Lincoln LN-7 User Manual
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OPERATING MANUAL
LN-7
SEMIAUTOMATIC WIRE FEEDER
IM-267
January, 1986
Shipping Damage Claims
When this equipment is shipped, title passes to the pur
chaser upon receipt by the carrier. Consequently, claims for
material damaged in shipment must be made by the pur
chaser against the transportation company at the time the
shipment is received.
............
LiWCOLiy
THE LINCOLN ELECTRIC COMPANY
World s Largest Manufacturer of Arc Welding Products • Manufacturer of industrial Motors
Sales and Service Worldwide
This manual covers
equipment which is
obsoiete and no ionger
in production by The
Lincoin Eiectric Co.
Specifications and
avaiiabiiity of optionai
features may have
changed.
Safety Depends On You
Lincoln arc welding equipment is designed and built with
safety in mind. However, your overall safety can be in
creased by proper installation .. . and thoughtful operation
on your part. DO NOT INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT READING THIS OPERAT
ING MANUAL AND THE ARC WELDING SAFETY PRE
CAUTIONS ON THE INSIDE FRONT COVER. And, most
importantly, think before you act and be careful.
Cleveland, Ohio 44117-1199 U.S.A
"7>
Arc Welding Safety Precautions
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ
AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING
MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED AS WELL AS
THE FOLLOWING GENERAL INFORMATION.
1. HAVE ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR WORK performed
only by qualified people.
2. ELECTRIC SHOCK can kill.
Protect yourself from possible dangerous electrical
shock:
a. The electrode and work (or ground) circuits are elec
trically “hot” when the welder is on. Never permit
contact between “hot” parts of the circuits and bare
skin or wet clothing. Wear dry, hole-free gloves to
insulate hands.
b. Always insulate yourself from the work and ground
by using dry insulation. When welding in damp lo
cations, on metal floors, gratings or scaffolds, and
when in positions such as sitting or lying, make cer
tain the insulation is large enough to cover your full
area of physical contact with work and ground.
c. Always be sure the work cable makes a good electri
cal connection with the metal being welded. The
connection should be as close as possible to the area
being welded.
d. Ground the work or metal to he welded to a good
electrical ground.
e. Maintain the electrode holder, work clamp, welding
cable and welding machine in good, safe operating
condition.
f. Never dip the electrode in water for cooling.
g. Never simultaneously touch electrically “hot” parts
of electrode holders connected to two welders be
cause voltage between the two can be the total of
the open circuit voltage of both welders.
h. If using the welder as a power source for mechanized
welding, the above precautions also apply for the
automatic electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun.
i. When working above floor level, protect yourself
from a fall should you get a shock.
Also see Items 6c and 8.
J-
3. FUMES AND GASES can be dangerous to your health.
a. Welding may produce fumes and gases hazardous
to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to
keep fumes and gases away from the breathing zone.
When welding on galvanized, lead or cadmium
plated steel and other metals which produce toxic
fumes, even greater care must be taken.
b. Do not weld in locations near chlorinated hydrocar
bon vapors coming from degreasing, cleaning or
spraying operations. The heat and rays of the arc
can react with solvent vapors to form phosgene, a
highly toxic gas, and other irritating products.
c. 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.
d. Read and understand the manufacturer’s instructions
for this equipment and the consumables to be used,
including the material safety data sheet (MSDS) and
follow your employer’s safety practices.
e. Also see item 9b.
4. ARC RAYS can injure eyes and bum skin.
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
Z87.1 standards.
b. Use suitable clothing made from durable, flame-
resistant material to protect your skin and that of
your helpers from the arc rays.
c. Protect other nearby personnel with suitable non
flammable screening and/or warn them not to watch
the arc nor expose themselves to the arc rays or
to hot spatter or metal.
5. FIRE OR EXPLOSION can cause death or property
damage.
a. Remove fire hazards well away from the 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. Have a fire extinguisher readily available.
b. Where compressed gases are to be used at the job
site, special precautions should be used to prevent
hazardous situations. Refer to “Safety in Welding
and Cutting” (ANSI Standard Z49.1) and the operat
ing information for the equipment being used.
c. When not welding, make certain no part of the elec
trode circuit is touching the work or ground. Acci
dental contact can cause overheating and create a
fire hazard.
December 1985
-2-
d. Do not heat, cut or weld tanks, drums or containers
until the proper steps have been taken to insure that
such procedures will not cause flammable or toxic
vapors from substances inside. They can cause an
explosion even though they have been “cleaned.”
For information purchase “Recommended Safe Prac
tices for the Preparation for Welding and Cutting
of Containers and Piping That Have Held Hazardous
Substances.”, AWS F4.1-80 from the American
Welding Society (see address below).
e. Vent hollow castings or containers before heating,
cutting or welding. They may explode.
f. Also see items 6c and 9c.
6. For Welding in General.
a. Droplets of molten slag and metal are thrown or
fall from the welding arc. Protect yourself with 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 when in a welding area. Use glasses with
side shields when near slag chipping operations.
b. Keep all equipment safety guards, covers and de
vices in position and in good repair. Keep hands,
hair, clothing and tools away from V-belts, gears,
fans and all other moving parts when starting,
operating or repairing equipment.
c. Be sure the work cable is connected to the work
as close to the welding area as practical. Work cables
connected to the building framework or other loca
tions some distance from the welding area increase
the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains
or cables until they fail.
7. For Gas-Shielded Arc Welding.
a. Use only compressed gas cylinders containing the
correct shielding gas for the process used and prop
erly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suit
able for the application and maintained in good con
dition.
b. Always keeps cylinders in an upright position sec
urely chained to an undercarriage or fixed support.
c. Cylinders should be located:
• Away from areas where they may be struck or
subjected to physical damage.
• A safe distance from arc welding or cutting oper
ations and any other source of heat, sparks, or flame.
d. Never allow the electrode, electrode holder, or any
other electrically “hot” parts to touch a cylinder.
e. Keep your head and face away from the cylinder
valve outlet when opening the cylinder valve.
f. Valve protection caps should always be in place and
handtight except when the cylinder is in use or con
nected for use.
g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publica
tion P-1 “Precautions for Safe Handling of Compres
sed Gases in Cylinders” available from the Compres
sed Gas Association, 1235 Jefferson Davis High
way, Arlington, VA 22202.
8. For Electrically Powered Equipment.
a. Turn off input power using the disconnect switch
at the fuse box before working on the equipment.
b. Make the electrical installation in accordance with
the National Electrical Code, all local codes and the
manufacturer’s recommendations.
c. Properly ground the equipment in accordance with
the National Electrical Code and the manufacturer’s
recommendations.
9. For Engine Powered Equipment.
a. Turn the engine off before troubleshooting and
maintenance work unless the maintenance work re
quires it to be running.
b. Operate the internal combustion engines in open,
well-ventilated areas or vent the engine exhaust
fumes outdoors.
c. Do not add the fuel near an open flame, welding
arc or when the engine is running. Stop the engine
and, if possible, allow it to cool when refueling to
prevent spilled fuel from vaporizing on contact 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 fumes have been eliminated.
d. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when
the maintenance requiring their removal is complete.
Always use the greatest care when working near
moving parts.
e. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing
on |he throttle control rods while the engine is run
ning.
f. To prevent accidentally starting gasoline engines
while turning the engine or welding generator during
maintenance work, disconnect the spark plug wires,
distributor cap or magneto wire as appropriate.
g. To avoid scalding, do not remove the radiator pres
sure cap when the engine is hot.
For more detailed information it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting
— ANSI Standard Z49.1” from the American Welding So
ciety, P.O. Box 351040 Miami, Rorida 33135.
December 1985
Need Welding Training?
The Lincoln Electric Company operates the oldest and most respected Arc Welding
School in the United States at its corporate headquarters in Cleveland, Ohio. Over
60,000 students have graduated. Tuition is low and the training is “hands on”.
For details write: Lincoln Welding School
22801 St. Clair
Cleveland, Ohio 44117
and ask for bulletin ED-80 or call 216-481-8100 and ask for the Welding School
Registrar.
-4-
The Lincoln Electric Company
Cleveland, Ohio 44117
SEC J1 INDEX
Sec. J2 INSTALLATION INSTRUCTIONS
Wire Feed Unit and Wire Reel....................................................................................................................................................... Sec. J2.2.1
Wire Feed Rolls and Guide Tubes..................................................................................................................................................Sec. J2.2.2
Gun & Gun Cable Assemblies . .....................................................................................................................................................Sec. J2.2.3
Input Cable: LN-7 to Power Source...............................................................................................................................................Sec. J2.3.1
Connection Diagrams; LN-7 to Lincoln Power Sources .............................................................................................................Sec. J2.3.2
Connection Diagrams: LN-7 to Other Power Sources.................................................................................................................Sec. J2.3.3
Optional Feature Installation
K-178 Mounting Platform ........................................................................................................................................................Sec. J2.5.3
Auxiliary Equipment Contacts .................................................................................................................................................Sec. J2.5.5
K-162 SpintUe for Mounting 10 thru 30 Pound Spools .........................................................................................................Sec. J2.5.7
K-163 Undercarriage ................................................................................................................................................................ Sec. J2.5.8
Sec. J3 OPERATING INSTRUCTIONS
I } Adjusting Current and Voltage.................................................................................................................................................................. Sec. J3.1.1
Arc Starting......................................................................................................................................................................................Sec. J3.1.2
Circuit Protection............................................................................................................................................................................Sec. J3.1.4
Wire Reel Loading - 50 and 60 Pound Coils ................................................................................................................................Sec. J3.1.5
Wire Reel Loading - 10 to 30 Pound Spools .................................................................................................................................Sec. J3.1.6
Sequence of Welding ...................................................................................................................................................................... Sec. J3.1.7
Wire Reel Changing........................................................................................................................................................................ Sec. J3.1.9
For Iimershield® operating techniques and procedures request
‘Timershield Production Welding Guide”, bulletin N675
Index
k
.
,„.y
Sec. J6 MAINTENANCE
Wire Drive Motor and Gear Box ..................................................................................................................................................Sec. J6.1.1
Drive Rolls and Guide Tubes .........................................................................................................................................................Sec. J6.1.2
Wire Reel Mounting........................................................................................................................................................................Sec. J6.1.3
Control Box..................................................................................................................................................................................... Sec. J6.1.5
Gun Cable ............................................................................................................... »..................................................................Sec. J6.2.1
Gun Disassembly — K-115 and K-126..........................................................................................................................................Sec. J6.2.2
Electrical Sequence of Operation...................................................................................................................................................Sec. J6.4
Troubleshooting ..............................................................................................................................................................................Sec. J6.6
Parts Lists.........................................................................................................................................................................................Sec. J7
Wiring Diagrams ....................................................................................................................................Filed at the back of this manual.
January 1976
-5-
-6-
f ^
The Lincoln Electric Company
Cleveland, Ohio 44117
SEC.J2.2 MECHANICAL INSTALLATION
Sec. J2.2.1
Wire Feed Unit and Wire Reel
The LN-7 is shipped ready to install in the work
location.
September 1971
Sec. J2.2.2
Wire Feed Rolls and Guide Tubes
NOTE: The maximum sizes the LN-7 will satisfactorily
feed are 7/64” Innershield® and 3/32” solid electrodes.
The drive roll, idle roll and guide tubes for the electrode
size specified on the order is shipped with the wire feed
unit. The electrode sizes that can be fed with each roll and
guide tube are stenciled on each part. Instructions to install
these parts on new machines or replace them on used
machines, are as follows;
A. Loosen the idle roll tension nut (item 28) approximately
3 full turns or use a screwdriver to pry the idle roll arm
down at point B .
B. Remove hex head screw (item 3) & the drive roll clamp
ing collar (item 4). (On new machines remove the tape &
drive roll key from the collar.) Insert the key (item 5)
into the keyway of the output shaft.
C. Wipe the drive roll & spacer surfaces clean. Install one
drive roll (item 2), then the spacer & the second drive
roll. (For .030, .035 & .045 electrode, the drive roll
is one piece. For '/i6 electrode there is no spacer).
D. Install drive roll clkmping collar & hex head screw pre
viously removed. Tighten hex head screw securely.
E. Back out the two guide tube clamping set screws (item
29).
F. Insert the outgoing guide (item 7) (the one with the plas
tic insert) into the front hole. The guide tube for .030",
.035" and .045" wire has a non-symetrical chisel end.
Be certain the contour with the larger radius and the
exposed oval opening for the wire faces the grooved
Assembly and Installation
drive roll. Push the guide tube back as far as it will
go and tighten the clamping set crew. Insert the incom
ing guide tube (item 20) into the rear hole as far as
it will go and tighten the clamping set screw. These
set screws are dog point. When the two tubes are instal
led properly these dog points will lock into the annular
groves that are in each of the guide tubes,
G. Tighten the idle roll tension nut (item 28) or remove the
screwdriver used as a wedge in step A. The tension nut
should normally be tightened until it bottoms for wire
sizes 1/16” and larger. For smaller wire sizes and alumi
num wire the tension nut should be loosened if the wire
tends to buckle in the guide tube, cable or between the
drive rolls and outgoing guide tube.
H. To change drive rolls and guide tubes for a different size,
reverse the above procedure.
September 1976
Sec. J2.2.3
Gun & Gun Cable Assemblies
General
The LN-7 is used with various guns. In all cases the gun
and cable are shipped assembled ready to weld. Use the gun
and cable assembly for the electrode type (solid or Innershield) and electrode size to be used.
Note; The guns described below were available at the
time this sheet was printed. They may not be today. See
Lincoln Specification literature for up-to-date information.
Innershield® Guns
Squirtgun K-126 is recommended for most welding with
.062 through 3/32" electrodes. Install the insulated nozzle
extension (or thread protector) and the nozzle contact tip
for the stickout and electrode size being used.
K-126
For heavy duty welding with 3/32” electrode use K-1153/32 or K-115-45-3/32. Install a 3/32” contact tip and the
insulated nozzle extension for the stickout being used.
For welding with 7/64” electrode, use K-115-3/32 with
a M-11474-.120 nozzle or a K-11545-3/32 with a
M-11510-.120 nozzle. Also install a 7/64” contact tip and
the insulated nozzle extension for the stickout being used.
-7-
Assembly and Installation
Sec. J2.2.3 Continued
Gun Cable: LN-7 to Gun
Lay the cable out straight. Insert the connector on the
welding conductor cable into the brass block on the front
of the LN-7. Make sure it is all the way in and tighten the
locking screw with a 3/16” Allen Wrench. Keep this con
nection clean and bright. Insert the control cable polarized
plug into the receptacle below the nameplate.
Linconditioner'i’M Guns ^
For locations where smoke accumulation is a problem
and conventional exhaust systems are ineffective, the
available smoke removal type Innershield guns and vacuum
units can be used. Instructions are shipped with the
equipment.
April 1974
The Lincoln Electric Company
Cleveland, Ohio 44117
-8-
The Lincoln Electric Company
Cleveland, Ohio 44117
SEC. J2.3 ELEaRICAL INSTALLATION
Sec. J2.3.1
Input Cable: LN-7 to Power Source
The input cable between the wire feeder and the power
source consists of a four-conductor control cable and an
electrode cable. The control cable has lugged leads on the
power source end and a polarized plug on the wire feeder
end. With the power source turned off, install the input
cable per the following instructions: i
I. Connect the end of the control cable with the lugged
‘.-leads to a constant voltage type power source. For
Lincoln power sources follow exactly thé instructions
(including all jumpers on the power source terminai
strips) for the specific power source per the wiring
diagrams in Sec. J2.3.2.
Assembly and Installation
lead length should not exceed 400’. When using the
longer lengths of extension cables, it may be necessary
to add parallel electrode cables to limit the voltage drop
in the cable.
4. Loosen the screws holding the clamp to the rear vertical
support of the wire feeder frame. Put only the electrode
cable under the clamp.
5. Coimect the end of the electrode cable to the end of the
brass block on the wire feeder using the bolt provided.
Be sure the cable is placed to allow easy access to the
drive roll and guide tube screws. (See photo below.)
Tighten the screws on the electrode cable clamp.
6. Run the control cable under the wire feed motor and
insert the plug into the mating receptacle below the
LN-7 nameplate.
2. For constant voltage power sources not included in Sec.
J2.3.2, request a copy of Sec. J2.3.3 for connection
instructions.
7. Connect a ground lead of sufficient size and length (per
the following table) between the To Work’ stud on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal contact.
Current
Amps
60% Duty Cycle
300 0
400 00
500 00 000
600 000 0000
Copper Ground Cable Length
Up to 50' 50' - 100'
00
000
3. If input cables longer than the standard length (available
as 7, 25, 50, 75 and 100’ lengths) must be used, 50’
K-177 extension cables can be installed. These have
polarized plugs on each end of the control cable and a
4/0 electrode cable. Install the extensions between the
standard input cable and the wire feeder. Total input
September 1976
-9-
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