RETURN TO MAIN MENU IM587-B LN-10 Heads & Controls August, 2007 Boom Mount or Bench Models For use with: LN-10 Control - Boom Mount Code 10442, 10831 10 Series Wire Drive - Boom Mount Code 10443, 10444, 10763, 10764, 10818, 10819 LN-10 Boom Package Code 10445, 10765, 10820 Synergic 7F Drive Code 10190, 10191 LN-10 - Bench Model Code 10440, 10441, 10761, 10762, 10816, 10817 LN-10 - Zipline Boom Package Code 10497, 10498 , 10771, 10772, 10824 Safety Depends on You Lincoln arc welding and cutting equipment
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 ARC RAYS can burn. 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 SAFETY Mar.
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! 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 TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .......................................................................................................A-1 General Description..............................................................................................................A-1 Recommended Processes and Equipment ..........................................................
vii TABLE OF CONTENTS Page ...... Diagrams ..........................................................................................................Section F Wiring (LN-10 Control) ...........................................................................................F-1 Wiring (10 Series Wire Drive) ................................................................................F-2 Dimension Print......................................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – LN-10 Heads & Controls SPEC.# WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER LOW SPEED RATIO HIGH SPEED RATIO TYPE Speed K1563-1,-3 10 Series 35-500 IPM Std Drive Boom Mount (0.89-12.7 M/M) Wire Size Solid Cored .025 - 3/32 in. .035 - .120 in (0.6 - 2.4 mm) (0.9 - 3.0 mm) .50 - 750 IPM (1.25 - 19.0 M/M) Wire Size Solid Cored .025 - 1/16 in. .035 - 5/64 in. (0.6 - 1.6 mm) (0.9 - 2.0 mm) K1563-2,-4 10 Series 55 - 825 IPM Hi-Speed Boom Mount (1.40 - 21.
A-2 A-2 INSTALLATION 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 wire type and size range for the wire drive used, and gear ratio change selected, are given in the Specifications.
A-3 5/16-18 THREAD 11.00 A-3 INSTALLATION 2.25 10.50 CLEARANCE FOR 1/4 BOLT 6.00 .50 13.75 14.00 12.75 10.00 3.00 FEED PLATE DOOR OPEN CLEARANCE FOR 1/4 BOLT BOTTOM FRONT 10.50 14.50 5.00 2.63 14.50 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.
A-4 INSTALLATION A-4 The electrode supply may be either from reels, ReadiReels, spools, or bulk packaged drums or reels. Observe the following precautions: a) Loosen the clamping collar screw using a 3/16" Allen wrench. The clamping collar screw is accessed from the bottom of the feedplate. It is the screw which is perpendicular to the feeding direction.
A-5 INSTALLATION 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. Synergic 7F Wire Drives (K679) use 4-Roll drive roll kits with 2 driven rolls, per Table C.1 in ACCESSORIES.
A-6 INSTALLATION 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” position and close Pressure Door. TO SET IDLE ROLL PRESSURE, see “Idle Roll Pressure Setting” in OPERATION.
A-7 A-7 INSTALLATION 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 up with appropriate holes in connector. Tighten gun by turning large nut on gun cable clockwise.
A-8 A-8 INSTALLATION ELECTRICAL INSTALLATION WARNING Current 60% Duty Cycle Copper Work Cable Size, AWG 400 Amps 00 (67 mm2) 500 Amps 000 (85 mm2) 600 Amps 000 (85 mm2) Up to 100 ft Length (30m) 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.
A-9 INSTALLATION OPTIONAL FEATURES INSTALLATION A-9 When installed and properly configured, the K1561-1 Robotics Interface Module allows complete control of the welding process from the robot controller. 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 3pin plug.
B-1 B-1 OPERATION OPERATING INSTRUCTIONS Safety Precautions WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Unless using cold feed feature 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 Control switch setup or changing drive roll and/or guide tubes.
B-2 B-2 OPERATION For K679-1 (Single Head Boom) with 50-770 IPM (1.27-19.5 m/m) Low Speed Ratio set S1 DIP Switch as follows: Setting the DIP Switches The DIP switches are each labeled with an “ON” arrow showing the on direction for each of the 8 individual switches in each DIP switch (S1 and S2).
B-3 B-3 OPERATION DC-250: * Metric/English Wire Feed Speed Display Selection Pwr Sources ON 1 2 3 4 5 6 7 S1 8 S1 The LN-10 Control is set up for Wire Feed Speed display in Metric units (m/min.
B-4 B-4 OPERATION S2 switch 2 ON = 4-Step without current interlock operation: The LN-10 control is set up for Robotics Mode by setting the S2 DIP Switch 4 (Labeled “R”). For Robotics Interface Mode to operate, a K1561-1 Robotics Interface Module must be installed. M 4 S R + ON 1 2 3 4 5 6 7 8 Robotics Mode Selection S2 S2 S2 switch 4 ON = Robotics mode ON 1) Closing Trigger initiates gas flow.
B-5 OPERATION 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 setting S2 DIP Switch 6 (Labeled “-”). S2 switch 6 ON - Minimum Limits Setting mode ON M 4 S R + ON 1 2 3 4 5 6 7 8 S2 S2 When Minimum Limits Setting mode is selected, all keys except the procedure key are disabled. Welding is not allowed while in this mode. The mode is used for minimum limits setup only.
B-6 B-6 OPERATION KEYPAD AND DISPLAY OPERATION LINCOLN COLD FEED FORWARD Power to the LN-10 is supplied and controlled from the power source. The LN-10 automatically senses the loss of power when the power source is turned off. Dual procedure settings, including; trigger mode, cold feed speed, Run-in and weld speed and voltage, timers and acceleration are automatically saved for each feeder when power is removed.
B-7 B-7 OPERATION Trigger Mode Selection Display Control Keys Trigger Mode Select key - enables operator to choose mode of operation shown by the indicator lights. Pressing key causes mode lights to sequence (top to bottom) starting from the current indicated selection.
B-8 B-8 OPERATION CONTROL 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 displayed. After Weld procedure is set, Run-in procedure should be set to optimize arc starting. Speed encoder knob can adjust run-in speed between min. rated speed and up to the procedure Weld speed setting. Run-in speed setting can not exceed Weld speed setting.
B-9 OPERATION 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 the two screws at the top of the LN-10 control box and open the control box door. 3. Put DIP switch S2 switch 5 in the ON position. 4. Close the control box door.
B-10 DUAL PROCEDURE CONTROL (K1449-1) B-10 OPERATION REMOTE When this option is connected to the LN-10 Control Box receptacle, and the Procedure Key selects “REMOTE” the front panel knob controls and procedure selection is transferred to the knob encoder controls and Procedure Selector Switch of the remote, which function in the exact same manner. Remote knob encoders set Weld voltage and wire feed speed, as well as Trigger Cold Feed Speed, but not Timers or Run-In.
B-11 B-11 OPERATION To Mount a 50-60 Lb. (22.7-27.2 kg) Coil: (Using K1504-1 Coil Reel) (For 50-60 lb ReadiReels a K438 Readi-Reel Adapter must be used). 1) Turn the Reel or spool until the free end of the electrode is accessible. 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 and remove the reel cover. (See Figure B.2).
B-12 B-12 OPERATION 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 repeat above steps. 3) If the only result is drive roll slippage, disengage the gun, pull the gun cable forward about 6" (150 mm).
B-13 OPERATION B-13 WIRE REEL CHANGING WIRE FEED OVERLOAD PROTECTION At the end of a coil, remove the last of the old electrode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the following procedure: The LN-10 has solid-state overload protection of the wire drive motor.
B-14 OPERATION EXPLANATION 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 section). OFF Displayed on WFS and voltage displays; indicates limits for WFS or voltage are off for the displayed procedure. (See “Maximum and Minimum Limits Setting Modes” in this section).
C-1 C-1 ACCESSORIES TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll DH Drive (4-Driven) 4-Roll Single Drive (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 KP655 - 035S 0.045” (1.2 mm) KP1505 - 045S KP655 - 052S 0.052” (1.4 mm) KP1505 - 052S KP655 - 052S 1/16” (1.
C-2 ACCESSORIES INPUT CABLE ASSEMBLIES: C-2 K683-3 DUAL PROCEDURE SWITCH K1797-25 Consists of a 14-conductor control cable extension 25ʼ in length. K1797-50 Consists of a 14-conductor control cable extension 50ʼ in length. Note: Extensions can only be connected up to 100ʼ Maximum length. K1520-1 115V/42V TRANSFORMER KIT Required to use LN-10 with Lincoln Power Sources without 42VAC auxiliary and a 14-pin connector receptacle.
C-3 ACCESSORIES 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 K4662 connector (such as the K497-21,-22,-23 dedicated Magnum 400 guns and the K497-20,-21 dedicated Magnum 200 guns).
C-4 ACCESSORIES K498 Magnum 200 FM GMAW gun and cable assemblies are rated for 200 amps 60% duty cycle. (Consult sales specifications for appropriate models) K534 Magnum 250L FM GMAW gun and cable assemblies are rated for 250 amps, 30% duty cycle. (Consult sales specifications for appropriate models) K478 Magnum 300 FM GMAW gun and cable assemblies are rated for 300 amps, 60% duty cycle.
D-1 MAINTENANCE D-1 MAINTENANCE Avoiding Wire Feeding Problems Safety Precautions Wire feeding problems can be avoided by observing the following gun handling and feeder set up procedures: • Do not kink or pull cable around sharp corners. WARNING ELECTRIC SHOCK can kill. • Keep the electrode cable as straight as possible when welding or loading electrode through cable. • Do not touch electrically live parts such as output terminals or internal wiring.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Rough wire feeding or wire not feed- 1. Gun cable kinked and/or twisted. ing, but drive rolls are turning. 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 or cable liner. 9.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 1. Improper procedures or techniques. Poor arc striking with sticking or “blast-offs”, weld porosity, narrow and ropy looking bead, or electrode 2. Improper gas shielding. stubbing into the plate while welding. Tip seizes in the diffuser. 1. Tip overheating because of prolonged or excessive high current and/or duty cycle welding.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Speed does not change when weld 1. Run-in and weld speeds are set current flows. to the same value. 2. Current sensing reed switch is not operating properly. 3. The wiring from the control p.c. board to the weld current sensing reed switch is damaged. 4. Damaged control p.c. board. Voltmeter does not function proper- 1.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 1. The connector from the control Pressing the procedure key does p.c. board to the display p.c. not select between A - Remote - B. board or the connector from the display p.c. board to the keypad are loose or improperly inserted. 2. Damaged keypad 3. Damaged display p.c. board. 4. Damaged control p.c. board. Pressing the timer or control key has 1.
E-6 E-6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION One of the knobs changes the dis- 1. The display is in a mode that can only use one encoder. play, but the other doesnʼt. 2. The connector from the control p.c. board to the encoder p.c. boards may be loose or improperly inserted. 3. Damaged encoder p.c. board. 4. Damaged control p.c. board. Neither knob changes the display. 1.
E-7 E-7 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The K1449-1 remote control is not functioning when the Procedure LED is in the REMOTE position. POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 1. The remote control Amphenol connection is not securely attached. 2. Faulty wiring from the Amphenol connector to the control p.c. board. 3. Damaged remote control. 4. Damaged control p.c. board. Dual procedure switch is not functioning at the gun. 1.
E-8 E-8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) ʻErʼ is displayed on power up. POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 1. EEPROM error detected. 2. Damaged control p.c. board. ʻGLPʼ is displayed. 1. Ground Loop Protection fault occurred 2. GLP reed switch failure. 3. Damaged control p.c. board. 1.
E-9 TROUBLESHOOTING E-9 Observe all Safety Guidelines detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE - CONTROL P.C. BOARD c. If PC board is visibly damaged mechanically, inspect for cause, then remedy before installing a replacement PC board. WARNING ELECTRIC SHOCK can kill. • Have a qualified individual install and service this equipment. • Turn the power source input power off at the disconnect switch before working on this equipment. • Do not touch electrically hot parts.
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.
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(15.30) (30.35) BENCH MODEL DIMENSION PRINT M 18903 7-2000 (14.43) (5.25) (10.66) (20.
LN-10 6.00 3.00 2.25 10.40 11.00 2.42 5/16-18UNC-2B (4 PLACES) 4.08 14.71 4.44 5.25 6.55 12.74 M18904 7-2000 WIRE DRIVE DIMENSION PRINT 7.
14.65 LN-10 10.10 12.75 R .141 (3 SLOTS) 14.67 2.63 2.80 GRAPHICS SHOWN REPRESENT M17869-1. 5.25 10.92 13.75 5-2-97 M18299 4.58 3 YEAR WARRANTY WARNING 4.
● 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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