Lincoln Electric IM476 User Manual

IM476-A

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LN-742 & LN-742H Wire Feeders

For use with machines having Code Numbers:

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. DO

NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most

importantly, think before you act and be careful.

August, 2005

10027 10028 10048 10049 10238 10239 10240 10241

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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

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.

____________________________________________________

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 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.

____________________________________________________

1.d. Keep all equipment safety guards, covers

and devices 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.

____________________________________________________

1.e. 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.

___________________________________________________

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 rods while the engine is running.

___________________________________________________

1.g. 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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

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 work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

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.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

ARC RAYS 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 skin and that of your helpers from the arc rays.

4.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.

FUMES AND GASES can be dangerous.

5.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 with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon

coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

5.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.

5.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. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

vapors

iii

SAFETY

iii

WELDING 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.

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. 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 operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.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 been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away 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.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.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 operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY 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 manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Mar ‘95

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. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

TABLE OF CONTENTS

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

Technical Specifications - LN-742 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Input Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Gun Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Water Connections (For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . A-6

GMAW Shielding Gas Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . B-1

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Acceleration Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

English or Metric Speed Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Drive Roll Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Idle Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Wire Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Wire Reel Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Flux System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Power Input Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Welding Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Spindles, Stands, and Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Attaching the Wire Reel Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

How To Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-228

LN-742 & LN-742H

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – LN-742

INPUT VOLTAGE

40 to 42V ±10%, 50/60 Hz, 4.0 Amps

WIRE FEED SPEED

A-1

SYSTEM

LN-742

LN-742H

SYSTEM

LN-742

LN-742H

LN-742

LN-742H

OPERATING

STORAGE

BOTH LN-742 AND LN-742H

2 ROLL FEEDER WITHOUT WIRE STAND

WIRE SPEED RANGE

50 in. to 770 in. per minute (1.25 to 19.5 m/min)

80 in. to 1200 in. per minute (2.00 to 30.5 m/min)

WIRE DIAMETERS

ELECTRODE

SOLID

CORED

0.025 in. through 1/16 in. (0.6 through 1.6 mm)

0.025 in. through 0.045 in. (0.6 through 1.2 mm)

0.045 in. through 3/32 in. (1.2 through 2.4 mm)

DIAMETER

0.035 in. (0.9 mm)

TEMPERATURE RATING (ALL MODELS)

-4˚F to 104˚F (-20˚C to +40˚C)

-40˚F to 104˚F (-40˚C to +40˚C)

PHYSICAL DIMENSIONS

LENGTH

9.62 in.

(244 mm)

WIDTH

9.76 in.

(247 mm)

HEIGHT

10.89 in.

(277 mm)

TOTAL WEIGHT

LESS ELECTRODE

24 lbs

(11.0 kg)

2 ROLL FEEDER WITH WIRE STAND (K377)

4 ROLL FEEDER WITHOUT WIRE STAND

4 ROLL FEEDER WITH WIRE STAND (K377)

ENVIRONMENTAL RATING (ALL MODELS)

20.68 in.

(525 mm)

10.60 in.

(269 mm)

21.66 in.

(550 mm)

IP21 (IEC 529)

LN-742 & LN-742H

9.76 in.

(247 mm)

11.60 in.

(295 mm)

11.60 in.

(295 mm)

17.00 in.

(432 mm)

11.11 in.

(282 mm)

17.00 in.

(432 mm)

34 lbs

(15.5 kg)

28.7 lbs

(13.1 kg)

38.7 lbs

(17.7 kg)

A-2

NUT

STUD

ELECTRODE

CONTROL

CABLE

COPPER

STRAP

MOUNTING LOCATION

INSTALLATION

A-2

The LN-742 wire feeders can be mounted directly on top of the power source providing that it is secure and level. The LN-742 can also be mounted to an undercarriage when portability is required. The LN-742 should be installed upright on a horizontal surface.

A K178-1 mounting platform is available for mounting the LN-742 to the top of Idealarc power sources. Refer to Section C, Accessories, for details.

INPUT CABLE CONNECTIONS

Refer to Section C, Accessories, for descriptions of the various input cable assemblies available for the LN-742 wire feeder.

WARNING

Turn input power off before connecting the LN-742 wire feeder.

------------------------------------------------------------------------

For connecting an LN-742 to a specific Lincoln power source, follow steps 1 through 5, and refer to the connection diagram in Figure A.3. The welding cable used must be sized according to the current and the duty cycle of the application.

1. Connect the end of the control cable with the 14pin cable plug to the mating receptacle on the power source.

2. Connect the electrode lead to the power source output terminal of the desired polarity.

3. Referring to Figure A.1, route the other end of the electrode cable through the large oval hole in the rear panel of the LN-742 case. Connect the electrode to the copper strap on the side of the gearbox using the stud and nut provided.

FIGURE A.1 – INPUT CONTROL CABLE AND

ELECTRODE CABLE CONNECTIONS.

With input power disconnected at the source, install the input cable per connection diagram A.3, and complete the following instructions:

LN-742 & LN-742H

A-3

WIRE REEL MOUNTING ASSEMBLY

CONTROL

CABLE

ELECTRODE

CABLE

STRAIN RELIEF CLAMP

INSTALLATION

A-3

4. Connect the remaining end of the control cable with the eight-socket cable plug to the mating receptacle on the LN-742.

5. Referring to Figure A.2, install the input cable under the wire reel mounting stand strain relief clamp. Remove the screws holding the clamp to the base of wire reel mounting assembly. Put the input cable under the clamp and reinstall the screws.

The connection diagram, Figure A.3, shows the electrode as positive. To change polarity, turn the power source off. Reverse the electrode and work cables at the power source, and set the wire feeder voltmeter polarity switch on the power source to the proper polarity.

Pins not listed in the table in Figure A.3 are not connected on the cable.

If using the K589-1 remote control kit, set the power source control switch to the “Remote” position.

FIGURE A.2 – STRAIN RELIEF CLAMP.

LN-742 & LN-742H

A-4

ELECTRIC

SHOCK

CAN KILL

TURN INPUT POWER OFF BEFORE CONNECTING THE LN-742 WIRE FEEDER.

WARNING

CLEVELAND, OHIO U.S.A

LINCOLN

POWER SOURCE

LN-742

WIRE FEEDER

LN-742

INPUT CABLE

ASSEMBLY

TO WORK

ELECTRODE CABLE

14-SOCKET BOX RECEPTACLE, FRONT VIEW AND 14-PIN CABLE PLUG, REAR VIEW

FUNCTIONS ARE LISTED FOR REFERENCE ONLY AND EACH MAY OR MAY NOT BE PRESENT IN YOUR EQUIPMENT.

14-SOCKET BOX RECEPTACLE, REAR VIEW AND 14-PIN CABLE PLUG, FRONT VIEW

14 PIN

AMPHENOL

K=42

I=41 I=41

H=21 H=21C=2 C=2

G=75 G=75D=4 D=4

F=76

2 TRIGGER CIRCUIT

TRIGGER CIRCUIT

OUTPUT CONTROL

WORK

42V AC

LEAD FUNCTION

F=76E=77 E=77

INSTALLATION

FIGURE A.3 – LN-742 WIRE FEEDER TO LINCOLN POWER SOURCE – CONNECTION DIAGRAM.

A-4

LN-742 & LN-742H

A-5

AMPHENOL

PLUG

GUN CABLE

ASSEMBLY

CONDUCTOR

BLOCK

LOCKING

KNOB

INSTALLATION

A-5

WORK CABLE

Connect a work lead of sufficient size and length (Table A.1) between the proper output stud on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact.

TABLE A.1 – WORK LEAD SPECIFICATIONS

Copper Work Cable Size, AWG

Current 60% Up To 50 Ft 50 Ft-100 Ft

Duty Cycle (15.2 m 300 Amps 0 (53 mm

400 Amps 00 (67 mm 500 Amps 00 (67 mm2) 000 (85 mm2) 600 Amps 000 (85 mm2) 0000 (107 mm2)

) (15.2-30.4 m2)

) 00 (67 mm2)

) 000 (85 mm2)

GUN AND CABLE ASSEMBLIES

The LN-742 can be used with several guns. In most cases, Lincoln guns and cables are shipped assembled, ready to weld. Use the gun and cable assembly for the electrode type (solid, Outershield , or Innershield) and electrode size to be used. Refer to Section C, Accessories, for different gun types.

Connect the control cable amphenol plug into the mating 5-cavity receptacle on the front of the control section below the keypad.

FIGURE A.4 – GUN CABLE CONNECTIONS.

GUN CABLE CONNECTIONS

Lay the cable out straight. Insert the connector on the welding conductor cable through the large hole in the front panel of the LN-742 and into the brass conductor block on the front of the gearbox. Refer to Figure A.4. Make sure it is all the way in and tighten the locking knob. Keep this connection clean and bright.

LN-742 & LN-742H

A-6

INSTALLATION

A-6

WATER CONNECTIONS (FOR WATER COOLED GUNS)

The LN-742 must have a K590-1 Water Solenoid Kit installed (see Section C, Accessories). Refer to Figure A.5 and perform the following steps:

The maximum water pressure permitted for use with the LN-742 is 55 psi (3.8 bar).

NOTE: If not using a Lincoln water cooler, and if your water cooling device is not designed for use with a waterline solenoid valve, you may remove the solenoid and screw the male fitting (after applying sealant) directly into the brass manifold block.

FIGURE A.5 – WATER CONNECTIONS.

1. Using male 5/8-18 UNF left-hand thread fittings, connect appropriate water hoses to the coolant inlet and outlet on the back of the LN-742. Connect the other ends of these hoses to the appropriate ports on your water cooling units.

2. In the event the water line fittings on your water cooled gun are incompatible with the female quick connects on the front of the LN-742, male quick connects are provided for installation on 3/16 in. I.D. hose (customer to provide appropriate clamps). The feeder connectors self seal when disconnected.

LN-742 & LN-742H

A-7

GAS

SUPPLY

HOSE

GAS

INERT

GAS

FITTING

INSTALLATION

A-7

GMAW SHIELDING GAS HOOKUP

WARNING

Gas under pressure is explosive. Always keep gas cylinders in an upright position and chained to the undercarriage or a stationary support. See American National Standard Z-49.1, “Safety In Welding And Cutting”, published by the American Welding Society.

------------------------------------------------------------------------

Customer must provide a cylinder of shielding gas, a pressure regulator, a flow control valve, and a hose from the flow valve to the gas inlet fitting of the LN-742. Install per Figure A.6 and the following:

1. Connect the supply hose from the gas cylinder flow valve outlet to the 5/8-18 female inert gas fitting on the back panel of the LN-742.

2. Install the barbed fitting and union nut to the 5/8-18 female inert gas fitting on the front of the LN-742. Connect 3/16 in. (4.8 mm) I.D. gas hose from the gun to the barbed fitting.

When the gun is to be removed, this fitting can be easily detached by loosening the union nut.

The LN-742 can be used with any shielding gas recommended in the electrode’s product literature at a maximum pressure of 60 psi (4.1 bar). This may include gasses such as Argon, Helium and Nitrogen and blended gases such as Ar-He, Ar-N2, Ar-O2,Ar-

CO2, CO2, AR-CO2,-O2.

FIGURE A.6 – SHIELDING GAS HOOKUP.

LN-742 & LN-742H

B-1

OPERATION

B-1

OPERATING INSTRUCTIONS

Read and understand the entire Operation Section prior to operating the machine.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work or ground.

• Always wear dry insulating gloves.

GENERAL DESCRIPTION

The K617 LN-742 semiautomatic constant speed wire feeder is specifically equipped for gas metal arc welding using flux-cored Outershield electrodes and solid wire. The LN-742 is also suitable for self-shielded flux-cored Innershield electrodes, submerged arc welding (if constant voltage is satisfactory), and other open arc welding. It has been factory assembled with the following features:

• Wire feed control [50 to 770 in./min (1.25 to 19.5 m/min) for the LN-742; 80 to 1200 in./min (2.00 to

30.5 m/min) for the LN-742H].

• Factory installed gas solenoid valve and gas fittings.

• Wire drive uses a permanent magnet motor and includes tool-less “quick-release” idle roll pressure arm, outgoing guide tube and gun cable fastening.

• Optional factory installed water solenoid and fittings for use with water cooled welding guns.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that

have held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional Safety Guidelines detailed in the beginning of this manual.

The LN-742 4-Roll is designed to provide the additional feeding force required when using gun cables over 15 ft (4.6 m) long or when the wire is pulled long distances (such as when bulk packages are used). Because the four-roll feeder has twice the contact surface, it can also help when feeding softer wires by delivering the same or more feeding force as the two-roll with less overall wire deformation.

RECOMMENDED PROCESSES AND EQUIPMENT

The LN-742 is recommended for use in MIG and Innershield welding applications with constant voltage power sources with 42 VAC auxiliary power and a 14pin connector receptacle, such as the Invertec V300PRO, V350-PRO, DC-400, DC-600, DC-655 DC-650PRO, or Lincoln CV type power sources.

The LN-742 is capable of the following wire feed ranges:

• 0.025 to 1/16 in. (0.6 to 1.6 mm) solid wire for gasmetal-arc or CV submerged arc processes.

• 0.045 to 3/32 in. (1.2 to 2.4 mm) cored wire for Outershield gas-metal-arc processes.

LN-742 & LN-742H

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