Lincoln Electric LN-10, IM587-B User Manual
IM587-B
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 CCode 10190, 10191
LN-10 - Bench Model Code 10440, 10441, 10761, 10762, 10816, 10817
LN-10 - Zipline Boom Package Code 10497, 10498
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For use with:
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.
LN-10 Heads & Controls
Boom Mount or Bench Models
, 10771, 10
August, 2007
772, 10824
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
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.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.
___________________________________________________
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.
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 ʻ95
ii
SAFETY
ii
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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
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.d. 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.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
vapors
AUG 06
to
iii
SAFETY
iii
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
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. 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.
the welding sparks from starting a fire.
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan, 07
iv
SAFETY
iv
Mar. ʻ93
Thank You
vv
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!
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. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
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.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications.......................................................................................................A-1
General Description..............................................................................................................A-1
Recommended Processes and Equipment ..........................................................................A-2
Installation of the LN-10 Boom Mount Wire Feeder Components........................................A-2
Mounting the LN-10 Wire Drive Unit .............................................................................A-2
Mounting Synergic 7F Wire Drive Unit (K679-1 or -2)...................................................A-3
Mounting the LN-10 Control Box ..................................................................................A-3
Connecting Wire Drive Unit to Control Box ...................................................................A-3
Electrode Routing..........................................................................................................A-4
Wire Drive Speed Range Selection......................................................................................A-4
Control Speed Range Setting .......................................................................................A-4
10 Series Wire Drive Ratio Selection ............................................................................A-4
Wire Feed Drive Roll Kits .....................................................................................................A-5
Procedure to Install Drive Roll and Guide Tubes .................................................................A-5
Synergic 7F 4-Roll Kits (KP655 and KP656).................................................................A-5
10 Series Wire Drive Roll Kit Installation ......................................................................A-5
Gun and Cable Assemblies with Standard Connection........................................................A-6
GMAW Guns .................................................................................................................A-6
Innershield Guns ...........................................................................................................A-6
Gun Cable Connection with Standard Connection........................................................A-6
Gun and Cable Assemblies with Fast-Mate Connection ......................................................A-6
GMAW Guns .................................................................................................................A-6
Gun Cable Connection with Fast-Mate Connection ......................................................A-7
Water Connections (For Water Cooled Guns) .....................................................................A-7
10 Series Wire Drives ...................................................................................................A-7
Synergic 7F Drives (K679) ............................................................................................A-7
GMAW Shielding Gas ...................................................................................................A-7
Gas Guard Regulator ....................................................................................................A-7
Electrical Installation.............................................................................................................A-8
Input Cable: LN-10 Control to Power Source................................................................A-8
Work Cable ...................................................................................................................A-8
Optional Features Installation...............................................................................................A-9
Boom and Bench Conversions.............................................................................................A-9
vi
Operation ............................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
Duty Cycle ............................................................................................................................B-1
LN-10 Control DIP Switch Setup ............................................................................B-1 thru B-5
Keypad and Display Operation...............................................................................B-6 thru B-9
Dual Procedure Remote Control (K1449-1)...........................................................................10
Wire Reel Loading..............................................................................................................B-10
Feeding Electrode and Brake Adjustment..........................................................................B-11
Drive Roll Pressure Setting ................................................................................................B-11
Procedure for Setting Angle of Feedplate ..........................................................................B-12
Gas Guard Regulator Setting .............................................................................................B-12
Making a Weld....................................................................................................................B-12
Wire Reel Changing ...........................................................................................................B-13
Loss of Voltage Sense Shutdown ......................................................................................B-13
Wire Feed Overload Protection ..........................................................................................B-13
Grounding Lead Protector ..................................................................................................B-13
Explanation of Prompting and Error Messages..................................................................B-14
Accessories.....................................................................................................Section C
Drive Roll and Guide Tube Kits............................................................................................C-1
Other Optional Features.........................................................................................C-2 thru C-4
Maintenance ....................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Avoiding Wire Feeding Problems.........................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Procedure for Removing Feedplate from Wire Feeder ........................................................D-1
Troubleshooting..............................................................................................Section E
Safety Precautions ...............................................................................................................E-1
Troubleshooting Procedures .................................................................................E-2 Thru E-8
Procedure for Replacing PC Boards ....................................................................................E-9
vii
TABLE OF CONTENTS
Page ......
Diagrams ..........................................................................................................Section F
Wiring (LN-10 Control)...........................................................................................F-1
Wiring (10 Series Wire Drive) ................................................................................F-2
Dimension Print......................................................................................................F-3
Parts List ......................................................................................................P311 Series
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS – LN-10 Heads & Controls
WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER
SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO
Speed Wire Size Speed Wire Size
K1563-1,-3 10 Series 35-500 IPM .025 - 3/32 in. .035 - .120 in .50 - 750 IPM .025 - 1/16 in. .035 - 5/64 in.
Std Drive
K1563-2,-4 10 Series 55 - 825 IPM .025 - 1/16 in. .035 - 5/64 in. 80 - 1250 IPM .025 - .045 in. .035 - .045 in.
Hi-Speed
K679-1 Synergic 7F* 50 - 770 IPM .025 - 1/16 in. .035 - 5/64 in. --- --- --Std Drive
K679-2 Synergic 7F* --- --- --- 80 - 1200 IPM .025 - .045 in. .035 - .045 in.
Hi-Speed
K1559-1,-3 LN-10 35-500 IPM .025 - 3/32 in. .035 - .120 in. 50 - 750 IPM .025 - 1/16 in. .035 - 5/64 in.
Std Drive
K1559-2,-4 LN-10 55 - 825 IPM .025 - 1/16 in. .035 - 5/64 in. 80 - 1250 IPM .025 - .045 in. .035 - .045 in.
Hi-Speed
Boom Mount (0.89-12.7 M/M) (0.6 - 2.4 mm) (0.9 - 3.0 mm) (1.25 - 19.0 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm)
Boom Mount (1.40 - 21.0 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm) (2.00 - 31.8 M/M) (0.6 - 1.2 mm) (0.9 - 1.2 mm)
Boom Mount (1.27 - 19.5 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm)
Boom Mount (2.00 - 30.5 M/M) (0.6 - 1.2 mm) (0.9 - 1.2 mm)
Bench Model (0.89-12.7 M/M) (0.6 - 2.4 mm) (0.9 - 3.0 mm) (1.25 - 19.0 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm)
Bench Model (1.40 - 21.0 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm) (2.00 - 31.8 M/M) (0.6 - 1.2 mm) (0.9 - 1.2 mm)
CONTROLS, HEADS AND COMPLETE UNITS
SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING
K1562-1
Control Controls 4.0 Amps 50/60 Hz (K1562-1) (375.9 mm) ( 360.7mm) (106.7 mm) (8.2 Kg)
K1563-1Δ,-3Δ 10 Series 7.81 “ 14.71 “ 11.00“ 25.0 Lbs
Std Drive
K1563-2,-4 (13.6 Kg)
Hi-Speed
K679-1 Synergic 7F* 11.5“ 7.16“ 8.06“ 16.5 Lbs -20°C -40°C
Std Drive Boom Mount ( 285.8mm) (181.9 mm) (204.7mm) (7.5 Kg.)
Δ,-2Δ LN-10 40-42 Vac + 10% 14.80 “ 14.20 “ 4.20 “ 18.0 Lbs
6.0 Amps 50/60 Hz (K1562-2)
Boom Mount (198.4 mm) (373.6 mm) (27.94 mm) (11.3 Kg)
Solid Cored Solid Cored
Dimensions
Height Width Depth Weight Operating Storage
K-1563-1,-2
30.0 Lbs
K-1563-3,-4
+40°C +40°C
to to
K679-2 Synergic 7F*
Hi-Speed
K1559-1,-3 LN-10 40-42 Vac + 10% 20.46 “ 14.73 “ 30.35 “ 65.0 Lbs
Std Drive
K1559-2,-4 (31.8 Kg)
Hi-Speed
• Excluding Wire Reel
Δ Included with K1561-Series, LN-10 Boom Packages
*Synergic 7F wire drives use 4-roll drives with 2 driven rolls(Drive roll kits not common with 10 Series heads)
Boom Mount
Bench Model 4.0 Amps 50/60 Hz (K1559-1,-2) (519.7 mm) (366.5 mm) (770.9 mm) (29.5 Kg)
6.0 Amps 50/60 Hz (K1559-3,-4) 70.0 Lbs
GENERAL DESCRIPTION
The LN-10 is a modular line of 42VAC input 4-roll wire feeders. A single control with dual procedure presettability of
wire feed speed (in IPM or M/min) and arc voltage is used
with a single DC welding power source.
The LN-10 models have controls providing keypad or
remote selectability of either of two procedures.
The units offer 4 independently selectable gun trigger
modes for each procedure; cold feed, 2 step and 4-step trigger and spot weld mode.
Also, 4 selectable, presettable timers for each procedure;
preflow, postflow, burnback and spot weld time.
Arc starting can be optimized for each procedure with 5
selectable wire feed acceleration rates, and independent
control of slower run-in procedure.
A gas purge key is provided, as well as cold feed forward
and reverse keys with independently adjustable forward
feed speed setting.
K-1559-1,-2
K-1559-3,-4
LN-10
A-2
All of these features are selected with a tactile-feel keypad,
and are set independently using one of two rotating knob
encoders, setting levels are displayed on one of two digital
LED displays.
The 10 Series Wire Drive assemblies include a heavy duty
head with externally changeable gear ratio and 4 driven roll
drives housed together in a single combination mounting
and connection box. Gun adapters are available to permit
use with a variety of standard welding guns.
Available Models:
The LN-10 Wire Feeder system is available configured in
both Bench and Boom models.
INSTALLATION
A-2
The wire type and size range for the wire drive used,
and gear ratio change selected, are given in the
Specifications.
Recommended power sources are Lincoln Electric
Company constant voltage power sources with 42
VAC auxiliary power and a 14-pin connector receptacle. At the time of printing these include: CV 250,
CV300-I, CV-300, CV400-I, CV-400, CV500-I, DC400, DC-600, CV-655, Invertec V300-PRO, V350PRO DC-650 PRO and DC- 655.
The DC-250, DC-1000 and the Pulse Power 500 (CV
mode only) may also be used with the LN-10 if the
optional K1520-1 115V / 42V Transformer Kit is used.
Bench Models consists of an LN-10 control and a 10
Series wire drive assembly premounted on a platform
with a dual 2" O.D. spindle mounting.
Boom Models consist of an LN-10 control and a choice of
wire drives designed to be mounted separately and joined
by available head to control cable assemblies.
The head to control cable assemblies are available in
two types; one control cable is required for each head:
K1498-”L”
K681-”L” Same as above but does not include
LN-10 Boom Packages (K1564-Series) are also available which include:
• LN-10 Control Box
• 10 Series Wire Drive
• Appropriate length Control and Weld Cables to
connect Control to Wire Drive
• Accessories specific to the Boom package
ordered
Includes a control cable with a 14-pin
ms style connection on each end, and
a 3/0 weld cable. Available in lengths
“L” of 16, 20 or 25 ft. (4.9, 6.1 or 7.6 m)
weld cable available in lengths “L” of
12, 16 or 25 ft. (3.6, 4.9 or 7.6 m).
RECOMMENDED PROCESSES AND
EQUIPMENT
The LN-10 Wire Feeder system is recommended for
use with solid wire gas-metal-arc or CV Submerged
arc processes, as well as cored wire for Outershield
GMA or Innershield processes.
SAFETY PRECAUTIONS
INSTALLATION OF THE LN-10
BOOM MOUNT WIRE FEEDER
COMPONENTS
Mounting the 10 Series Double Header
Wire Drive
Mount the 10 Series wire drive to the boom or structure using the four 5/16-18 threaded mounting holes
located on the bottom of the drive connection box.
See Figure A.1 for the size and location of the mounting holes. The feed plate assembly is electrically "hot"
when the gun trigger is pressed. Therefore, make certain the feed plate does not come in contact with the
structure on which the unit is mounted.
The wire drive unit should be mounted so that the
drive rolls are in a vertical plane so dirt will not collect
in the drive roll area. Pivot the feed plate so it will
point down at an angle so the wire feed gun cable will
not be bent sharply as it comes from the unit. See
“Procedure for setting angle of Feed Plate” in the
OPERATION section of this manual.
ELECTRIC SHOCK can
kill.
• Turn the input power off at the power source
disconnect switch before attempting to connect
the input power to the LN-10 Control.
• Only qualified personnel should perform this installation.
----------------------------------------------------------------------------------------
LN-10
A-3
5/16-18 THREAD
2.25
INSTALLATION
CLEARANCE
FOR 1/4 BOLT
10.50
A-3
.50
6.00
11.00
FEED PLATE
3.00
BOTTOM FRONT
10.50
14.50
DOOR OPEN
5.00
FIGURE A.1
Mounting Synergic 7F Wire Drive Unit
(K679-1 or -2)
Mount the wire feed unit by means of the insulated
mounting bracket attached to the bottom of the gearbox.
Reference L9777 (included with Drive unit) to find the
size and location of the mounting holes. The gearbox
assembly is electrically “hot” when the gun trigger is
pressed. Therefore, make certain the gearbox does not
come in contact with the structure on which the unit is
mounted.
The wire feed unit should be mounted so that the drive
rolls are in a vertical plane so dirt will not collect in the
drive roll area. Position the mechanism so it will point
down at about a 45° angle so the wire feed gun cable will
not be bent sharply as it comes from the unit.
Note: The K1562-1 control box must be used with the
K679-1 or -2.
Mounting the LN-10 Control Box
The same control box is used for both a 10 Series drive,
or a Synergic 7F drive. The back plate of the control box
has two keyhole slots and one bottom slot for mounting.
See Figure A.2 for the size and location of these slots.
Mount the box at some convenient location close to the
wire drive unit which will enable the desired control cable
to reach between the control box and the wire drive unit.
a) Drill the required holes in the mounting surface,
partially install 1/4-20 screws.
14.00
10.00
14.50
2.63
2.63
5.25
12.75
13.75
CLEARANCE
FOR 1/4 BOLT
FIGURE A.2
Connecting Wire Drive Unit to Control Box
One head to control cable assembly is required. The
Head to Control cable assemblies are available in two
types:
K1498-"L" -Includes a control cable with 14-pin ms-style
connectors on each end, and a 3/0 weld
cable (rated 600 amps, 60% duty cycle) to
route between the wire drive and the control
box. Available in lengths "" of 16 ft. (4.9 m),
20 ft. (6.1 m) and 25 ft. (7.6 m)
K681-"L" - Same as K1498, but does not include weld
cable. Available in lengths "L" of 12 ft (3.6 m),
16 ft (4.9 m) and 25 ft. (7.6 m).
a) Making certain the cables are protected from any
sharp corners which may damage their jackets,
mount the cable assembly along the boom so the end
with the female amphenol connector pins is at the
wire feed unit.
b) Connect the 14-socket cable connectors to the mating
receptacles on the back of the wire feed unit connection box.
c) At the same end, connect the electrode lead to the
1/2" connection bolt on the front of the left wire drive
head feed plate.
d) At the control box end, connect the 14 pin connectors
of the cable to the mating receptacle on the bottom of
the control box.
b) Mount the box.
c) Tighten the screws.
e) At the control box current sensor, slip the cover box
up off the sensor and connect the electrode cable(s)
to the top bolt connection.
LN-10
A-4
INSTALLATION
A-4
Electrode 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.
c) If more than one wire feed unit shares the same
boom and are not sharing the some power
source output stud, their wire and reels must be
insulated from each other as well as insulated
from their mounting structure.
WIRE DRIVE SPEED RANGE
SELECTION
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.
b) Loosen the retaining screw, which is also
accessed from bottom of feeder, using a 3/16"
Allen wrench. Continue to loosen the screw
until the feedplate can be easily pulled off of the
wire feeder.
3) Loosen, but do not remove, the screw on the lower
right face of the feedplate with a 3/16" Allen
wrench.
4) Remove the screw on the left face of the feedplate.
If changing from high speed (larger gear) to low
speed (smaller gear), line the lower hole on the left
face of the feedplate with the threads on the
clamping collar. Line the upper hole with the
threads to install larger gear for high speed feeder.
If feedplate does not rotate to allow holes to line
up, further loosen the screw on right face of feedplate.
The rated speed and wire size range for each wire
drive head is shown in the SPECIFICATIONS in the
front of this section.
Control Speed Range Setting
The speed range is set up to match the wire feed
head connected to the LN-10 control by properly setting the switch (S1) code on the control board inside
the control box. See OPERATION “Setting the DIP
Switches” for setting instructions.
10 Series Wire Drive Ratio Selection
The 10 Series type drives include two external gear
sizes; a 1" dia. gear and a 1-1/2" dia. gear. The smaller gear provides the low speed range ratio, and the
larger gear provides the high speed range ratio per
the SPECIFICATIONS in the front of this section.
The following procedure is for changing ratio of the 10
Series wire drive:
1) Pull open the Pressure Door.
5) Install gear onto output shaft and secure with flat
washer, lock washer, and Phillips head screw
which were previously removed.
6) Tighten the screw on lower right face of feedplate.
7) Re-attach feedplate to wire feeder if removed in
Step 2.
8) Feedplate will be rotated out-of-position due to the
gear change. To re-adjust angle of feedplate:
a) Loosen the clamping collar 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.
b) Rotate feedplate to the desired angle and tight-
en clamping collar screw.
9) Make sure to properly set the switch (S2) code on
the control board inside the control box for the
new gear size installed. See OPERATION “Setting
the DIP Switch” for setting instructions.
2) Remove the Phillips head screw retaining the pinion gear to be changed and remove the gear. If the
gear is not easily accessible or difficult to remove,
remove the feedplate from the gearbox. To remove
feedplate:
LN-10
A-5
INSTALLATION
A-5
WIRE FEED DRIVE ROLL KITS
NOTE: The maximum rated solid and cored wire
sizes for each wire drive head and selected
drive ratio is shown on the SPECIFICATIONS
in the front of this section.
The electrode sizes that can be fed with each roll and
guide tube are stenciled on each part. Check the kit
for proper components.
Synergic 7F Wire Drives (K679) use 4-Roll drive roll
kits with 2 driven rolls, per Table C.1 in ACCESSORIES. These kits are common with those used for
the 4-Roll LN-7 GMA and LN-9 GMA Lincoln Wire
Feeders, but are not common with those used with the
10 Series wire drive units. Installation instructions are
included with the kits.
10 Series Wire Drives use 4-Roll drive roll kits with 4
driven rolls, per Table C.1 in ACCESSORIES.
PROCEDURE TO INSTALL DRIVE
ROLL AND WIRE GUIDES
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.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.
3) Remove clamping screw & clamping collar from
the drive shaft closest to the incoming side of the
feeder.
4) Install drive roll onto keyed shaft. (Do not exceed
the maximum wire size rating of the wire drive.)
Replace collar and tighten clamping screw.
5) Back out the set screw for the middle guide tube.
Install the middle guide tube and slide it up against
the drive roll. DO NOT TIGHTEN THE MIDDLE
GUIDE AT THIS TIME.
6) Install the outgoing drive roll following the same
procedure as steps 3 & 4.
7) Center the middle guide between the two drive
rolls and tighten in place.
8) Back out the screws for the incoming and outgoing
guide tubes.
9) Install the longer guide tube in the rear hole near
the incoming drive roll. Slide the tube in until it
almost touches the roll. Tighten in place.
10) Install the remaining guide tube in the front hole.
Be certain that the proper plastic insert is used.
Fine wire chisel point tube must have largest
radius next to drive roll. Tighten in place.
11) Re-latch both quick release levers.
12) To start new electrode, straighten the first 6"
(150mm) and cut off the first 1" (25 mm). Insert
free end through the incoming tube. Press gun
trigger and push wire into the drive roll.
TO SET IDLE ROLL PRESSURE, see “Idle Roll
Pressure Setting” in OPERATION.
10 Series Wire Drive Roll Kit Installation
(KP1505 and KP1507)
Observe all additional Safety Guidelines detailed
throughout this manual.
Synergic 7F Wire Drive 4-Roll Kits (KP655
and KP656)
1) Turn OFF welding power source.
2) Release both quick release levers by sliding the
levers sideways into the open positions.
LN-10
1) Turn OFF Welding Power Source.
2) Pull open Pressure Door to expose rolls and wire
guides.
3) Remove Outer Wire Guide by turning knurled
thumb screws to unscrew from Feedplate.
4) Remove drive rolls, if any are installed, by pulling
straight off shaft. Remove inner guide.
5) Insert inner Wire Guide, groove side out, over the
two locating pins in the feedplate.
A-6
INSTALLATION
A-6
6) Install each drive roll by pushing over shaft until it
butts up against locating shoulder on the drive roll
shaft. (Do Not exceed maximum wire size rating of
the wire drive).
7) Install Outer Wire Guide by sliding over locating
pins and tightening in place.
8) Engage upper drive rolls if they are in the “open”
position and close Pressure Door.
TO SET IDLE ROLL PRESSURE, see “Idle Roll
Pressure Setting” in OPERATION.
GUN AND CABLE ASSEMBLIES
WITH STANDARD CONNECTION
The 10 Series Wire Drive Heads each require a
K1500 Gun Adapter installed See “Gun Adapters” in
ACCESSORIES section. The K1500-2 Gun Adapter
and Trigger Cable for Magnum 200-400 guns are factory included with the LN-10.
GMAW Guns
An expanding line of Magnum gun and cable assemblies are available to allow welding with solid and
cored electrodes using the GMAW process See the
appropriate Magnum literature for descriptions of the
200 to 550 ampere air cooled gun and cables that are
available. Gun cable lengths range from 10 ft. (3.0 m)
to 25 ft. (7.6 m) and feed electrode sizes .025" (0.6
mm) to 3/32" (2.4 mm). The entire line of Magnum
Fast-Mate gun and cable assemblies can also be
used by installing a K489-2 Fast-Mate adapter kit.
See “Gun and Cable Assemblies with Fast-Mate
Connection” in this section for details.
Innershield Guns
Gun Cable Connection with Standard
Connection
1. Check that the drive rolls and guide tubes are
proper for the electrode size and type being used.
If necessary, change them per “Wire Drive Roll
Kits” in this section.
2. Lay the cable out straight. Insert the connector on
the welding conductor cable into the brass conductor block on the front of the wire drive head. Make
sure it is all the way in and tighten the hand clamp.
Keep this connection clean and bright. Connect the
trigger control cable polarized plug into the mating
5 cavity receptacle on the front of the wire drive
unit.
3. For GMA Gun Cables with separate gas fitting (10
Series Wire Drive using K1500-1 Gun Adapter),
connect the 3/16" I.D. gas hose from the wire drive
unit to the gun cable barbed fitting.
GUN AND CABLE ASSEMBLIES
WITH FAST-MATE CONNECTION
(Requires K489-2 Fast Mate™ Adapter Kit used with
the K1500-1 Gun Adapter)
GMAW Guns
An expanding line of Magnum Fast-Mate™ air cooled
and water cooled gun and cable assemblies are available to allow welding with solid and cored electrodes
using the GMAW process. See the appropriate
Magnum literature for descriptions of the 200 to 400
ampere air cooled gun and cables that are available
as well as the Magnum “Super Cool” 450 ampere
water cooled gun and cable. Gun cable lengths range
from 10 ft. (3.0 m) to 25 ft. (7.6 m) and feed electrode
sizes .025" (0.6 mm) to 5/64" (20 mm).
K126 and K115 gun and cable assemblies are available to allow welding with Innershield electrodes. Gun
cable lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m)
The 350 ampere K126 will feed electrode sizes .062
(1.6 mm) to 3/32" (2.4 mm). The 450 ampere K115
will feed 5/64" (2.0 mm) to 3/32" (2.4 mm) electrode.
Three smoke extraction gun and cable assemblies are
available, 250 ampere K309, 350 ampere K206 and
the 500 ampere K289. All gun cable lengths are 15 ft.
(4.5 m). These guns will feed electrode sizes .062"
(1.6 mm) to 3/32" (2.4 mm) and require the use of the
K184 vacuum unit for use with the LN-10.
An expanding line of Magnum X-Tractor gun and
cable assemblies provides fume extraction capability
for welding with solid and cored electrodes using the
GMAW process. See the appropriate Magnum literature for descriptions of the 250 to 400 ampere air
cooled gun and cables that are available. Gun cable
lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m) and
feed electrode sizes .035" (0.9 mm) to 1/16" (1.6 mm).
These guns require the use of either the K173-1 or
K184* vacuum units.
*Requires S14927-8 connector hose and an S20591
hose adapter.
LN-10
A-7
INSTALLATION
A-7
Gun Cable Connection with Fast-Mate
Connection
1. Check that the drive rolls, feeder guide tubes and
gun connector guide tube are appropriate for the
electrode size being used. If necessary, change
them per “Wire Drive Roll Kits” in this section.
2. Connect gun to gun connector making sure all pins
and gas tube line up with appropriate holes in connector. Tighten gun by turning large nut on gun
cable clockwise.
10 SERIES WIRE DRIVE WATER
CONNECTIONS (FOR WATER
COOLED GUNS)
10 Series Wire Drive: must have a K590-4 Water
Connection Kit installed for water cooled guns. (See
ACCESSORIES).
Using male quick-connect fittings, connect the water
hoses to the coolant inlet and outlet on the back of the
wire drive. Connect the other ends of these hoses to
the appropriate ports on the water cooling units.
GMAW Shielding Gas
WARNING
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.
• Keep cylinder away from welding or other live electrical circuits.
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply when not
in use.
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 wire
drive unit.
In the event the water line fittings on your water
cooled gun are incompatible with the female quick
connects on the front of the wire drive, male quickconnects (L.E. Part No. S19663) are provided in the
Kit for installation on 3/16" (5 mm) I.D. hose
(Customer to provide appropriate clamps). The feeder
connectors self seal when disconnected.
Synergic 7F Wire Drive (K679) :Must have a
K682-2 Water Connection Kit installed. (See ACCESSORIES).
Using hose clamps provided with the K682-2 kit, connect appropriate water hoses to the coolant inlet and
outlet fittings on the back of the K682-2 Kit. Connect
the other ends of these hoses to the appropriate ports
on the water cooling units.
In the event the water line fittings on your water
cooled gun are incompatible with the female quick
connects on the front of the K682-2 Kit male quickconnects are provided with the kit for installation on
3/16 (5 mm) I.D. hose (Customer to provide appropriate clamps). The feeder connectors self seal when
disconnected.
Connect a supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on the
back panel of the wire drive or, if used, on the inlet of
the Gas Guard regulator. (See Below).
Gas Guard Regulator - The Gas Guard Regulator is
an optional accessory (K659-1) on these models.
Install the 5/8-18 male outlet of the regulator to the
5/8-18 female gas inlet on the back panel of the wire
drive. Secure fitting with flow adjuster key at top.
Attach gas supply to 5/8-18 female inlet of regulator
per instructions above.
LN-10
A-8
INSTALLATION
A-8
ELECTRICAL INSTALLATION
Current
Copper Work Cable Size, AWG
60% Duty
Cycle
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.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed throughout this manual.
Input Cable: LN-10 Control to Power
Source
400 Amps
500 Amps
600 Amps
Up to 100 ft Length (30m)
00 (67 mm2)
000 (85 mm
2
)
000 (85 mm2)
K1501-10 (Control Cable only)
Consists of a 9-conductor control cable with 14-pin
control cable plug, without electrode cable, and is
available in a length of 10 ft. (3 m).
With input power disconnected from the power
source, install the input cable per the following:
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) Connect the 9-socket plug of the control cable to
the mating receptacle on the bottom of the LN-10
control box.
4) Slip the current sensor cover off enough to expose
the input connector stud. Connect the electrode
cable from the power source to this stud with the
nut provided, then reclose the current sensor
cover.
Work Cable
Connect a work lead of sufficient size and length (per
the following table) between the proper output terminal on the power source and the work. Be sure the
connection to the work makes tight metal-to-metal
electrical contact.
LN-10
A-9
INSTALLATION
OPTIONAL FEATURES
INSTALLATION
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. K686-2 Adapter permits 3-pin plug and 5-pin
gun trigger plug to be connected to LN-10 5-pin
Trigger/Dual Procedure receptacle.
Connect the 5-pin plug of the K686-2 Adapter to the
LN-10 Wire Feeder Trigger/Dual Procedure 5-socket
receptacle.
The 3-pin plug of the K683-1 Dual Procedure switch
connects to the 3-socket receptacle of the Adapter,
and the 5-pin plug of the welding un connects to the 5socket receptacle of the Adapter.
K683-3 Dual Procedure Switch Kit includes gun
switch, and mountings for Lincoln Innershield and
Magnum guns, with 15 ft. (4.5m) control cable and 5pin plug with two leads to connect to gun trigger.
A-9
When installed and properly configured, the K1561-1
Robotics Interface Module allows complete control of
the welding process from the robot controller.
The Lincoln Electric Companyʼs Automation Center
should be contacted for questions regarding installation or operation of the Robotics Interface Module.
All other options, see ACCESSORIES section, are
shipped with installation instructions.
BOOM AND BENCH CONVERSIONS
The modular design of these feeders allows them to
be converted from bench to boom models or vise
versa. Some additional parts are required to make this
conversion.
Materials Required for bench to boom
conversion:
S13100-197 Plug and Lead assembly, allows a con-
trol cable to connect from control box to the wire drive.
G2868 Mounting Bracket, allows reed switch to be
relocated to control box.
Connect the 5-pin plug of the K683-3 Dual procedure
Switch to the LN-10 Wire Feeder Trigger/Dual
Procedure 5-socket receptacle.
The two lead plug cord extending out of the 5-pin plug
of the Dual Procedure switch is to be connected to the
two trigger leads of the welding gun per the instructions shipped with the kit.
K1449-1 Dual Procedure Remote Control
Provides remote rotating knob encoder control of Wire
Feed Speed and Voltage, along with a dual procedure
selector switch, when the remote control is connected
and REMOTE is selected by the LN-10 Procedure
key. The LN-10 A or B procedure light will also be on
to indicate which procedure is selected by the remote
control.
The 4-pin plug of the remote control connects to the
mating receptacle on the bottom of the LN-10 Control
box.
The K1450-”L” Extension cable is used to extend the
16 ft (5m) cable attached to the remote control.
Lengths “L” are available to match the Length of the
control to boom mount wire drive cable being used.
K1561-1 Robotics Interface Module - The module
plugs directly into the LN-10 control board and provides an interface to a properly equipped Fanuc robot.
K1498-16 AND K1498-25 Control Box to Wire Drive,
Control cable and power cable from control box to
wire drive.
Materials Required for boom to bench
conversion:
L10286-1 Wire Reel Stand, for LN-10 or STT-10,
mount the reed switch onto the reel stand.
S22777 Control Box Support Bracket, to mount the
control box onto the wire drive.
S13100-198 Plug and Lead Assembly, electrical connection between control box and wire drive.
LN-10
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