Lincoln Electric LN-10 HEADS & CONTROLS IM587-B manual

LN- 10 Heads & Controls Boom Mount or Bench M odels OPERA TOR’S MANUAL IM587-B August, 2007 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPA[...]

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. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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 ski[...]

iii SAFETY iii FOR ELECTRICALL Y 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 manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

iv SAFETY iv Mar. ʻ93[...]

v v Thank You 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[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ....................................................................................................... A-1 General Description .........................................[...]

T ABLE OF CONTENTS Page ...... Diagrams ..........................................................................................................Section F Wiring (LN-10 Control) ...........................................................................................F-1 Wiring (10 Series Wire Drive) ..............................................[...]

WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO Speed Wire Size Speed Wire Size Solid Cored Solid Cored K1563-1,-3 10 Series 35-500 IPM .025 - 3/32 in. .035 - .120 in .50 - 750 IPM .025 - 1/16 in. .035 - 5/64 in. Std Drive Boom Mount (0.89-12.7 M/M) (0.6 - 2.4 mm) (0.9 - 3.0 mm) (1.25 - 19.0 M/M) (0.6 - 1.6 m[...]

A-2 INST ALLA TION LN-10 A-2 All of these features are selected with a tactile-feel keypad, and are set independently using one of two rotating knob encoders, setting levels are displayed on one of two digital LED displays. The 10 Series Wire Drive assemblies include a heavy duty head with externally changeable gear ratio and 4 driven roll drives h[...]

A-3 INST ALLA TION LN-10 A-3 FIGURE A.1 Mounting Synergic 7F Wire Drive Unit (K679-1 or -2) Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gearbox. Reference L9777 (included with Drive unit) to find the size and location of the mounting holes. The gearbox assembly is electrically “hot” when the[...]

A-4 INST ALLA TION LN-10 A-4 Electrode Routing The electrode supply may be either from reels, Readi- Reels, spools, or bulk packaged drums or reels. Observe the following precautions: a) The electrode must be routed to the wire drive unit so that the bends in the wire are at a mini- mum, and also that the force required to pull the wire from the re[...]

A-5 INST ALLA TION LN-10 A-5 WIRE FEED DRIVE ROLL KITS NOTE: The maximum rated solid and cored wire sizes for each wire drive head and selected drive ratio is shown on the SPECIFICATIONS in the front of this section. The electrode sizes that can be fed with each roll and guide tube are stenciled on each part. Check the kit for proper components. Sy[...]

A-6 INST ALLA TION LN-10 A-6 6) Install each drive roll by pushing over shaft until it butts up against locating shoulder on the drive roll shaft. (Do Not exceed maximum wire size rating of the wire drive). 7) Install Outer Wire Guide by sliding over locating pins and tightening in place. 8) Engage upper drive rolls if they are in the “open” po[...]

A-7 INST ALLA TION LN-10 A-7 Gun Cable Connection with Fast-Mate Connection 1. Check that the drive rolls, feeder guide tubes and gun connector guide tube are appropriate for the electrode size being used. If necessary, change them per “Wire Drive Roll Kits” in this section. 2. Connect gun to gun connector making sure all pins and gas tube line[...]

A-8 INST ALLA TION LN-10 A-8 ELECTRICAL INST ALLA TION Input Cable: LN-10 Control to Power Source K1501-10 (Control Cable only) Consists of a 9-conductor control cable with 14-pin control cable plug, without electrode cable, and is available in a length of 10 ft. (3 m). With input power disconnected from the power source, install the input cable pe[...]

A-9 INST ALLA TION LN-10 A-9 OPTIONAL FEA TURES INST ALLA TION Dual Procedure Switch Options K683-1 Dual Procedure Switch (One per gun) - Requires K686-2 Adapter for LN-10. Kit includes gun switch, and mountings for Lincoln Innershield and Magnum guns, with 15 ft. (4.5 m) control cable and 3- pin plug. K686-2 Adapter permits 3-pin plug and 5-pin gu[...]

B-1 OPERA TION B-1 LN-10 OPERA TING INSTRUCTIONS Safety Precautions Duty Cycle The LN-10 models are rated at 60% duty cycle * for a maximum current of 600 amps. * Based on a 10 minute time period (6 minutes on, and 4 minutes off). LN-10 CONTROL DIP SWITCH SETUP Initial set up of the LN-10 control for the system com- ponents being used and for gener[...]

B-2 OPERA TION B-2 Setting the DIP Switches The DIP switches are each labeled with an “ON” arrow showing the on direction for each of the 8 indi- vidual switches in each DIP switch (S1 and S2). The functions of these switches are also labeled and set as described below: Wire Drive Head Selection The LN-10 control is set up for proper presettabl[...]

Metric/English Wire Feed Speed Display Selection The LN-10 Control is set up for Wire Feed Speed dis- play in Metric units (m/min.) or English units (IPM) by setting S2 DIP Switch 1 (Labeled “M”): S2 switch 1 OFF = IPM (as shipped) S2 switch 1 ON = m/min 4-Step T rigger Mode Operation Selection The LN-10 Control is set up for 4-Step Trigger mod[...]

S2 switch 2 ON = 4-Step without current interlock operation: 1) Closing Trigger initiates gas flow. 2 ) Opening Trigger initiates gas preflow timer fol- lowed by Run-in speed and strike voltage until arc strike initiates welding. (Trigger is released before arc is struck, but once established breaking arc stops the feeder operation). 3 ) Reclosing [...]

B-5 OPERA TION B-5 Minimum Limits Setting Mode Selection The LN-10 control is set up for allowing a minimum weld WFS and arc voltage setting for each procedure by set- ting S2 DIP Switch 6 (Labeled “-”). S2 switch 6 ON - Minimum Limits Setting mode ON When Minimum Limits Setting mode is selected, all keys except the procedure key are disabled. [...]

B-6 OPERA TION B-6 Keypad and Display Description Keypad - Seven key, membrane type with "snap" tac- tile feel and embossed domes. Long life design. Spatter resistant surface. Displays - Two digital LED displays with .56" (14.2 mm) character height. Top (3-1/2 digit) displays Preset and Actual (while welding) arc voltage in volts wit[...]

B-7 OPERA TION B-7 T rigger Mode Selection Trigger Mode Select key - enables operator to choose mode of operation shown by the indicator lights. Pressing key caus- es mode lights to sequence (top to bottom) starting from the current indicated selection. Top Light - Indicates gun trigger has been selected to perform the Cold Feed Forward function in[...]

B-8 OPERA TION B-8 Control Select key - enables operator to choose Run-In procedure as indicated by the light turning on. When light is on, the settings of Run-In Wire Feed Speed and Voltage are dis- played. After Weld procedure is set, Run-in pro- cedure should be set to optimize arc starting. Speed encoder knob can adjust run-in speed between min[...]

B-9 OPERA TION B-9 Maximum and Minimum Limits Setting Modes Limits setting modes are available for limiting the range for setting wire feed speed and voltage. The limits can be set independently for each procedure. The following steps should be followed for setting the maximum and minimum limits: 1. Turn off the power at the power source. 2. Remove[...]

B-10 OPERA TION B-10 DUAL PROCEDURE REMOTE CONTROL (K1449-1) When this option is connected to the LN-10 Control Box receptacle, and the Procedure Key selects “REMOTE” the front panel knob controls and proce- dure selection is transferred to the knob encoder con- trols and Procedure Selector Switch of the remote, which function in the exact same[...]

B-1 1 OPERA TION B-1 1 T o Mount a 50-60 Lb. (22.7-27.2 kg) Coil: (Using K1504-1 Coil Reel) (For 50-60 lb Readi- Reels a K438 Readi-Reel Adapter must be used). The Spindle must be located in the UPPER mounting hole. 1) With the K1504-1 Coil Reel mounted on to the 2" (51 mm) spindle (or with reel laying flat on the floor) loosen the spinner nut[...]

B-12 OPERA TION B-12 1 ) Press end of gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds. 2) If the wire "birdnests", jams, or breaks at the drive roll, the drive roll pressure is too great. Back the pressure setting out 1/2 turn, run new wire through gun, and repe[...]

B-13 OPERA TION B-13 WIRE REEL CHANGING At the end of a coil, remove the last of the old elec- trode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the follow- ing procedure: 1) Cut the end of the electrode off at the gun end. Do not break it off by hand because this puts a slight bend in the wire ma[...]

B-14 OPERA TION B-14 EXPLANA TION OF PROMPTING AND ERROR MESSAGES Display Prompt or Error Acc Displayed on Voltage display, indicates WFS display is showing acceleration setting, “1" to “5" (See “Acceleration Selection” in this sec- tion). OFF Displayed on WFS and voltage displays; indi- cates limits for WFS or voltage are off for[...]

TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll 4-Roll DH Drive Single Drive (4-Driven) (2-Driven) Solid Steel Electrode 0.025” (0.6 mm) KP1505 - 030S KP655 - 025S 0.030” (0.8 mm) KP1505 - 030S KP655 - 030S 0.035” (0.9 mm) KP1505 - 035S KP655 - 035S 0.040” (1.0 mm) KP1505 - 040S KP655 - 035S 0.040” (1.0 mm) KP1505 - 045S KP6[...]

C-2 ACCESSORIES C-2 K683-3 DUAL PROCEDURE SWITCH Kit includes gun switch, and mountings for Lincoln Innershield and Magnum guns, with 15 ft. (4.5m) con- trol cable and 5-pin plug with two leads to connect to gun trigger. SPINDLE ADAPTERS: K162H (Not required for LN-10 Bench Models) Spindle for boom mounting Readi-Reels and 2" (51 mm) I.D. spoo[...]

C-3 ACCESSORIES C-3 Magnum 200/300/400 Guns The easiest and least expensive way to use Magnum 200/300/400 guns with the LN-10 wire feeder is to order them with the K466-2 connector kit, or to buy a completely assembled Magnum gun having the K466- 2 connector (such as the K497-21,-22,-23 dedicated Magnum 400 guns and the K497-20,-21 dedicated Magnum[...]

C-4 ACCESSORIES C-4 K1561-1 ROBOTICS INTERF ACE MODULE The module plugs directly into the LN-10 control board and provides an interface to a properly equipped Fanuc robot. When installed and properly configured, the K1561-1 Robotics Interface Module allows com- plete control of the welding process from the robot controller. The Lincoln Electric Com[...]

D-1 MAINTENANCE D-1 LN-10 A voiding Wire Feeding Problems Wire feeding problems can be avoided by observing the following gun handling and feeder set up proce- dures: • Do not kink or pull cable around sharp corners. • Keep the electrode cable as straight as possible when welding or loading electrode through cable. • Do not allow dolly wheels[...]

E-1 TROUBLESHOOTING E-1 LN-10 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible m[...]

Rough wire feeding or wire not feed- ing, but drive rolls are turning. Variable or “hunting” arc. 1. Gun cable kinked and/or twisted. 2. Wire jammed in gun and cable. 3. Check for current position of drive rolls relative to split wire guide groove. 4. Drive rolls may not be seated properly. 5. Gun cable dirty. 6. Worn drive roll. 7. Worn nozzle[...]

1. Improper procedures or techniques. 2. Improper gas shielding. 1. Tip overheating because of prolonged or excessive high current and/or duty cycle welding. 1 . The wire drive motor may be over- loaded. “Hxx” will be displayed on the WFS display, where “xx” is the num- ber of seconds until the wire drive attempts to run again. 2 . A jumper[...]

TROUBLESHOOTING LN-10 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSI[...]

TROUBLESHOOTING LN-10 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSI[...]

TROUBLESHOOTING LN-10 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSI[...]

TROUBLESHOOTING LN-10 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSI[...]

TROUBLESHOOTING LN-10 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSI[...]

TROUBLESHOOTING E-9 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PC BOARD TROUBLESHOOTING GU[...]

F-1 DIAGRAMS F-1 LN-10 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.[...]

F-2 DIAGRAMS F-2 LN-10 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.[...]

F-3 DIAGRAMS F-3 LN-10 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. 5 1 2[...]

F-4 DIAGRAMS F-4 LN-10 M 18903 7-2000 (1 5.3 0) (3 0.3 5) (2 0.4 6) (1 4.4 3) (5. 25 ) (1 0.6 6) BENCH MODEL DIMENSION PRINT DIMENSION PRINT[...]

LN-10 F-5 DIAGRAMS F-5 3.00 6.00 2.42 12.74 7.81 6.55 14.71 4.44 5/16-18UNC-2B (4 PLACES) 5.25 11.00 2.25 4.08 10.40 W I RE DR I VE D I ME N S ION PR IN T M18904 7-2000 DIMENSION PRINT[...]

LN-10 F-6 DIAGRAMS F-6 WA R NING G R APHICS SHOWN R EP R ESENT M17869-1. 3 YEA R WA RR ANTY 4.58 4.27 5.25 2.80 R .141 (3 SLOTS) 10.92 13.75 2.63 10.10 12.75 14.67 14.65 5-2-97 M18299 Boom Model Control Box Dimension Print DIMENSION PRINT[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE PARA E[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

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