IM847-D RETURN TO MAIN MENU LF-72 WIRE FEEDER For use with machines having Code Numbers: March, 2010 11075, 11076, 11077 11209, 11210, 11211, 11227 11290, 11291, 11292, 11293 11606, 11607, 11608, 11609 11708, 11709, 11710, 11711 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines 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 Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY 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.
iii iii SAFETY 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.
iv iv SAFETY 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 suivantes: 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.
v TABLE OF CONTENTS Thank You v 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! 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.
vi vi TABLE OF CONTENTS Page Installation ............................................................................................................Section A Technical Specifications ...............................................................................................A-1 Safety Precautions........................................................................................................A-2 Location ..........................................................................................
vii vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance.............................................................................................D-1 Periodic Maintenance ............................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS: LF-72 Wire Feeder SPEC.# TYPE WIRE FEED SPEED RANGE Wire Size LF-72 K2327-1 K2327-4 K2327-2 K2327-5 K2327-3 K2327-6 K2327-7 SPEC.# TYPE LF-72 K2327-4 Base Model Solid Cored 50-800 IPM (1.27-20.3 m/m) .023 - 1/16 in. (0.6 - 1.6 mm) .035 - 5/64 in (0.9 - 2.
A-2 A-2 INSTALLATION SAFETY PRECAUTION MOUNTING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. For location and size, LF-72 Bench Model Rear Mounting Holes (See Figure A.1) and for Bottom Mounting Holes (See Figure A.2). • Turn off the input power to the power source at the disconnect switch or fuse box before working on this equipment.
A-3 A-3 INSTALLATION BENCH MOUNT BOOM MOUNT The LF-72 mounts in a variety of configurations. As shipped from the factory, the LF-72 is suitable for bench mounting or placing directly on top of the welding power source (CV-xxx and DC-xxx product family only). When boom mounting, remove the wire reel stand (if assembled) and secure the wire feeder directly to the desired surface.
A-4 A-4 INSTALLATION 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 connected to the welding system at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts.
A-5 A-5 INSTALLATION COAXIAL WELD CABLES Coaxial welding cables are specially designed welding cables for pulse welding or STT welding. Coaxial weld cables feature low inductance, allowing fast changes in the weld current. Regular cables have a higher inductance which may distort the pulse or STT wave shape. Inductance becomes more severe as the weld cables become longer.
A-6 A-6 INSTALLATION ANALOG CONTROL CABLE CONTROL CABLE CONNECTIONS • All control cables can be connected end to end to extend their length. The control cable connecting the wire feeder to the power source is specially made for the welding environment. The wire feeder power requires overcurrent protection. Connect the wire feeder only to power sources with overcurrent protection of no more than 15 amps.
A-7 A-7 INSTALLATION ANALOG MILLER CONTROL CABLE ADAPTER K2335-1 This Lincoln Electric wire feeder may be mounted to a limited number of Miller Electric power sources. The Miller power source must have the amphenol pin definition shown in the table below for proper operation of the wire feeder. Operation of Lincoln wire feeders on Miller power sources may result in lack of high speeds or reduce pull force on high wire feed speeds.
A-8 WELDING GUN/WIRE FEEDER TRIGGER CONNECTOR Wire Feeder Amphenol A B A-8 INSTALLATION D C Refer to the power source instruction manual for instructions for connecting the wire feeder for STT welding. Welding G un E REMOTE SENSE LEAD SPECIFICATIONS WIRE DRIVE SYSTEMS Trigger Lead Drive Roll Kits are designed to feed specific types and wire sizes. The LF-72 Bench Model comes with the combo KP1696-1.
A-9 A-9 INSTALLATION WELDING GUNS, TORCHES AND ACCESSORIES GUN RECEIVER BUSHING The LF-72 wire feeder comes with a K1500-2 gun receiver bushing. MAGNUM GUN AND CABLE ASSEMBLIES The LF-72 wire feeder model will accept a number of optional gun and cable assemblies. An example of installing the Gun and Cable is shown in Figure A.3 with a 15 ft. (4.6m) long Magnum 400 gun and cable. Figure A.3a with a 15 ft. (4.6m) long Magnum Pro 350 gun and cable. 3.
A-10 A-10 INSTALLATION PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS WIRE DRIVE CONFIGURATION (See Figure A.5) Changing the Gun Receiver Bushing (See Figure A.4 ) WARNING WARNING 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.
A-11 A-11 INSTALLATION 7. Disconnect the shielding gas hose from the gun bushing, if required. PRESSURE ARM ADJUSTMENT WARNING 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. ELECTRIC SHOCK can kill.
A-12 INSTALLATION WIRE REEL LOADING A-12 3. Re-install the retaining collar. Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle. FIGURE A.8 WARNING • 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.
A-13 INSTALLATION FIGURE A.9 WELD WIRE ROUTING The electrode supply may be either from reels, ReadiReels, 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 minimum, and also that the force required to pull the wire from the reel into the wire drive unit is kept at a minimum. b) The electrode is “hot” when the gun trigger is pressed and must be insulated from the boom and structure.
A-14 INSTALLATION A-14 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. 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.
A-15 A-15 INSTALLATION (For Codes 11209, 11210, 11211 and above) To install Lincoln conduit: (See Figure A.10b) INSTALLING ELECTRODE CONDUIT KITS 1. Turn off power at the welding power source. WARNING 2. Remove the “O” ring holding the ball bushing assembly to the back of the wire feeder. Remove the ball bushing assembly. ELECTRIC SHOCK can kill. • Turn the input power OFF at the disconnect switch before working on this equipment. • Do not touch electrically hot parts.
A-16 A-16 INSTALLATION ALUMINUM WIRE PREPARATIONS (For Codes 11209, 11210, 11211 and above) Tools required: (See Figure A.12b) • 9/64" Hex key wrench WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the disconnect switch before working on this equipment. • Do not touch electrically hot parts. 1. Turn off power at the welding power source. 2. Remove the snap ring holding the ball bushing assembly to the back of the wire feeder. Remove the ball bushing assembly. FIGURE A.
A-17 INSTALLATION BASE MODEL BENCH MODEL STANDARD DUTY BENCH MODEL HEAVY DUTY LF-72 A-17
A-18 A-18 INSTALLATION TYPICAL SYSTEM CONFIGURATIONS The LF-72 is capable of welding with many different welding processes. These processes may require reconfiguring the LF-72 with other products that may or may not be included with the model you purchased. Use the Table 1 and 2 below to identify the basic items which are included in the LF-72 to utilize the various Welding Processes that the machine is capable of controlling. TABLE 1 PART NO.
B-1 B-1 OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING 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.
B-2 B-2 OPERATION PROCESS LIMITATIONS COMMON WELDING ABBREVIATIONS FCAW (Cable Innershield or Outershield) • Flux Core Arc Welding • Rated for up to 1/16(1.6 mm) solid electrode and 5/64 (2.0 mm) cored electrode. • The maximum WFS is 800 in/min (20.3 M/min). • The LF-72 is not recommended for GMAW-Pulse (synergic), GTAW, GTAW-Pulse, SAW, CAG, SMAW. • Do not use push-pull equipment with the LF-72. • For K2327-2, -5 Bench model, std. duty: Maximum spool size = 44 lb.
B-3 B-3 OPERATION FRONT PANEL CONTROLS AND CONNECTIONS CASE FRONT CONTROLS FIGURE B.1 6 1 2 7 3 4 5 8 ITEM DESCRIPTION 1 Location for Optional Remote Voltage Control (See Accessory Section For Kit Number). 2 Location for Optional Burnback and Postflow Timer Kit (See Accessory Section For Kit Number). 3 Thermal LED, Motor Overload. 4 Cold Feed - Gas Purge Switch, press the switch up to feed wire with weld output off. Press the switch down for gas flow with weld output off.
B-4 OPERATION B-4 1. REMOTE VOLTAGE CONTROL KIT 3. THERMAL LED, MOTOR OVERLOAD The optional remote voltage control kit adjusts the arc voltage from the minimum to the maximum voltage of the welding power source. Rotate the knob counterclockwise to reduce the arc voltage and rotate the knob clockwise to raise the arc voltage. The thermal light illuminates when the wire drive motor draws too much current.
B-5 OPERATION Trigger Interlock Trigger Interlock operation provides for operator comfort when making long welds. When the gun trigger is first pulled, the welding power source energizes the output and the wire feeder feeds wire for welding. The gun trigger is then released while the weld is made. To stop welding, the gun trigger is pulled again, and when it is released the welding power source output turns off and the wire feeder stops feeding wire.
C-1 ACCESSORIES OPTIONAL KITS: K2329-1 Remote Voltage Control Kit. K2330-1 Timer Kit. K2328-1 Standard Duty Wire Reel Stand. K2331-1 Lift Bail Kit. K2332-1 K1796-xx K1803-1 K1840-xx K1841-xx K1842-xx Includes: 10k potentiometer, harness, knob and decal with a 0-10 scale and mounting hardware. Includes: Panel and harness for adjusting burnback and postflow times. Includes: Wire Reel Stand for up to 44 lbs (20 kg) spools, Spindle and mounting hardware.
C-2 ACCESSORIES OPTIONAL KITS: Includes: 14 pin to 14 pin wire feeder to power source control cable. K1797-xx Control Cable. K2335-1 Adapter for Miller Power Sources. K1520-1 42 Volt Transformer Kit. K1798 Adapter Cable for Control Cable to Terminal Strip Power Sources. Includes: K910-1 Ground Clamp. Includes: One 300 Amp Ground Clamp. K910-2 Ground Clamp. Includes: One 500 Amp Ground Clamp.
C-3 ACCESSORIES OPTIONAL KITS: K489-7 Gun Receiver Bushing (for Lincoln Fast-Mate guns.) Includes: Gun receiver bushing with trigger connector. K466-2 Magnum 200/300/400 to K1500-2 Adapter. Includes: Gun adapter, cotter pin, hex key wrench, wrench. K613-7 Magnum 550 to K1500-3 Adapter Lincoln Conduit. Includes: Trigger adapter, gun adapter and hex key wrench. K1546-1 Incoming Bushing, for Lincoln Conduit .025- 1/16" (0.6 - 1.6mm) wire. Includes: Incoming bushing and hex key wrench.
C-4 ACCESSORIES OPTIONAL KITS: Includes: Cover, backing plate, wire conduit, incoming bushing for .025 - 1/16" (0.6 1.6 mm) wire, incoming bushing for 1/16" - 1/8" (1.6 - 3.2 mm) wire, thumb screw, mounting hardware and hex key. K1634-1 Plastic Wire Cover for 30-44 lb. (13.6 - 20.0 kg) Wire packages. (For use with Standard Duty Bench Models and Heavy Duty Bench Models.) K1634-2 Plastic Wire Cover for up to 60 lb. (27.2kg) Wire packages. (For use with Heavy Duty Bench Models.
D-1 D-1 MAINTENANCE CALIBRATION SPECIFICATION MAINTENANCE WARNING Safety Precautions ELECTRIC SHOCK can kill. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • When inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released. • Turn OFF input power at welding power source before installation or changing drive roll and/or guide tubes.
D-2 D-2 MAINTENANCE FIGURE D.1 6. Adjust the WFS knob to 300 ipm. Center the knob pointer with the name plate graphics. Activate the gun trigger. 7. Insert the shorting plug into connector J2 on the p.c. board. The shorting plug shorts pins 1 & 5. (See Figure D.2) 8. Remove the shorting plug. Set aside. (For Codes below 11289 use 9 thru 17) 9. Adjust the WFS knob to minimum. 10. Insert the shorting plug into connector J2. 11. Adjust the WFS knob until the motor measures 51 ± 5.5 ipm. (9.5 ± 1.0 rpm). 12.
E-1 TROUBLESHOOTING WARNING E-1 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 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The wire feeder does not feed wire 1. Verify the power source is turned and the drive rolls do not spin. on. 2. Verify the circuit breaker for the wire feeder on the power source has not tripped. 3. Check that the gun trigger is operating properly. 4.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) Variable or "hunting" arc. 1. Check for proper size contact. Make sure the contact tip is not worn, free of spatter and not melted. 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.
2 1 8 5 4 3 J1,J14 2 1 LF-72 ARC CURRENT M N K L I J G H E F C D A B 553 4 1 67 42 51 41 50 76A 75A 2 4 77A 6 3 41 41A N.B. 16 8 L1 580 - BAFFLE MOUNTED RECTIFIER DIODE BRIDGE 42 552A 552C 552B COLOR CODE BWRU- BLACK WHITE RED BLUE 575C 551 556 552 B U R TACH 67 J3 1 2 COMMON ANALOG P.C. BOARD B J2 563 N.B.
2 8 5 J1,J14 4 3 LF-72 M N K L I J G H E F C D A B 553 4 67 42 41 76A 75A 2 4 77A 6 3 41 N.B. 16 8 L1 580 - BAFFLE MOUNTED RECTIFIER DIODE BRIDGE 42 552A 552B COLOR CODE BWRU- BLACK WHITE RED BLUE 575C 551 556 552 B U R TACH 67 J3 1 2 COMMON ANALOG P.C. BOARD J2 563 B J1 576 N.B. W 1 2 3 4 5 6 550 554 552A 553 575C 575B L5 P5 8 6 7 550 551 4 3 2 5 562 575B 563 1 L2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 562 577 580 575 L4 N.A.
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.
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-5 DIMENSION PRINTS BENCH MODEL BENCH MODEL STANDARD DUTY LF-72 F-5
F-6 DIMENSION PRINTS BENCH MODEL HEAVY DUTY LF-72 F-6
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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