Lincoln Electric SVM143-A User Manual

DH-10 Heads & Controls

Boom Mount or Bench Models

OPERATOR’S MANUAL

SVM143-A

March, 1999

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.

For use with: DH-10 Control - Boom Mount Code 10357

DH-10 Drive - Boom Mount Codes 10358 (Std.), 10359 (Hi/Std.)

DH-10 Boom Package Codes 10380, 10495, 10496 (Std.), and 10517, 10518, 10519 (Hi/Std.)

Standard - Single Head Drive Codes 10190, 10191

DH-10 Feeder Double Head - Bench Model Codes 10360 (Std.), 10361 (Hi/Std.)

• 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

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

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FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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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.

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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.

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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.

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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.

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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.

SAFETY

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.

WARNING

Mar ‘95

ELECTRIC AND MA GNETIC 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.

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

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 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 Diesel Engines

The Above For Gasoline Engines

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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.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors

to form phosgene, a highly toxic gas, and other irritating products.

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.

SAFETY

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.

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.

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.

Mar ‘95

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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.

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SAFETY

iii

Mar ‘95

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.

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

though

they have been “cleaned”. For information, purchase “Recommended Safe Practices for the

Preparation

for Welding and Cutting of 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.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses 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.

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instruc tions 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.

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.

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 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

RETURNTOMAIN INDEX

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

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

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

Technical Specifications — DH-10 Complete Units or Controls & Heads A-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . A-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Installation of the DH-10 Boom Mount Wire Feeder Components . . . . . A-4

Wire Drive Speed Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Wire Feed Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Procedure to Install Drive Roll and Wire Guides . . . . . . . . . . . . . . . . . . A-6

Gun and Cable Assemblies with Standard Connection . . . . . . . . . . . . . A-7

Gun and Cable Assemblies with Fast-Mate Connection . . . . . . . . . . . . A-8

DH Double Head Drives Water Connections

(For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Optional Features Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

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

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

DH-10 Control Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Keypad and Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Dual Procedure Remote Control (K1449-1) . . . . . . . . . . . . . . . . . . . . . . B-8

Wire Reel Loading - Readi-Reel, Spools or Coils . . . . . . . . . . . . . . . . . B-8

Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . B-10

Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Procedure for Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . B-10

Gas Guard Regulator Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Wire Reel Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Loss of Voltage Sense Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Grounding Lead Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Explanation of Prompting and Error Messages . . . . . . . . . . . . . . . . . . . B-12

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

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

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Wire Reel Mounting - Readi-Reels and

10 to 30 lb (4.5 to 14 kg) Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Procedure for Removing Feedplate from Wire Feeder . . . . . . . . . . . . . D-3

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Input Receptacle, Control Board, and Operator Controls . . . . . . . . . . . E-3

Wire Feed Heads and Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . F-31

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-288

DH-10

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SECTION A-1

INSTALLATION

DH-10

SECTION A-1

TABLE OF CONTENTS

-INSTALLATION SECTION-

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

Technical Specifications — DH-10 Complete Units or Controls & Heads . . . . . . . . . . . . . . . . . . . . A-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Available Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Installation of the DH-10 Boom Mount Wire Feeder Components . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Mounting the DH Double Header Wire Drive Unit (K1497-1 or -2) . . . . . . . . . . . . . . . . . . . . . . . A-4

Mounting Single Head Wire Drive Unit (K679-1 or -2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Mounting the DH-10 Control Box (K1496-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Connecting Wire Drive Unit to Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Wire Drive Speed Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Control Speed Range Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Double Header (DH) Wire Drive Ratio Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Wire Feed Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Procedure to Install Drive Roll and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Single Drive 4-Roll Kits (KP655 and KP656) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

DH Drive Roll Kit Installation (KP1505 and KP1507) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Gun and Cable Assemblies with Standard Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

GMAW Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Innershield Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Gun Cable Connection with Standard Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Gun and Cable Assemblies with Fast-Mate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

GMAW Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Gun Cable Connection with Fast-Mate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

DH Double Head Drives Water Connections (For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . . A-8

DH Double Head Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Single Head Drives (K679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

GMAW Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Input Cable: DH-10 Control to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Optional Features Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

A-2

INSTALLATION

DH-10

A-2

TECHNICAL SPECIFICATIONS – DH-10 Complete Units or Controls & Heads

WIRE DRIVE HEADS (BOOM MOUNT)•

SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO

Wire Size Wire Size

Speed Solid Cored Speed Solid Cored

K1497-1¤DH-10 35 - 500 IPM .025 - 3/32 in. .030 - .120 in. 50 - 750 IPM .025 - 1/16 in. .030 - 5/64 in.

Double Head (0.89 - 12.7 m/m) (0.6 - 2.4 mm) (0.8 - 3.0 mm) (1.25 - 19.0 m/m) (0.6 - 1.6 mm) (0.8 - 2.0 mm)

K1497-2◊ DH-10 35 - 500 IPM .025 - 3/32 in. .030 - .120 in. 50 - 750 IPM .025 - 1/16 in. .030 - 5/64 in.

Left Head (0.89 - 12.7 m/m) (0.6 - 2.4 mm) (0.8 - 3.0 mm) (1.25 - 19.0 m/m) (0.6 - 1.6 mm) (0.8 - 2.0 mm) DH-10 55 - 825 IPM .025 - 1/16 in. .035 - 5/64 in. 80 - 1250 IPM .025 - .045 in. .035 - .045 in.

Right Head (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)

K1563-1 LN-10 35 - 500 IPM .025 - 3/32 in. .030 - .120 in. 50 - 750 IPM .025 - 1/16 in. .030 - 5/64 in.

Single Head (0.89 - 12.7 m/m) (0.6 - 2.4 mm) (0.8 - 3.0 mm) (1.25 - 19.0 m/m) (0.6 - 1.6 mm) (0.8 - 2.0 mm)

K1563-2 LN-10 55 - 825 IPM .025 - 1/16 in. .035 - 5/64 in. 80 - 1250 IPM .025 - .045 in. .035 - .045 in.

Single Head (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)

K679-1* Synergic 7F 50 - 770 IPM .025 - 1/16 in. .035 - 5/64 in. --- --- --Std Drive

Single Head* (1.27 - 19.5 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm)

K679-2* Synergic 7F --- --- --- 80 - 1200 IPM .025 - .045 in. .035 - .045 in. Hi.-Sp. Drive

Single Head* (2.00 - 30.5 m/m) (0.6 - 1.2 mm) (0.9 - 1.2 mm)

CONTROLS SECTION OF COMPLETE UNITS

SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING

Dimensions

Height Width Depth Weight Operating Storage K1499-1 Double Head 40 - 42 Vac + 10% 20.50 in. 19.75 in. 31.50 in. 84.5 lbs Control Bench Model 4.0 Amps 50/60 Hz (520.7 mm) (501.7 mm) (800.1 mm) (38.3 kg) +40°C to +40°C to

-20°C -40°C K1499-2 Double Head Control Bench Model

• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual.

CONTROLS (BOOM MOUNT)

SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING

Dimensions

Height Width Depth Weight Operating Storage K1496-1∆ DH-10 40 - 42 Vac + 10% 14.80 in. 14.20 in. 4.20 in. 18.0 lbs +40°C to +40°C to Control Controls 4.0 Amps 50/60 Hz (375.9 mm) ( 360.7mm) (106.7 mm) (8.2 kg) -20°C -40°C

• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual. ∆ Included with all K1521-[ ] DH-10 Standard and Zipline Boom Packages

The K1496-1 DH-10 control can be used with any of the following Wire Drive Heads

• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual. ¤ Included in K1521-1,-2,-3 DH-10 Boom Packages. ◊ Included in K1521-4,-5,-6 DH-10 Boom Packages. *Single head drives use 4-roll drives with 2 driven rolls (Drive roll kits not common with -10 Series drives)

The K1499-1 or -2 DH-10 consists of a control and a double head 10 series wire drive assembly pre-

mounted on a platform with two 2 in. O.D. spindle mountings. Specifications for the units follow:

The various components of the DH-10 system are available separately or in kits for mounting on boom

assemblies. The description of the various components follow:

WIRE DRIVE SPECIFICATIONS FOR COMPLETE UNITS•

SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO

Wire Size Wire Size

Speed Solid Cored Speed Solid Cored

K1499-1 DH-10 35 - 500 IPM .025 - 3/32 in. .030 - .120 in. 50 - 750 IPM .025 - 1/16 in. .030 - 5/64 in.

Double Head (0.89 - 12.7 m/m) (0.6 - 2.4 mm) (0.8 - 3.0 mm) (1.25 - 19.0 m/m) (0.6 - 1.6 mm) (0.8 - 2.0 mm)

K1499-2 DH-10 35 - 500 IPM .025 - 3/32 in. .030 - .120 in. 50 - 750 IPM .025 - 1/16 in. .030 - 5/64 in.

Right Head (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)

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A-3

INSTALLATION

DH-10

A-3

GENERAL DESCRIPTION

The DH-10 is a modular line of 42 VAC input dual head 4-roll wire feeders. A single control with dual procedure presettability of wire feed speed (in IPM or M/min) and arc voltage for each head is used with a single DC welding power source.

The DH-10 models have controls providing keypad or remote selectability of wire drive head, and either of two procedures preset independently for each head.

The units offer 4 independently selectable gun trigger modes for each head procedure; cold feed, 2 step and 4-step trigger and spot weld mode.

Also, 4 selectable, presettable timers for each head procedure; preflow, postflow, burnback and spot weld time.

Arc starting can be optimized for each head 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.

All of these features are selected with a tactile-feel keypad, and are set independently for each head using one of two rotating knob encoders, setting levels are displayed on one of two digital LED displays.

The DH Wire Drive assemblies include two heavy duty heads 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 DH-10 Wire Feeder system is available configured in both Bench and Boom models.

Bench Models consists of a DH-10 control and a DH double header wire drive assembly premounted on a platform with a dual 2 in. O.D. spindle mounting.

Boom Models consist of a DH-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” 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) for recommended boom lengths of 8-9 ft, 10-12 ft, or 16-18 ft (2.4-2.7 m, 3.0-3.7 m, or 4.9-5.5 m) respectively.

K681-“L” Same as above but does not include

weld cable available in lengths “L” of 12, 16, or 25 ft (3.6, 4.9, or 7.6 m).

The DH-10 boom packages are available in standard packages as follows:

K1521-1 includes:

• DH-10 Control (Same as K1496-1)

• DH-10 Std. Wire Drive Head (Same as K1497-1)

• 16 ft (4.9 m) Control Cable (Same as K681-16)

• 16 ft (4.9 m) Control and Weld Cable (Same as K1498-16)

K1521-2 includes:

• DH-10 Control (Same as K1496-1)

• DH-10 Std. (Left)/Hi-Speed (Right) Heads (Same as K1497-2)

• 16 ft (4.9 m) Control Cable (Same as K681-16)

• 16 ft (4.9 m) Control and Weld Cable (Same as K1498-16)

Also there are four additional Zipline Boom Packages (K1521-2, -3, -5, and -6). For specifications see IM596-4.

RECOMMENDED PROCESSES AND EQUIPMENT

The DH-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.

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, CV-655, Invertec V300-PRO, DC-650 PRO and DC-655.

The DC-250, DC-600, DC-1000 and the Pulse Power 500 (Non-Pulsed CV mode only) may also be used with the DH-10 if the optional K1520-1 115V / 42V Transformer Kit is used.

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A-4

INSTALLATION

DH-10

A-4

SAFETY PRECAUTIONS

INSTALLATION OF THE DH-10 BOOM MOUNT WIRE FEEDER COMPONENTS

Mounting the DH Double Header Wire Drive Unit (K1497-1 or -2)

Mount the DH wire drive unit to the boom or structure using the four 5/16-18 threaded mounting holes located on the bottom of the DH 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.

Mounting Single Head 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.

Mounting the DH-10 Control Box (K1496-1)

The same control box is used for both a DH double header drive, or up to two single head drives. 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.

1. Drill the required holes in the mounting surface, partially install 1/4-20 screws.

2. Mount the box.

3. Tighten the screws.

ELECTRIC SHOCK can kill.

• Turn the input power off at the power source disconnect switch before attempting to connect the input power to the DH-10 Control.

• Only qualified personnel should perform this installation.

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

WARNING

FIGURE A.1

5/16-18 THREAD

2.25

FEED PLATE DOOR OPEN

5.00

10.50

18.50

3.00

6.00

11.00

BOTTOM FRONT

FIGURE A.2

CLEARANCE FOR 1/4 BOLT

2.63

12.75

14.50

13.75

5.25

CLEARANCE

FOR 1/4 BOLT

10.50 .50

10.00

2.63

14.00

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A-5

INSTALLATION

DH-10

A-5 Connecting Wire Drive Unit to Control Box

One head to control cable assembly is required for each head being used; however, only one electrode cable is required if an electrode cable jumper (provided) is connected between the two heads. 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 “L”

of 16 ft (4.9 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).

1. 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.

2. Connect the 14-socket cable connectors to the mating receptacles on the back of the wire feed unit connection box. Feeder Head 1 uses the left receptacle and Feeder Head 2 uses the right receptacle, when facing the front of the wire drive.

3. At the same end, connect the electrode lead to the 1/2 in. connection bolt on the rear of the left wire drive head feed plate. If only one electrode cable is being used, comparable size electrode cable jumper (provided) must be connected between the two heads.

4. At the control box end, connect the 14-pin connectors of the cables to the mating receptacles on the bottom of the control box. Feeder Head 1 should be connected to the left receptacle and Feeder Head 2 should be connected to the right receptacle, when facing the front of the control box.

5. 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.

Electrode Routing

The electrode supply may be either from reels, ReadiReels, spools, or bulk packaged drums or reels. Observe the following precautions:

1. The electrode must be routed to the wire drive unit so that the bends in the wire are at a mini-

mum, and also that the force required to pull the wire from the reel into the wire drive unit is kept at a minimum.

2. The electrode is “hot”when the gun trigger is pressed and must be insulated from the boom and structure.

3. 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

The rated speed and wire size range for each wire drive head is shown in

Specifications

in the front of

this section.

Control Speed Range Setting

The speed range is set up to match each wire feed head connected to the DH-10 control by properly setting the switch (S2) code on the control board inside the control box. See

Operation, Setting the DIP

Switches

for setting instructions.

Double Header (DH) Wire Drive Ratio Selection

The Double Head type drives include two external gear sizes; a 1 in. diameter gear and a 1-1/2 in. diameter gear. The smaller gear provides the low speed range ratio, and the larger gear provides the high speed range ratio per

Specifications

in the front

of this section. The following procedure is for changing ratio of the

DH drive:

1. Pull open the Pressure Door.

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 gear box.

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A-6

INSTALLATION

DH-10

A-6

To remove feedplate:

a. Loosen the clamping collar screw using a

3/16 in. 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 in. 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 in. 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.

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. Install gear onto output shaft and secure with flat washer, lock washer, and Phillips head screw which were previously removed.

8. Re-attach feedplate to wire feeder if removed in Step 2.

9. 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 in.

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

tighten clamping collar screw.

10. 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 Switches

for setting

instructions.

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.

Single Head Drives (K679) use 4-Roll drive roll kits with 2 driven rolls, per

Table C.1

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 DH wire drive units. Installation instructions are included with the kits.

DH Double Head Drives use 4-Roll drive roll kits with 4 driven rolls, per

Table C1

Accessories

. Each

head requires a separate drive roll kit.

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.

Observe all additional Safety Guidelines detailed throughout this manual.

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Single 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.

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 in. (150 mm) and cut off the first 1 in. (25 mm). Insert free end through the incoming tube. Press gun trigger and push wire into the drive roll.

To set idle pressure, see

Idle Roll Pressure Setting

Operation

DH Drive Roll Kit Installation (KP1505 and KP1507)

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.

A-7

INSTALLATION

DH-10

A-7

5. Insert inner Wire Guide, groove side out, over the two locating pins in the feedplate.

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 inOperation

GUN AND CABLE ASSEMBLIES WITH STANDARD CONNECTION

The DH Wire Drive Heads each require a K1500 Gun Adapter installed See

Gun Adapters

Accessories

section.

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 0.025 in. (0.6 mm) to 3/32 in. (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

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

0.062 in. (1.6 mm) to 3/32 in. (2.4 mm). The 450 ampere K115 will feed 5/64 in. (2.0 mm) to 3/32 in. (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 0.062 in. (1.6 mm) to 3/32 in. (2.4 mm) and require the use of the K184 vacuum unit for use with the DH-10.

A-8

INSTALLATION

DH-10

A-8 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 (DH Drive using K1500-1 Gun Adapter), connect the 3/16 in. 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 DH 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 0.025 in. (0.6 mm) to 5/64 in. (20 mm).

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 0.035 in. (0.9 mm) to 1/16 in. (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.

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.

DH DOUBLE HEAD DRIVES WATER CONNECTIONS (FOR WATER COOLED GUNS)

DH Double Head Drives: must have a K590-4

Water Connection Kit installed for each water cooled gun. (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.

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 in. (5 mm) I.D. hose (Customer to provide appropriate clamps). The feeder connectors self seal when disconnected.

Single Head Drives (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 in. (5 mm) I.D. hose (Customer to provide appropriate clamps). The feeder connectors self seal when disconnected.

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A-9

INSTALLATION

DH-10

A-9 GMAW Shielding Gas

The 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.

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.

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.

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

WARNING

ELECTRICAL INSTALLATION

Input Cable: DH-10 Control to Power Source

Available Cable Assemblies: K1501 (Control Cable Only) Consists of a 9-conductor

control cable with a 14-pin control cable plug, without electrode cable, and is available in lengths of 10 ft (3 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m), 50 ft (15 m) and 100 ft (30 m).

K1502 Consists of a 9-conductor control cable with a 14-pin plug and a 3/0 (85 mm2) electrode cable with stud terminal. It is rated at 600 amps, 60% duty cycle and is available in lengths of 10 ft (3 mm), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m) and 100 ft (30 m) is also available with a 4/0 (107 mm2) electrode cable.

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.

WARNING

Observe all additional Safety Guidelines detailed throughout this manual.

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A-10

INSTALLATION

DH-10

A-10

K1503 Consists of a 9-conductor control cable with a

14-pin plug and 2/0 (67 mm2) electrode cable with Twist-Mate™ connector. It is rated at 500 amps, 60% duty cycle and is available in lengths of 10 ft (3 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m) and 100 ft (30 m) is also available with a 3/0 (85 mm2) electrode cable.

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 14-pin 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 DH-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.

Copper Work Cable Size, AWG

Up to 100 ft Length (30 m)

Current

60% Duty

Cycle

400 Amps 500 Amps 600 Amps

00 (67 mm2) 000 (85 mm2) 000 (85 mm2)

OPTIONAL FEATURES INSTALLATION

K1501, K1502 and K1503 Input Cable Assemblies

See

Electrical Installation

for instructions.

K1520-1 115V/42V Transformer Kit. Required to use DH-10 with Lincoln Power Sources without 42 VAC auxiliary and a 14-pin connector receptacle. These power sources include the DC-250, DC-600, DC-1000 and Pulse Power 500. Also can be used with older DC-400 models. Mounts on power source per installation instructions included with the kit.

Spindle Adapters K162H Spindle for boom mounting Readi-Reels and

2 in. (51 mm) I.D. spools with 60 lb (27.2 kg) capacity. User mounted to appropriately prepared boom framework. Includes an easily adjustable friction brake for control of overrun (Two 2 in. spindles standard on DH10 Bench models).

When a 2 in. (51 mm) spindle is used with ReadiReels, or coils not on 12 in. (305 mm) O.D. spools, an adapter is required:

Coil Adapter K1504-1 Permits 50 to 60 lb (22.7 to 27.2 kg) coils to

be mounted on 2 in. (51 mm) O.D. spindles. K435 Permits 14 lb (6 kg) Innershield coils to be

mounted on 2 in. (51 mm) O.D. spindles. K468 Permits 8 in. (203 mm) O.D. spools to be

mounted on 2 in. (51 mm) O.D. spindles.

Readi-Reel Adapters K363P Adapts Lincoln Readi-Reel coils of electrode

30 lb (14 kg) and 22 lb (10 kg) to a 2 in. (51 mm) spindle. Durable molded plastic one piece construction. Designed for easy loading; adapter remains on spindle for quick changeover.

K438 Adapts Lincoln Readi-Reel coils of electrode 50 to 60 lb (22.7 to 27.2 kg) to a 2 in. (51 mm) spindle.

K1634-1 Wire Reel Enclosure Kit. Provides the necessary parts to cover the wire and protect if from excessive dirt and contamination. This kit is not for use with 60 lb coils (most 30 lb, 15 kg, 44 lb fiber spools, and smaller coils will work). The kit includes a two-part reel cover, a Magnum conduit adapter for the incoming end of the wire feeder feed plate and a short length of

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A-11

INSTALLATION

DH-10

A-11

Magnum conduit to go between the reel cover and the feedplate.

Gun Adapters (For DH Wire Drive Heads) Adapts DH heads for desired gun connection K489-7 for Fast-Mate (or European style) gun connec-

tions, including Dual Schedule Fast-Mate guns. K1500-1 for standard Lincoln Innershield gun connec-

tion, or with Fast-Mate™ guns with K489-2 Fast-Mate Adapter Kit. Also for Magnum 200/300/400 with K466-1 Connection Kit or Magnum 550 with K613-1.

K1500-2 for Magnum 200/300/400 gun with K466-10 Connection Kit. (Also Tweco 4).

K1500-3 for Magnum 550 gun with K613-7 Connection Kit. (Also Tweco 5).

Install to either Head of the DH drive per instructions shipped with the Gun Adapter.

Dual Procedure Switch Options K683-1 Dual Procedure Switch (One per gun) -

Requires K686-2 Adapter for DH-10. Kit includes gun switch, and mountings for Lincoln Innershield and Magnum guns, with 15 ft (4.5 m) control cable and 3-pin plug. K686-2 Adapter permits 3-pin plug and 5-pin gun trigger plug to be connected to DH-10 5-pin Trigger/Dual Procedure receptacle.

Connect the 5-pin plug of the K686-2 Adapter to the DH-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 gun connects to the 5-socket receptacle of the Adapter.

K683-3 Dual Procedure Switch (One per gun) Kit includes gun switch, and mountings for Lincoln Innershield and Magnum guns, with 15 ft (4.5 m) control cable and 5-pin plug with two leads to connect to gun trigger.

Connect the 5-pin plug of the K683-3 Dual procedure Switch to the DH-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.

K590-4 Water Connection Kit (For DH Drive Only). Install per the instructions shipped with the kit. One used per gun.

K682-2 Water Connection Kit (K679 Single Head Drive Only). Install to either side of wire feed unit mounting bracket per instructions shipped with the kit.

K659-1 Gas Guard Regulator (One used per gun). Adjustable flow regulator with removable adjustor key for CO2 and Argon blend gases. Mounts onto feeder inlet, and reduces gas waste and arc start “blow” by reducing surge caused by excess pressure in supply hose.

Install the 5/8-18 male outlet of the regulator to one, or both of the 5/8-18 female gas inlets 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 GMAW Shielding Gas in this section.

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 DH-10 Procedure key. The DH-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 DH-10 Control box. Only one remote is used with a DH-10 control.

The K1450-“L” Extension cable is used to extend the 16 ft (5 m) 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.

K1558-1 Remote Switch Interface Module, can be used with the DH-10, using a G3041-2 (or higher) Control Board.

The module provides for user interface connection of an external switch (flow switch, etc) which must be closed to enable the feeder welding operation. Also, the module provides for interface connection of external equipment (fume extractor, etc.) To the module’s isolated relay contacts which actuate when the feeder welding gas solenoid is activated (representing welding operation in process).

When used with the DH-10, the module provides these input and output switch function connections independently for each head operation.

This module is necessary when using the K1536-1 waterflow sense kit with the DH-10.

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A-12

INSTALLATION

DH-10

A-12

SECTION B-1

OPERATION

SECTION B-1

DH-10

TABLE OF CONTENTS

-OPERATION SECTION-

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

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

DH-10 Control Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Setup DIP Switch Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Setting the DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Wire Drive Head Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Welding Power Source Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Metric/English Wire Feed Speed Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

4-Step Trigger Mode Operation Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Low Security Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

High Security Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Keypad and Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Keypad and Display Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Power-Down Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Operation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Trigger Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Display Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Digital “Memory” Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Acceleration Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Security Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

Dual Procedure Remote Control (K1449-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

Wire Reel Loading - Readi-Reels, Spools or Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

To Mount a 30 lb (14 kg) Readi-Reel Package

(Using the Molded Plastic K363-P Readi-Reel Adapter) (FIGURE B.1) . . . . . . . . . . . . . . . . . . . B-8

To Mount 10 to 44 lb (4.5 to 20 kg) Spools (12 in/300 mm Diameter) or

14 lb (6 kg) Innershield Coils (FIGURE B.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

To Mount a 50 to 60 lb (22.7 to 27.2 kg) Coil:

(Using K1504-1 Coil Reel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Procedure for Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Gas Guard Regulator Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Wire Reel Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Loss of Voltage Sense Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Grounding Lead Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Explanation of Prompting and Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

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For K1497-2 (DH-10 Boom) or K1499-2 (DH-10 Bench) with Left Head 35-500 IPM (0.89-12.7 m/m) & Right Head 55-825 IPM (1.40-21.0 m/m) Low Speed Ratio set S2 DIP switch as follows:

For K1497-2 (DH-10 Boom) or K1499-2 (DH-10 Bench) with Left Head 50-750 IPM (1.25-19.0 m/m) & Right Head 80-1250 IPM (2.00-31.8 m/m) High Speed Ratio set S2 DIP switch as follows: (initial fac-

tory setting)

B-2

OPERATION

B-2

Setting the DIP Switches

The DIP switches are each labeled with an “ON” arrow showing the on direction for each of the 8 individual switches in each DIP switch (S1 and S2). The functions of these switches are also labeled and set as described below:

Wire Drive Head Selection

The DH-10 control is set up for proper presettable wire feed speed by setting S2 DIP switches (1 to 4) for Head 1 (left side head) and DIP switches (5 to 8) for Head 2 (right side head) as appropriate per the following examples for the head specification and DH drive external gear selection being used:

NOTE: Set the proper 4 switches labelled for Head 1 (Left Head) or Head 2 (Right Head) as appropriate for the way that Head is being used.

DH-10 HEADS: For K1497-1 (DH-10 Boom) or K1499-1 (DH-10

Bench) with 35-500 IPM (0.89-12.7 m/m) Low Speed Ratio set S2 DIP switches as follows:

For K1497-1 (DH-10 Boom) or K1499-1 (DH-10 Bench) with 50-750 IPM (1.25-19.0 m/m) High Speed Ratio set S2 DIP switch as follows: (initial fac-

tory setting)

DH-10

SAFETY PRECAUTIONS

DUTY CYCLE

The DH-10 models are rated at 60% duty cycle*

for a

maximum current of 600 amps.

* Based on a 10 minute time period (6 minutes on, and 4 minutes off).

DH-10 CONTROL SWITCH SETUP

Initial set up of the DH-10 control for the system components being used and for general operator preferences is done using a pair of 8-pole DIP switches located inside the DH-10 control box.

Setup DIP Switch Access

1. Shut off the input power to the DH-10 control by turning off the power at the welding power source it is connected to.

2. Remove the two screws on the top of the DH-10 control box door and swing the door down to open.

3. Locate the two 8-pole DIP switches, near the top left corner of the DH-10 Control P.C. board, labeled S1 and S2.

4. Switch settings are only programmed during input power-up restoration.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Unless using cold feed feature when inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before Control switch setup or changing drive roll and/or guide tubes.

• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

• Only qualified personnel should operate this Equipment.

WARNING

Observe all additional Safety Guidelines detailed throughout this manual.

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

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B-3

OPERATION

B-3

DH-10

SINGLE HEADS:

For K1563-1 (LN-10 Boom) with 35-500 IPM (0.89-

12.7 m/m) Low Speed Ratio set S2 DIP Switches as

follows:

For K1563-1 (LN-10 Boom) with 50-750 IPM (1.25-

19.0 m/m) High Speed Ratio set S2 DIP Switch as

follows: (initial factory setting)

For K1563-2 (LN-10 Boom) with 55-825 IPM (1.40-

21.0 m/m) Low Speed Ratio set S2 DIP Switch as

follows:

For K1563-2 (LN-10 Boom) 80-1250 IPM (2.00-31.8 m/m) High Speed Ratio set S2 DIP Switch as fol-

lows: (initial factory setting)

For K679-1 (Single Head Boom) with 50-770 IPM (1.27-19.5 m/m) Low Speed Ratio set S2 DIP Switch

as follows:

For K679-2 (Single Head Boom) with 80-1200 IPM (2.00-30.5 m/m) High Speed Ratio set S2 DIP

Switch as follows:

NOTE: Any single drive may be connected to the Head 1 or Head 2 connector. Both settings are configured the same way.

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

HEAD 1

1 2 3 4 5 6 7 8

HEAD 2

Welding Power Source Selection

The DH-10 Control is set up for proper presettable weld voltage control by setting S1 DIP switches (1 to

4) as appropriate per the following information for the welding power source being used:

CV-250/CV 300-I:

CV-300/CV 400-I:

CV-400/CV 500-I:

CV-655/DC-655: (initial factory setting)

DC-250:

DC-400:

DC-600:

DC-650 PRO:

DC-1000:

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

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Pulse Power 500:

V300 PRO:

Other Power Source Independent:

Set the DIP switches as shown for all other power sources which can be controlled with a 10KΩ potentiometer circuit.

All DH-10 features operate as described elsewhere in this manual except for the following differences:

1. Instead of displaying a preset value in volts, the top display will show a number from “0.00” to “10.00” in increments of “0.02”. The number can be used for setting run-in “voltage” as well as “weld preset voltage”. When the trigger is closed or while welding, the top display will display actual arc voltage. The voltage displayed while welding can be used to determine the arc voltage to be expected for a given number setting. Actual arc voltage display will still flash for 5 seconds after a weld has been completed.

2. If a loss of arc voltage occurs, wire will NOT stop feeding. The Loss of Voltage Sense Shutdown feature is disabled to permit the use of the DH-10 with power source connections that do not connect the work voltage back to the DH-10 through the input power cable. The actual weld voltage while welding will NOT properly be shown on the top display if the work voltage is not available to the DH-10 through the input power cable.

B-4

OPERATION

B-4

DH-10

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Metric/English Wire Feed Speed Display Selection

The DH-10 Control is set up for Wire Feed Speed display in Metric units (m/min) or English units (IPM) by setting S1 DIP switch 6 (Labeled “M”):

S1 switch 6 OFF = IPM (as shipped)

S1 switch 6 ON = m/min

4-Step Trigger Mode Operation Selection

The DH-10 Control is set up for 4-Step Trigger mode operation with or without weld current interlock by setting S1 DIP switch 7 (Labeled “4”).

When 4-Step trigger mode is selected on the DH-10 keypad (See Keypad and Display Operation in this section) S1 DIP switch setting determines the 4-step trigger operation:

S1 switch 7 OFF = 4-Step with current interlock operation: (As shipped)

1. Closing Trigger initiates gas preflow time followed by Run-in speed and strike voltage until arc strike initiates welding.

2. Opening Trigger after welding arc is established continues welding with weld current interlock. (Breaking arc stops the feeder operation).

3. Reclosing Trigger continues welding but shuts off current interlock function.

4. Reopening Trigger stops wire feed and initiates burnback time, then gas postflow time.

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

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B-5

OPERATION

B-5

S1 switch 7 ON = 4-Step without current interlock operation:

1. Closing Trigger initiates gas flow.

2. Opening Trigger initiates gas preflow timer followed by Run-in speed and strike voltage until arc strike initiates welding. (Trigger is released before arc is struck, but once established breaking arc stops the feeder operation).

3. Reclosing Trigger stops wire feed and initiates burnback time, then gas postflow time.

4. Reopening Trigger stops gas flow if, or when, postflow time is over.

Low Security Mode Selection

The DH-10 Control is set up for Low Security Mode (See “Security Modes” in this section) by setting S1 DIP Switch 8 (Labeled “S”):

S1 switch 8 ON = Low Security mode ON

S1 switch 8 OFF = Low Security mode OFF (as

shipped)

NOTE: High Security mode must be OFF for Low Security mode to function.

High Security Mode Selection

The DH-10 Control is set up for High Security Mode (See

Security Modes

in this section) by setting S1

DIP switch 5 (Not labeled):

S1 switch 5 ON = High Security mode ON

S1 switch 5 OFF = High Security mode OFF (as

shipped)

DH-10

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Security

Pwr Sources

M 4

1 2 3 4 5 6 7 8

Keypad and Display Description

Keypad - Eight key, membrane type with “snap” tac-

tile feel and embossed domes. Long life design. Spatter resistant surface.

Displays - Two digital LED displays with 0.56 in. (14.2 mm) character height. Top (3-1/2 digit) displays Preset and Actual (while welding) arc voltage in volts with (+) or (-) polarity indicators, and also displays all timers in seconds. Bottom (4 digit) displays preset wire feed speed in IPM, or m/m, and acceleration selection.

Indicator Lights - Extra bright red LEDs for viewing at almost any angle. Always indicate the feeder and procedure selected, trigger mode being used and function or timer being displayed.

Rotating Encoders - Knob controls increase or decrease settings of volts and wire feed speed (initially factory set to minimum). Alternately, the top encoder adjusts timer settings and bottom selects acceleration settings when selected for these parameters to be displayed.

Power-Down Save

Power to the DH-10 is supplied and controlled from the power source. The DH-10 automatically senses the loss of power when the power source is turned off.

KEYPAD AND DISPLAY OPERATION

VOLTS / WFS

SPOT

VOLTS

FEEDER

WIRE FEED SPEED

RUN-IN

BURNBACK

SPOT

PREFLOW

GAS PURGE

FORWARD

COLD FEED

POSTFLOW

G3030

LINCOLN

REVERSE

COLD FEED

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A.

PROCEDURE

TRIGGER

COLD FEED

2-STEP STD

4-STEP LOCK

REMOTE

WFS

TIMER

CONTROL

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B-6

OPERATION

B-6

Dual procedure settings, including; trigger mode, cold feed speed, Run-in and weld speed and voltage, timers and acceleration are automatically saved for each feeder when power is removed. This feature does not require batteries and when power is restored it will automatically return all settings to the state they were in when power was removed. The operator may overwrite any or all of these settings following power up recall.

Operation Keys

Feeder Lights - Indicate the wire feed

head selected for procedure, mode, timer and cold feed functions settings. The feeder may be selected by pressing the Feeder select key, or by the last feeder gun trigger that was closed.

Procedure Lights - Indicate which procedure (A or B) is selected for the selected feeder. A and B procedure for Feeder 1 is independently set from A and B Procedure for Feeder 2. The Procedure select key selects A or B, or if REMOTE Light is selected, the pro-

cedure selection light is controlled by connection of an optional Dual Procedure gun switch (K683-1, -3) or Dual Procedure Remote Control (K1449-1).

Cold Feed Keys - energize the wire feeder but not the power source or gas solenoid valve. Cold Feed

Forward speed is factory set at 200 IPM, but is adjustable with WFS encoder knob and displayed on WFS display (with “Cld” shown on the Voltage display) only while pressing Cold Feed Forward, and the last speed set is stored in memory for the next cold feeding, unless changed in Cold Feed trigger mode (see following section). Cold Feed Reverse retracts wire at a fixed 80 IPM speed which is not adjustable.

Gas Purge key - energizes the gas solenoid valve but not the wire feeder or power source.

DH-10

FEEDER

GAS PURGE

FORWARD

COLD FEED

REVERSE

COLD FEED

PROCEDURE

REMOTE

Trigger Mode Selection

Trigger Mode Select key -

enables operator to choose mode of operation shown by the indicator lights. Pressing key causes mode lights to sequence (top to bottom) starting from the current indicated selection.

Top Light - Indicates gun trigger has been selected to perform the Cold Feed Forward function in exactly the same manner as Cold Feed Forward key (See

Operation Keys - Cold Feed Keys

) with the same memory stored adjustable speed setting, and “Cld” shown on the Voltage display.

Second Light - indicates 2-step (standard) trigger mode.

1. Trigger closure energizes the solenoid valve, then the wire feeder and the power source after Preflow time.

2. Releasing the trigger turns off the wire feeder, then power source after burnback time and then the gas solenoid valve after Postflow time.

Third Light - indicates 4-step (lock) trigger mode. This mode may be selected to include or exclude weld current interlock. (See

4-Step Trigger Mode

Operation Selection

in this section for 4-step Trigger

Mode operation) Bottom Light - indicates Spot Weld Mode, which will

only light if a spot time is set (See

Display Control

Keys

in this section). If set to 0.0 seconds, spot mode light selection will be skipped. Trigger closure energizes the gas solenoid valve, then wire feeder and the power source. The spot timer starts when current flows. The wire feeder and power source then solenoid valve are all turned off when the spot on timer times out even though the trigger is opened or is still closed. Preflow/Postflow and burnback timers are also functional in spot mode. (See

Display Control

Keys

in this section).

SPOT

TRIGGER

COLD FEED

2-STEP STD

4-STEP LOCK

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B-7

OPERATION

B-7

Display Control Keys

Timer Select key - enables operator to

choose burnback, spot or gas timers, as indicated by the appropriate light.

Pressing the key causes lights to sequence (top to bottom, then all off) starting from the current indicated selection.

When a timer is selected the Voltage display shows the time setting in seconds, as indicated by “SEC” displayed on the speed display. The times are set using the Voltage encoder knob.

Top Light - indicates preflow time is being displayed, settable 0.0 to

2.5 seconds (0.2 sec as shipped). This is the time the shielding gas flows before the wire feed and power source are activated.

Second Light - indicates spot time is being displayed, settable 0.0 (as shipped) to 199.9 seconds.

Third Light - indicates burnback time is being displayed, settable 0.00 (as shipped) to 0.25 seconds. This is the time the arc power is delayed at the stop of the weld, and should be set to the lowest time required to prevent the wire sticking in the weld.

Bottom Light - indicates postflow time is being displayed, settable 0.0 to 10.0 seconds (0.5 sec as shipped).

This is the time the shielding gas flows after the wire feed and power source are deactivated.

Pressing Timer Select Key again, or closing the gun trigger, shuts all timer lights off, indicating weld Voltage and Wire Feed Speed are again being displayed, and set by the appropriate encoder knob.

Control Select key - enables operator to choose Run-In procedure as indicated by the light turning on. When light is on, the settings of Run-In Wire Feed Speed and Voltage are displayed. After Weld procedure is set, Runin procedure should be set to optimize arc starting.

Speed encoder knob can adjust run-in speed between min. rated speed and up to the procedure Weld speed setting. Run-in speed setting can not exceed Weld speed setting. Run-in speed setting of 100 IPM or less is recommended for optimum starting. Factory setting is near min. rated speed.

DH-10

TIMER

BURNBACK

SPOT

PREFLOW

POSTFLOW

CONTROL

VOLTS / WFS

RUN-IN

If set below minimum rated speed “---” will show on the WFS display, indicating Run-in speed is set to match weld speed setting.

The Run-in (strike) voltage can be set above or below the Weld voltage setting up to a max of 60 V. If set below a min of 10 V, the Run-In (strike) voltage display shows “---”, indicating the Run-In Voltage is set to match the weld voltage setting. Also, the difference between Run-in voltage and Weld voltage settings is maintained automatically if the Weld voltage setting is changed, so the run-in voltage encoder knob does not need to be changed to follow the Weld voltage setting.

When trigger is closed (and preflow time is over) the wire feeds at Run-In speed and volts until the welding arc strikes, which causes the feed speed and volts to change to Weld settings.

If the arc does not strike within about 2 seconds, the Run-In speed automatically changes to Weld speed to permit “Hot” feeding at higher speed setting for loading wire.

Pressing control key again, or closing the gun trigger, shuts off light indicating knob settings and displays are returned to Weld Voltage and Wire Feed Speed.

Digital “Memory”Voltmeter

When the welding gun trigger is activated, the top DH10 display reads actual welding voltage from 0.0 to

60.0 VDC with automatic polarity indication for positive (+) or negative (-) electrode.

If actual voltage drops below 8.0 volts for over 0.8 sec when the trigger is closed, Loss of Voltage Sense Shutdown will occur. See “Loss of Voltage Sense Shutdown” in this section.

The last welding voltage monitored at the end of the weld is displayed for 5 seconds after the weld has stopped, as indicated by a 5 second “blinking” display. This allows checking actual weld voltage after weld has stopped.

Any keypad or trigger operation will interrupt the 5 second memory display.

Acceleration Selection

To provide optimum starting of various processes and procedures, the wire feed acceleration of the DH-10 can be set to five levels; 1 thru 5, for each feeder and procedure. 1 is the slowest acceleration and 5 is the fastest.

GAS PURGE

CONTROL

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B-8

OPERATION

B-8

To change acceleration hold the Gas Purge Key closed, then press the Control key. The top (Voltage) display shows “Acc” indicating acceleration setting, 1 thru 5, is displayed on the bottom (Speed) display. Use the speed encoder knob to change setting of 1 thru 5.

To exit this function, and enter the acceleration setting into the procedure memory, press both keys again or close the trigger.

Security Modes

Both Low and High Security modes are provided to capture and prevent changing of procedure settings. Both modes are activated, or deactivated by setting S1 DIP switch located inside the DH-10 Control Box.

Low security mode is used to capture timer, acceleration and control selections and settings, then to disable these selections until low security mode is deactivated. Encoder knob setting changes of cold feed, weld speed and weld voltage are not disabled.

Low Security mode is activated, or deactivated, by shutting off the input power to the DH-10 with all Timer and Control settings as desired for both procedures for both Feeders. Then setting S1 DIP switch 8 inside the DH-10 Control Box ON or OFF and restoring input power (See

Low Security Mode Selection

in this section). When activated, the Timer and Control selections no

longer light, but function with the captured settings. All other keys and encoder knob controls function normally.

NOTE: High Security mode must be OFF for Low Security mode to function.

High Security mode functions the same as Low Security mode, but the Voltage and Wire Feed Speed encoder knob controls are also deactivated, including setting Cold Feed Speed (See

Operation Keys

and

Trigger Mode Selection

in this section).

High Security mode can only be activated, or deactivated, by shutting off the input power to the DH-10 with all settings as desired for both Procedures for both Feeders. Then setting S1 DIP Switch 5, inside the DH-10 Control Box, ON, or OFF, and restoring input power. (See

High Security Mode Selection

this section).

DH-10

DUAL PROCEDURE REMOTE CONTROL (K1449-1)

When this option is connected to the DH-10 Control Box receptacle, and the Procedure Key selects “REMOTE” the front panel knob controls and procedure selection is transferred to the knob encoder controls and Procedure Selector Switch of the remote, which function in the exact same manner. Remote knob encoders set Weld voltage and wire feed speed, as well as Trigger Cold Feed Speed, but not Timers or Run-In.

If using the optional K683-1, -3 Dual Procedure Switch, for either or both wire drives, to select A or B along with the (K1449-1) remote, both the front panel and remote Procedure selector and switch must be set to “REMOTE” and “Gun Switch” (center) positions.

The DH-10 Procedure lights indicate whether A or B is remotely selected.

WIRE REEL LOADING READI-REELS, SPOOLS OR COILS

To Mount a 30 lb (14 kg) Readi-Reel Package (Using the Molded Plastic K363-P Readi-Reel Adapter) (

FIGURE B.1

The Spindle should be located in the LOWER mounting hole.

1. Depress the Release Bar on the Retaining Collar and remove it from the spindle.

2. Place the Adapter on the spindle.

3. Re-install the Retaining Collar. Make sure that the Release Bar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

4. Rotate the spindle and adapter so the retaining spring is at the 12 o'clock position.

5. Position the Readi-Reel so that it will rotate in a direction when feeding so as to be de-reeled from bottom of the coil.

6. Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab.

7. Lower the Readi-Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter.

8. Slide cage all the way onto the adapter until the retaining spring “pops up” fully.

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B-9

OPERATION

B-9

Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi-Reel Cage in place. Retaining Spring must rest on the cage, not the welding electrode.

___________________________________________

9. To remove Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from spindle.

FIGURE B.1 — READI-REEL MOUNTING.

To Mount 10 to 44 lb (4.5 to 20 kg) Spools (12 in/300 mm Diameter) or 14 lb (6 kg) Innershield Coils (FIGURE B.1):

The Spindle should be located in the LOWER mounting hole.

(For 8 in. (200 mm) spools, a K468 spindle adapter must first be slipped onto spindle.)

(For 13-14 lb. (6 kg) Innershield coils, a K435 Coil Adapter must be used).

1. Depress the Release Bar on the Retaining Collar and remove it from the spindle.

2. Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the back side of the spool. Be certain the wire comes off the reel in a direction so as to de-reel from the bottom of the coil.

3. Re-install the Retaining Collar. Make sure that the Release Bar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

DH-10

CAUTION

To Mount a 50 to 60 lb (22.7 to 27.2 kg) Coil: (Using K1504-1 Coil Reel) (For 50 to 60

lb Readi-Reels a K438 Readi-Reel Adapter must be used).

The Spindle must be located in the UPPER mounting hole.

1. With the K1504-1 Coil Reel mounted on to the 2 in. (51 mm) spindle (or with reel laying flat on the floor) loosen the spinner nut and remove the reel cover. (See Figure B.2).

2. Before cutting the tie wires, place the coil of electrode on the reel so it unwinds from the bottom as the reel rotates.

3. Tighten the spinner nut against the reel cover as much as possible by hand using the reel cover spokes for leverage. DO NOT hammer on the spinner nut arms.

4. Cut and remove only the tie wire holding the free end of the coil. Hook the free end around the rim of the reel cover and secure it by wrapping it around. Cut and remove the remaining tie wires.

Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls. Failure to do this will result in “backlashing” of the coil, which may tangle the wire. A tangled coil will not feed so it must either be untangled or discarded.

___________________________________________

5. Be sure the coil reel is engaged with the spindle brake pin and the Release Bar on the Retaining Collar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

FIGURE B.2 — KI504-1 COIL REEL.

CAUTION

SPINNER NUT

COVER PLATE

SLOTS

CARDBOARD COIL LINER

COIL

TIE WIRE

SPRING LOADED ARM

REEL

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B-10

OPERATION

B-10

FEEDING ELECTRODE AND BRAKE ADJUSTMENT

1. Turn the Reel or spool until the free end of the electrode is accessible.

2. While tightly holding the electrode, cut off the bent end and straighten the first 6 in. (150 mm). Cut off the first 1 in. (25 mm). (If the electrode is not properly straightened, it may not feed or may jam causing a “birdnest”.)

3. Insert the free end through the incoming guide tube.

4. Press the Cold Inch key or the Cold Feed Mode gun trigger and push the electrode into the drive roll.

When feeding with the gun trigger, unless “COLD FEED” trigger mode is selected, the electrode and drive mechanism are always “HOT” to work and ground and could remain “HOT” several seconds after the gun trigger is released.

___________________________________________

5. Feed the electrode through the gun.

6. Adjust the brake tension with the thumbscrew on the spindle hub, until the reel turns freely but with little or no overrun when wire feeding is stopped. Do not overtighten.

DRIVE ROLL PRESSURE SETTING

The DH-10 pressure is factory pre-set to about position “2” as shown on the pressure indicator on the front of the feedplate door. This is an approximate setting.

The optimum drive roll pressure varies with type of wire, surface condition, lubrication, and hardness. Too much pressure could cause “birdnesting”, but too little pressure could cause wire feed slippage with load and/or acceleration. The optimum drive roll setting can be determined as follows:

1. Press end of gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds.

DH-10

WARNING

2. If the wire “birdnests”, jams, or breaks at the drive roll, the drive roll pressure is too great. Back the pressure setting out turn, run new wire through gun, and repeat above steps.

3. If the only result is drive roll slippage, disengage the gun, pull the gun cable forward about 6 in. (150 mm). There should be a slight waviness in the exposed wire. If there is no waviness, the pressure is too low. Increase the pressure setting turn, reconnect the gun, tighten locking clamp and repeat the above steps.

PROCEDURE FOR SETTING ANGLE OF FEEDPLATE

1. Loosen the clamping collar screw using a 3/16 in. 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.

2. Rotate feedplate to the desired angle and tighten clamping collar screw.

GAS GUARD REGULATOR SETTING

1. With the gas supply shut off, the Gas Guard regulator flow adjusting Key should be set to maximum (full clockwise) which is rated to be 60 SCFH (28 l/min).

2. Adjust gas supply flow rate for a level higher than will be required, then adjust Gas Guard flow adjusting Key counterclockwise to the desired gas flow rate.

MAKING A WELD

1. Use only a Lincoln Electric recommended constant voltage DC power source compatible with the DH-10 Wire Feeder.

2. Properly connect the electrode and work leads for the correct electrode polarity.

3. Use the Trigger Mode Selection key to set desired trigger mode for each feeder head and procedure. (Refer to

Trigger Mode Selection

this section.)

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B-11

OPERATION

B-11

4. Use Control Select and encoder knobs to set desired Weld feed speed and voltage then Run-in speed and voltage to optimize arc starting. (Set for each procedure if using front panel, remote control or optional dual procedure switch.) (Refer to

Operation Keys

and

Display Control Keys

in this

section.)

5. Adjust the wire feed acceleration, if desired, for each feeder and procedure. (Refer to

Acceleration Selection

in this section.)

6. Use Timer Select and Voltage Encoder knob to set desired timers. (Refer to

Trigger Mode

Selection

in this section.)

7. Feed the electrode through the gun and cable and then cut the electrode within approximately

0.38 in. (9.5 mm) of the end of the contact tip for solid wire and within approximately 0.75 in. (19 mm) of the extension guide for cored wire.

8. Connect work cable to metal to be welded. Work cable must make good electrical contact to the work. The work must also be grounded as stated in

Arc Welding Safety Precautions

9. If used, be sure shielding gas valve is turned on.

10. Position electrode over joint. End of electrode may be lightly touching the work.

11. Lower welding helmet, close gun trigger, and start welding. Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used.

12. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out and Postflow time, if used, is over.

13. If necessary to optimize arc starting, readjust wire speed acceleration, (Refer to

Acceleration

Selection

in this section) and/or Run-In speed,

(Refer to

Display Control Keys

in this section).

DH-10

When using an Open Arc process, it is necessary to use correct eye, head, and

body protection.

____________________________________

WARNING

WIRE REEL CHANGING

At the end of a coil, remove the last of the old electrode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the following procedure:

1. Cut the end of the electrode off at the gun end. Do not break it off by hand because this puts a slight bend in the wire making it difficult to pull it back through the nozzle.

2. Disconnect the gun cable from the gun connector on the DH-10 wire drive unit and lay the gun and cable out straight.

3. Using pliers to grip the wire, pull it out of the cable from the connector end.

4. After the electrode has been removed, reconnect the gun cable to the drive. Load a new reel of electrode per the instructions in

Wire Reel

in this section.

LOSS OF VOLTAGE SENSE SHUTDOWN

If the actual displayed voltage, when the trigger is closed, drops below 8.0 volts for over 0.8 second it is assumed the voltage feed back sensing circuit to the DH-10 is opened or faulty, so Loss of Voltage Sense Shutdown occurs until the trigger is released.

This shutdown stops the motor, shuts off the gas flow and disables the power source output to prevent the DH-10 voltage control from driving the power source output too high due to loss of proper feedback sensing via #21 (WORK) and #67 (ELECTRODE) sensing leads.

WIRE FEED OVERLOAD PROTECTION

The DH-10 has solid-state overload protection of the wire drive motor. If the wire drive motor becomes overloaded for an extended period of time, the protection circuitry turns off the power source, wire feed and gas solenoid, and then displays “H30” on the WFS display (with blank Voltage display). This indicates the wire drive motor is overloaded and will remain shut down for about 30 seconds before the unit will automatically reset. The “H30” display decrements every second until it reaches “H00”. At that time, the unit resets automatically and the previous displays will return indicating the unit is ready to operate again. Overloads can result from improper tip size, liner, drive rolls, or guide tubes, obstructions or bends in the gun cable, feeding wire that is larger than the rated capacity of the feeder or any other factors that would impede normal wire feeding. (See

Avoiding Wire

Feeding Problems

in the

Maintenance

section).

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B-12

OPERATION

B-12

GROUNDING LEAD PROTECTOR

The frame of the DH-10 Control is grounded to the frame of the power source by a lead in the control cable. An overload protector prevents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the electrode is electrically hot.

If such a grounding lead fault occurs, the WFS display will show “GLP,” (with blank Voltage display) and the trigger circuit will be disabled. To reset the circuit, release the trigger, make sure that the electrode is not touching the wire feeder frame, and then either press any key on the keypad or close the trigger. When the GLP circuit is reset, the “GLP” display is removed and the wire feeder is returned to normal operating mode.

EXPLANATION OF PROMPTING AND ERROR MESSAGES

Display Prompt or Error

Acc Displayed on Voltage display, indicates WFS

display is showing acceleration setting, “1” to “5” (see

Acceleration Selection

in this

section).

SEC Displayed on WFS display, indicates Voltage

display is showing a Timer setting in seconds. (See

Display Control Keys

in this

section.)

GLP Displayed on WFS display, indicates that the

Grounding Lead Protector circuit was activated due to excessive current flow into the wire feeder frame. When the GLP circuit

is activated the wire feeder is disabled (the trigger output to the power source is opened up, the motor is stopped, and the gas solenoid is turned off). To resume normal operation, release the trigger, make sure that the electrode is not touching the wire feeder frame, and then either press a key on the keypad or close the trigger. (See

Grounding Lead Protector

in this section.)

Cld Displayed on Voltage display when Cold

Feed Forward or Cold Feed Reverse Key is pressed, or Cold Feed Trigger mode is selected. Indicates wire is fed “cold” (no weld voltage) at the speed indicated on the WFS display. (See

Operation Keys

and

Trigger Mode Selection

in this section.)

--- Displayed on Voltage or WFS displays with RUN-IN selected, indicates setting will match those set for Weld Voltage and Wire Feed Speed. (See

Display Control Keys

in this

section.)

HXX Displayed on WFS display, indicates wire

feed overload. XX indicates time remaining in seconds before unit resets automatically. (See

Wire Feed Overload Protection

in this

section and

Avoiding Wire Feeding

Problems

in the

Maintenance

section.)

Er EEPROM error. Usually occurs at power-up.

Indicates one or more of the recalled settings is out of acceptable limits. Press any key to return to normal operation. Be sure to check all voltage, wire feed speed, acceleration and timer settings before you proceed.

DH-10

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