Lincoln Electric LN-7 GMA WIRE FEEDERS User Manual

LN-7 and LN-7 GMA Wire Feeders

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For machines with code numbers: 9100 and above

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 y our part. DO

NOT INSTAL L, O PERATE OR
REP A I R TH I S EQ U IPMEN T
WIT H O U T REA D I N G THI S
MAN U A L A N D TH E SA F E T Y
PRE CAUT I ONS CO N TAIN E D
THR O U G HOUT. And , most

importantly, think before you act
and be careful.

LN-7 GMA shown with optional

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OPERATOR’S MANUAL

Copyright © 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 ne ar an o pe n flam e

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 i t ma y be n ecessary to r emove sa fety

gu a rds t o perf o rm r e quir ed ma i nten ance . Rem o ve
guards only when necessary and replace them when the
ma i nten a nce r e qui r ing t h eir r e mov a l is co m plet e .
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 curren t flow in g through a ny conduc tor causes
local ized Electric and Magn etic Fields (EMF). Weld ing
curre nt cr eates EMF fi elds around welding cables and
welding machines

2.b. EMF fields m ay interfe re with some p ac em ak er s, 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. Nev er coil the el ec tr od e lead a ro und yo ur 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.

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 we t clot hing. W ear 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
mu st be per forme d unde r e lect rica lly haz ardo us
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,
electro de re el, welding head, nozzle or s emiautoma tic
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.

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. Ne ve r si multane ou sly touch elect rically “ho t” p ar ts o f
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.

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. Weldi ng may produce fumes and gases
hazardous to health. Avoid breathing these
fumes a nd gases. When weld in g, 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

we lding wit h e lectr odes whi ch requi re speci al
ve ntil atio n such a s stai nles s or har d faci ng (se e
instructions on container or MSDS) or on lea d or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum­st ance s, out door s, a res pira tor may be requ ired .
Additional precautions are also required when welding
on galvanized steel.

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 o r death. A lw ay s use en ough v en ti la ti on ,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t eria l s a fety data shee t ( M SDS) and fo llo w yo ur
employer’s safety practices. MSDS forms are available from
yo u r we ldin g di stri b uto r or fro m th e ma n ufa c tur e r.

5.f. Also see item 1.b.

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

Re m embe r th at weld i ng spar ks and hot
materials from welding can easily go through small cracks
an d ope ni ngs t o adjac ent a rea s. A voi d weldi ng nea r
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
Standar d Z49. 1) and the operating inform ation f or 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
Co n tain e rs and Pip i ng That Ha v e He ld Haz a rdou s
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
incre ase t he possibility of the welding curren t 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 wel di ng sparks fro m starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Us e only c ompr esse d gas c y lin d ers
containing the correct shielding gas for the
pr o cess u sed a n d pro perl y oper atin g
re g ulat o rs d e sig n ed f or t h e g a s a n d

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

7.b. Always keep cylinders in a n 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. Re ad a nd f oll ow t he i nst ru cti ons on c omp re sse d ga s
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. Ins tall equipme nt in accordance with the U .S. Nati onal
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.

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.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

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 pr ovoquer 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’o pérations de d égraissage, 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. Pr ot ég er l’autre personnel travaillant à proximité au

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

4. Des gouttes de laitier e n fusion sont ém ises 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.

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 customer’s 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.

TABLE OF CONTENTS

Page

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

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

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

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

Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

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

Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20

Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20

Gun Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20

Water Connections (For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . A-21

Shielding Gas Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22

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

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

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

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . B-2

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

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

Avoiding Ground Lead Protector (GLP) Activation . . . . . . . . . . . . . . . . . . B-3

Drive Roll Installation (2 Roll) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Drive Roll Installation (4 Roll) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

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

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

Acceleration Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Wire Speed and Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13

Wire Reel Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13

K417 Digital Voltmeter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13

Optional Flux Tank Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14

vi

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

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

Auxiliary Equipment Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Attaching the Wire Reel Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

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

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

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

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

Parts Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-283 Series

LN-7 & LN-7 GMA

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – LN-7 and LN-7 GMA

INPUT VOLTAGE

Supplied by power source: 115 VAC, 50/60 Hz, 2.5 Amps

WIRE FEED SPEED

LN-7 GMA 75 to 700 in. per minute (1.90 to 17.8 m/min)
LN-7 50 to 500 in. per minute (1.27 to 12.7 m/min)

WIRE DIAMETERS

A-1

TWO

ROLL

FEEDER

FOUR
ROLL

FEEDER

LN-7 GMA

LN-7

WITHOUT

WIRE STAND

WITH WIRE

STAND (K377)

WITHOUT

WIRE STAND

WITH WIRE

STAND (K377)

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

0.045 in. through 5/64 in.
(1.2 through 2.0 mm)

0.023 in. through 3/32 in.
(0.6 through 2.4 mm)

0.045 in. through 7/64 in.
(1.2 through 2.8 mm)

PHYSICAL DIMENSIONS

LENGTH

9.62 in.

(244 mm)

20.68 in.

(525 mm)

9.70 in.

(246 mm)

20.76 in.

(527 mm)

WIDTH

9.76 in.

(247 mm)

9.76 in.

(247 mm)

11.60 in.

(295 mm)

11.60 in.

(295 mm)

HEIGHT

10.89 in.

(277 mm)

17.00 in.

(432 mm)

11.11 in.

(282 mm)

17.00 in.

(432 mm)

solid electrode
cored electrode

solid electrode
cored electrode

TOTAL WEIGHT

LESS ELECTRODE

24 lbs

(10.9 kg)

36 lbs

(16.3 kg)

30.5 lbs

(13.8 kg)

42.5 lbs

(19.3 kg)

DUTY CYCLE:

The amount of welding performed in a 10 minute period, expressed as a percentage.

LN-7 & LN-7 GMA

A-2

INSTALLATION

LN-7 & LN-7 GMA

A-2

MOUNTING LOCATION

The LN-7 and LN-7 GMA wire feeder can be mounted
directly on top of the power source providing that it is
secure and level. It can also be mounted to an
undercarriage when portability is required.

MACHINE GROUNDING

The LN-7 and LN-7 GMA wire feeders are ground to
the power source through the input cable. The power
source grounding terminal must be properly connected
to electrical ground per the power source operating
manual.

INPUT CABLE CONNECTIONS

Various input cable assemblies are available for the
LN-7 GMA wire feeder. Refer to the Accessories
section for complete descriptions

Turn input power off before connecting the LN-7
GMA wire feeder.

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

For connecting an LN-7 GMA to a specific Lincoln
power source follow steps 1 through 6, and refer to the
connection diagrams in Figure A.3 through A.17 for the
specific power source. Table A.1 lists each figure
number with its corresponding power source.

Figure # Power Source

A.3 LN-7 GMA To DC-400, DC-250 and CV/CVI Power Sources With Terminal Strip - Connection

Diagram
A.4 LN-7 GMA To Pulsed Power 500 - Connection Diagram
A.5 LN-7 GMA To CV/CVI Power Sources With 14 Pin Amphenol Connector - Connection Diagram
A.6 LN-7 GMA To CV/CVI Power Sources With Twist-Mate Connector and 14 Pin Amphenol/Remote

Control - Connection Diagram
A.7 LN-7 GMA To CV/CVI Power Source (K867/K775) - Connection Diagram
A.8 LN-7 GMA To R3S-250 or R3S-325 - Connection Diagram
A.9 LN-7 GMA To SAM Motor Generator or Engine Welder - Connection Diagram

A.10 LN-7 GMA To DC-600 - Connection Diagram
A.11 LN-7 GMA To R3S-400, 600, or 800 - Connection Diagram
A.12 LN-7 GMA To Most Lincoln Motor Generators - Connection Diagram
A.13 LN-7 GMA To WP250 or G9 PRO - Connection Diagram
A.14 LN-7 GMA To Ranger 9 - Connection Diagram
A.15 LN-7 GMA To Ranger 10-LX - Connection Diagram
A.16 LN-7 GMA To Power Sources With No Output Contactor - Connection Diagram
A.17 LN-7 GMA To Power Sources With Contactor and No Terminal Strip - Connection Diagram

TABLE A.1 - LN-7 GMA CONNECTION DIAGRAMS

WARNING

A-3

INSTALLATION

LN-7 & LN-7 GMA

A-3

1. For K291 and K404 cables, connect the end of the
control cable with the lugged leads to the power
source. If lead #21 is extended to work, do not
connect leads to terminal #21 on terminal strip.
For K584, K594 or K480 cables connect the 14
pin amphenol connector to the power source.
Include any jumpers called for on the connection
diagram. Do not add any other jumpers or
connections.

Never operate a Lincoln power source that has a
jumper from #2 to #4 on the terminal strip, or a
power source without a contactor, with this wire
feeder. To do so would defeat the purpose of the
grounding lead protector circuit and could result in
the overheating of the electrical ground circuit to
the wire feeder.

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

2. For constant voltage power sources with an

output contactor but no terminal strip or 14-pin
control receptacle, see Figure A.17. For constant
voltage power sources without an internal output
contactor, and requiring a K240 Contactor Kit,
see Figure A.16.

3. If input cables longer than the standard length

must be used, K292 extension cables (50 ft/15.2
m) can be installed. These have polarized plugs
on each end of the control cable and include a 4/0
(107 mm

2

) electrode cable. Install the extensions
between the standard input cable and the wire
feeder. Total input cable length should not exceed
400 ft (122 m). When using longer lengths of
extension cables, it may be necessary to add
parallel electrode cables to minimize the voltage
drop in the cable.

4. Referring to Figure A.1, route the end of the
electrode cable through the large hole in the back
panel of the LN-7 case. Connect the electrode
cable to the brass conductor block on the front of
the gearbox using the 1/2-13 x .75 bolt provided.

Be sure the cable is placed to allow easy
access and clearance for the idle roll arm
pressure adjustment and to allow the drive
roll section cover to close.

WARNING

FIGURE A.1 – INPUT CONTROL CABLE AND
ELECTRODE CABLE CONNECTIONS.

CONDUCTOR

BLOCK

CONTROL

CABLE

ELECTRODE

A-4

INSTALLATION

LN-7 & LN-7 GMA

A-4

5. Connect the input control cable polarized
Amphenol plug into the mating 6-pin receptacle
on the rear of the control section.

6. 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 the wire reel mounting assembly, put
the input cable assembly under the clamp and
reinstall the screws.

FIGURE A.2 – STRAIN RELIEF CLAMP.

CONTROL

CABLE

STRAIN

RELIEF
CLAMP

ELECTRODE

CABLE

A-5

INSTALLATION

LN-7 & LN-7 GMA

A-5

FIGURE A.3 – LN-7 & LN-7 GMA TO DC-400, DC-250 AND CV/CVI POWER SOURCES WITH

TERMINAL STRIP - CONNECTION DIAGRAM.

WARNING

ELECTRIC

SHOCK

CAN KILL

–

+

TURN INPUT POWER OFF
BEFORE CONNECTING THE
LN-7 GMA WIRE FEEDER.

77

CLEVELAND, OHIO U.S.A

A-6

INSTALLATION

LN-7 & LN-7 GMA

A-6

FIGURE A.4 – LN-7 & LN-7 GMA TO PULSED POWER 500 - CONNECTION DIAGRAM.

WARNING

ELECTRIC

SHOCK

CAN KILL

–

+

TURN INPUT POWER OFF
BEFORE CONNECTING THE
LN-7 GMA WIRE FEEDER.

CLEVELAND, OHIO U.S.A

A-7

INSTALLATION

LN-7 & LN-7 GMA

A-7

FIGURE A.5 – LN-7 & LN-7 GMA TO CV/CVI POWER SOURCES WITH 14 PIN AMPHENOL

CONNECTOR - CONNECTION DIAGRAM.

WARNING

ELECTRIC

SHOCK

CAN KILL

+

–

TURN INPUT POWER OFF
BEFORE CONNECTING THE
LN-7 GMA WIRE FEEDER.

CLEVELAND, OHIO U.S.A

A-8

INSTALLATION

LN-7 & LN-7 GMA

A-8

FIGURE A.6 – LN-7 & LN-7 GMA TO CV/CVI POWER SOURCES WITH TWIST-MATE CONNECTOR

AND 14 PIN AMPHENOL/REMOTE CONTROL - CONNECTION DIAGRAM.

WARNING

ELECTRIC

SHOCK

CAN KILL

+

–

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH AT
THE FUSE BOX BEFORE
CONNECTING THE WIRE
FEEDER.

ONLY QUALIFIED PERSONS
SHOULD INSTALL, USE, OR
SERVICE THIS MACHINE.

CLEVELAND, OHIO U.S.A

A-9

INSTALLATION

LN-7 & LN-7 GMA

A-9

FIGURE A.7 – LN-7 & LN-7 GMA TO CV/CVI POWER SOURCE (K867/K775) - CONNECTION DIAGRAM.

WARNING

ELECTRIC

SHOCK

CAN KILL

–+

TURN INPUT POWER OFF
BEFORE CONNECTING THE
LN-7 GMA WIRE FEEDER.

CLEVELAND, OHIO U.S.A

A-10

INSTALLATION

LN-7 & LN-7 GMA

A-10

FIGURE A.8 – LN-7 & LN-7 GMA TO R3S-250 OR R3S-325 - CONNECTION DIAGRAM.

– +

WARNING

ELECTRIC

SHOCK

CAN KILL

TURN INPUT POWER OFF
BEFORE CONNECTING THE
LN-7 GMA WIRE FEEDER.

CLEVELAND, OHIO U.S.A

A-11

INSTALLATION

LN-7 & LN-7 GMA

A-11

FIGURE A.9 – LN-7 & LN-7 GMA TO SAM MOTOR GENERATOR OR ENGINE WELDER - CONNECTION

DIAGRAM.

WARNING

ELECTRIC

SHOCK

CAN KILL

TURN INPUT POWER OFF
BEFORE CONNECTING THE
LN-7 GMA WIRE FEEDER.

CLEVELAND, OHIO U.S.A

A-12

INSTALLATION

LN-7 & LN-7 GMA

A-12

FIGURE A.10 – LN-7 & LN-7 GMA TO DC-600 - CONNECTION DIAGRAM.

WARNING

ELECTRIC

SHOCK

CAN KILL

–

+

TURN INPUT POWER OFF
BEFORE CONNECTING THE
LN-7 GMA WIRE FEEDER.

CLEVELAND, OHIO U.S.A