properly. Too much pressure
may crush the wire.
7. Inspect the motor for worn brushes.
No shielding gas 1. Verify the gas supply is turned on and not empty.
2. Check the gas hose for cuts. Make sure it is not crushed.
3. Verify the shielding gas hose is connected to the gun bushing If all recommended possible areas
or welding gun. of misadjustment have been
checked and the problem persists,
Variable or "hunting" arc. 1. Check for proper size contact. Make sure the contact tip is not Contact your local Authorized Field
worn, free of spatter and not melted. Service Facility.
2. Clean and tighten all electrode and work connections.

3. Verify the proper polarity is being used for the weld procedure.
4. Make sure the proper electrode stick-out is being maintained.
5. Check the gas flow rate and mixture.
6. Verify the gun bushing is tightly mounted to the wire drive.
7. Verify the gun is tightly mounted to the gun bushing.
8. Verify the electrode lead is connected to the proper connection
block on the feed head.
9. Inspect the motor for worn brushes.
The motor overload errors 1. Check for sharp bends in the gun liner and conduit.
occur.
2. Examine the contact tip for wear and proper size. Replace as
necessary.
3. Check the gun liner and conduit. The welding electrode
should slide easily through both.
4. Verify the proper gun liner is installed.
5. Reduce the pressure arm setting.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR

F-1
 AUTODRIVE 4R220

F-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one
of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
DIAGRAMS
AUTODRIVE 4R220 DIAGRAMS

9.92
10.48
3.10

4.62

10.22
9.43

F-2
 WARNING
l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.
electrode with skin or wet clothing.
l Insulate yourself from work and

AVISO DE
ground.
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oídos y el

PRECAuCION
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
l Aislese del trabajo y de la tierra.

French

ATTENTION
l Ne laissez ni la peau ni des vête- l Gardez à l’écart de tout matériel l Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.

German

WARNuNG
l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese

ATENÇÃO
l Não toque partes elétricas e elec- l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
l Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
 WARNING
l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to guards off.
remove fumes from breathing zone.

AVISO DE
l Los humos fuera de la zona de res- Spanish
l Desconectar el cable de ali- l No operar con panel abierto o

PRECAuCION
piración. mentación de poder de la máquina guardas quitadas.
l Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
aspiración para gases.
French

ATTENTION
l Gardez la tête à l’écart des fumées. l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux
l Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones protection enlevés.
de travail.

German

WARNuNG
l Vermeiden Sie das Einatmen von l Strom vor Wartungsarbeiten l Anlage nie ohne Schutzgehäuse
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
l Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!

Portuguese

ATENÇÃO
l Mantenha seu rosto da fumaça. l Não opere com as tampas removidas. l Mantenha-se afastado das partes
l Use ventilação e exhaustão para l Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. l Não opere com os paineis abertos
l Não toque as partes elétricas nuas. ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
CustoMer AssistAnCe PoLiCY
The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. 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 possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information 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.