Lincoln Electric 10357 Operator's Manual
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Lincoln Electric 10357 Operator's Manual

Lincoln Electric 10357 Operator's Manual

Boom or bench, control-boom mount, drive-boom mount, boom package, standard-single head drive, feeder double head-bench
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Operator's Manual
DH-10 Boom or Bench
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Date Purchased
Code:
(ex: 10859)
Serial:
(ex: U1060512345)
IM572-D
| Issue D ate 7-Aug
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
DH-10 Control - Boom Mount Code 10357, 10830,
DH-10 Drive - Boom Mount Codes 10358, 10359,
10753, 10754,10811,10812, DH-10 Boom Package
Codes 10380, 10495, 10496, and 10517, 10518,
10519, 10757, 10769, 10815, 10770, 10774, 10775,
10776,
Standard - Single Head Drive Codes 10190, 10191,
DH-10 Feeder Double Head - Bench Model Codes
10360, 10361, 10755, 10756, 10813, 10814,
DH-10 Feeder Double Head - Bench Model Codes
11433,11434, 11435, 11436

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Summary of Contents for Lincoln Electric 10357

  • Page 1 Operator’s Manual DH-10 Boom or Bench For use with machines having Code Numbers: DH-10 Control - Boom Mount Code 10357, 10830, DH-10 Drive - Boom Mount Codes 10358, 10359, 10753, 10754,10811,10812, DH-10 Boom Package Codes 10380, 10495, 10496, and 10517, 10518,...
  • Page 2 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.
  • Page 3 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY CYLINDER may explode WELDING and CUTTING SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
  • Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
  • Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Page Installation .......................Section A Technical Specifications .......................A-1 General Description......................A-2 Recommended Processes and Equipment ................A-3 Installation of the DH-10 Boom Mount Wire Feeder Components ........A-3 Mounting the 10-Series Wire Drive Unit ................A-4 Mounting Synergic 7F Wire Drive Unit .................A-4 Mounting the DH-10 Control Box .................A-4 Connecting Wire Drive Unit to Control Box ..............A-4 Electrode Routing......................A-5...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS Page ..Diagrams ......................Section F Wiring (DH-10 Control) ..................F-1 Wiring (DH Wire Drive) ..................F-2 Dimension Print......................F-3 Parts Lists ....................P288 Series...

  • Page 9: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS –DH-10 Complete Units or Controls & Heads The K1499-1,-3 or -2,-4 DH-10 consists of a control and a double head 10 series wire drive assembly pre- mounted on a platform with two 2” O.D. spindle mountings. Specifications for the units follow: CONTROLS SECTION OF COMPLETE UNITS SPEC.# TYPE...

  • Page 10: General Description

    INSTALLATION GENERAL DESCRIPTION AVAILABLE MODELS: The DH-10 Wire Feeder system is available configured in The DH-10 is a modular line of 42VAC input dual head 4-roll both Bench and Boom models. wire feeders. A single control with dual procedure presetta- bility of wire feed speed (in IPM or M/min) and arc voltage Bench Models consists of a DH-10 control and a DH for each head is used with a single DC welding power...

  • Page 11: Recommended Processes And Equipment

    Specifications. 5.00 10.50 18.50 Recommended power sources are Lincoln Electric Company constant voltage power sources with 42 VAC aux- FIGURE A.1 iliary power and a 14-pin connector receptacle. At the time of printing these include: CV 250, CV300-I, CV-300,...

  • Page 12: Mounting The Dh-10 Control Box

    INSTALLATION Mounting the DH-10 Control Box (K1496-1,-2) b) Connect the 14-socket cable connectors to the mating receptacles on the back of the wire feed unit connec- tion box. Feeder Head 1 uses the left receptacle and The same control box is used for both a DH double Feeder Head 2 uses the right receptacle, when facing header drive, or up to two single head drives.

  • Page 13: Electrode Routing

    INSTALLATION Electrode Routing a) Loosen the clamping collar screw using a 3/16" Allen wrench. The clamping collar screw is accessed from the bottom of the The electrode supply may be either from reels, Readi- feedplate. It is the screw which is perpen- Reels, spools, or bulk packaged drums or reels.

  • Page 14: Wire Feed Drive Roll Kits

    INSTALLATION WIRE FEED DRIVE ROLL KITS TO SET IDLE ROLL PRESSURE, see “Idle Roll Pressure Setting” in OPERATION. NOTE: The maximum rated solid and cored wire DH Drive Roll Kit Installation (KP1505 and sizes for each wire drive head and selected KP1507) drive ratio is shown on the SPECIFICATIONS in the front of this section.

  • Page 15: Gun And Cable Assemblies With Standard Connection

    INSTALLATION 6) Install each drive roll by pushing over shaft until it Gun Cable Connection with Standard butts up against locating shoulder on the drive roll Connection shaft. (Do not exceed maximum wire size rating of the wire drive). 1. Check that the drive rolls and guide tubes are proper for the electrode size and type being used.

  • Page 16: Gun Cable Connection With Fast-Mate Connection

    INSTALLATION Gun Cable Connection with Fast-Mate GMAW Shielding Gas Connection WARNING 1. Check that the drive rolls, feeder guide tubes and gun connector guide tube are appropriate for the CYLINDER may explode if damaged. electrode size being used. If necessary, change •...

  • Page 17: Electrical Installation

    INSTALLATION ELECTRICAL INSTALLATION WORK CABLE Connect a work lead of sufficient size and length (per WARNING the following table) between the proper output termi- nal on the power source and the work. Be sure the ELECTRIC SHOCK can kill. connection to the work makes tight metal-to-metal •...

  • Page 18: Optional Features Installation

    A-10 A-10 INSTALLATION OPTIONAL FEATURES K1500-3 f or Magnum 550 gun with K613-7 Connection Kit. (Also Tweco 5). INSTALLATION K1500-4 (Miller Connection) for any gun having a K1501-10, K1797-25 and K1797-50 Input Cable newer style miller connection. Install gun adapters Assemblies per the instructions shipped with the unit.

  • Page 19: Boom And Bench Conversions

    A-11 A-11 INSTALLATION Configuration 2 K1558-1 Remote Switch Interface Module, can be K489-7 Dual Schedule Fast-Mate adapter used with the DH-10, using a G3041-2 (or higher) K683-1 Dual Procedure Switch (3 pin) Control Board. K686-2 “Y” adapter (3 pin +5 pin to 5 pin) The module provides for user interface connection of Non-DS Fast-Mate gun (Magnum 450WC, Magnum 200, Magnum an external switch (flow switch, etc) which must be...

  • Page 20: Operation

    OPERATION OPERATING INSTRUCTIONS Setting the DIP Switches Safety Precautions The DIP switches are each labeled with an “ON” WARNING arrow showing the on direction for each of the 8 indi- vidual switches in each DIP switch (S1 and S2). The ELECTRIC SHOCK can kill.
  • Page 21 OPERATION SINGLE HEADS: For K679-1 with 50-770 IPM (1.27-19.5 m/m) Low Speed Ratio set S2 DIP Switch as follows: For K1563-1,-3 with 35-500 IPM (0.89-12.7 m/m) Low Speed Ratio set S2 DIP Switches as follows: For K679-2 with 80-1200 IPM (2.00-30.5 m/m) High Speed Ratio set S2 DIP Switch as follows: For K1563-1,-3 with 50-750 IPM (1.25-19.0 m/m) High Speed Ratio set S2 DIP Switch as follows: (ini-...
  • Page 22 OPERATION Welding Power Source Selection DC-1000: Security The DH-10 Control is set up for proper presettable Pwr Sources weld voltage control by setting S1 DIP switches (1 to 4) as appropriate per the following information for the welding power source being used: For Codes 10814 and Below.
  • Page 23 CV-655 / DC-655: (initial factory setting) potentiometer circuit. Limits Pwr Sources The DH-10 is designed to work with the following Lincoln Electric power sources: CV250, CV300-I, CV300, CV400-I, CV400, CV500-I, CV655, DC250, DC-250: DC400, DC600, DC650 PRO, DC1000, Pulse Power Limits...
  • Page 24 OPERATION Metric/English Wire Feed Speed Display S1 switch 7 ON = 4-Step without current interlock operation: Selection ( For Codes 10814 and Below.) Security Pwr Sources The DH-10 Control is set up for Wire Feed Speed dis- play in Metric units (m/min.) or English units (IPM) by setting S1 DIP Switch 6 (Labeled “M”): 1) Closing Trigger initiates gas flow.
  • Page 25 OPERATION S1 switch 7 ON = 4-Step without current interlock Metric/English Wire Feed Speed Display operation: Selection ( For Codes 11433 and above.) Limits Pwr Sources The DH-10 Control is set up for Wire Feed Speed dis- play in Metric units (m/min.) or English units (IPM) by setting S1 DIP Switch 6 (Labeled “M”): 1) Closing Trigger initiates gas flow.

  • Page 26: Keypad And Display Operation

    CONTROL TIMER Procedure Lights - Indicate which REMOTE procedure (A or B) is selected for the selected feeder. A and B procedure for THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A. G3030 PROCEDURE Feeder 1 is independently set from A Keypad and Display Description and B Procedure for Feeder 2.
  • Page 27 OPERATION Trigger Mode Selection Display Control Keys Trigger Mode Select key Timer Select key - enables operator to TIMER COLD FEED - enables operator to choose burnback, spot or gas timers, as TRIGGER 2-STEP STD choose mode of operation indicated by the appropriate light. 4-STEP LOCK shown by the indicator Pressing the key causes lights to...
  • Page 28 The DH-10 is designed to work with the following tings is maintained automatically if the Weld voltage setting is Lincoln Electric power sources: CV250, CV300I, changed, so the run-in voltage encoder knob does not need to CV300, CV400-I, CV400, CV500-I, CV655, DC250, be changed to follow the Weld voltage setting.
  • Page 29 B-10 B-10 OPERATION SECURITY MODES Security mode is activated, or deactivate, by shutting For Codes 10814 and Below. off the input power to the DH-10 with all Timer and Control settings as desired for both procedures for Both Low and High Security modes are provided to capture and both Feeders.

  • Page 30: Dual Procedure Remote Control (K1449-1

    B-11 B-11 OPERATION 8. Set the minimum WFS and voltage limits for pro- WIRE REEL LOADING - READI-REELS, cedure A and procedure B for both feeder 1 and SPOOLS OR COILS feeder 2 using the two encoder knobs and the To Mount a 30 Lb.
  • Page 31 B-12 B-12 OPERATION To Mount a 50-60 Lb. (22.7-27.2 kg) Coil: WARNING (Using K1504-1 Coil Reel) (For 50-60 lb Readi- Reels a K438 Readi-Reel Adapter must be used). Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY The Spindle must be located in the UPPER mounting hole.

  • Page 32: Feeding Electrode And Brake Adjustment

    MAKING A WELD tion “2" as shown on the pressure indicator on the front of the feedplate door. This is an approximate 1) Use only a Lincoln Electric recommended constant setting. voltage DC power source compatible with the DH- 10 Wire Feeder.

  • Page 33: Wire Reel Changing

    B-14 B-14 OPERATION WIRE REEL CHANGING 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 proce- At the end of a coil, remove the last of the old elec- dure if using front panel, remote control or optional trode coil from the conductor cable by either pulling it dual procedure switch.) (Refer to “Operation Keys”...

  • Page 34: Wire Feed Overload Protection

    B-15 B-15 OPERATION WIRE FEED OVERLOAD PROTECTION Displayed on WFS display, indicates Voltage The DH-10 has solid-state overload protection of the display is showing a Timer setting in sec- wire drive motor. If the wire drive motor becomes onds. (See “Display Control Keys” in this overloaded for an extended period of time, the protec- section) tion circuitry turns off the power source, wire feed and...

  • Page 35: Accessories

    ACCESSORIES TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll 4-Roll DH Drive Single Drive (4-Driven) (2-Driven) Solid Steel Electrode 0.023” - 0.025” (0.6 mm) KP1505 - 030S KP655 - 025S 0.030” (0.8 mm) KP1505 - 030S KP655 - 030S 0.035”...
  • Page 36 ACCESSORIES INPUT CABLE ASSEMBLIES: (One required per DH-10 Control Box) K683-3 DUAL PROCEDURE SWITCH (One per gun) Kit K1501-10 (Control Cable Only) Consists of a 9-conductor con- includes gun switch, and mountings for Lincoln Innershield and Magnum guns, with 15 ft. (4.5m) control cable and 5-pin trol cable with a 14-pin control cable plug, without electrode plug with two leads to connect to gun trigger.
  • Page 37 ACCESSORIES K1500-2 for Magnum 200/300/400 gun with K466-10 con- K498 Magnum 200 FM GMAW gun and cable assemblies nection kit. (Also Tweco 4). are rated for 200 amps 60% duty cycle. (Consult sales specifications for appropriate models) K1500-3 for Magnum 550 gun with K613-7 connection. K534 Magnum 250L FM GMAW gun and cable assemblies (Also Tweco 5).

  • Page 38: Maintenance

    MAINTENANCE MAINTENANCE Avoiding Wire Feeding Problems Wire feeding problems can be avoided by observing Safety Precautions the following gun handling and feeder set up proce- dures: WARNING a) Do not kink or pull cable around sharp corners. ELECTRIC SHOCK can kill. b) Keep the electrode cable as straight as possible •...
  • Page 39 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 40: Troubleshooting

    TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Rough wire feeding or wire not 1. Gun cable kinked and/or twisted. feeding, but drive rolls are turning. 2. Wire jammed in gun and cable. 3.
  • Page 41 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Poor arc striking with sticking or 1. Improper procedures or techniques. “blast-offs”, weld porosity, narrow and ropy looking bead, or electrode 2. Improper gas shielding. stubbing into the plate while weld- ing.
  • Page 42 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Neither sideʼs drive motor turns 1. Damaged control p.c. board. although arc voltage is present and the gas solenoid is on. No control of wire feed speed on 1.
  • Page 43 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Cold feed forward or cold feed 1. The connector from the control reverse buttons on keypad do not p.c. board to the display p.c. work, but motor control otherwise board or the connector from the functions properly for both motors.
  • Page 44 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Feeder key does not select head 1 1. The connector from the control or 2, but the head can be selected p.c. board to the display p.c. by pulling the gun trigger.
  • Page 45 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION One of the knobs changes the dis- 1. The display is in a mode that play, but the other doesnʼt. can only use one encoder. 2.
  • Page 46 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Displays & LEDʼs on keypad are 1. The connectors from the control off. The green and red LEDʼs on p.c. board to the display p.c. the control p.c.
  • Page 47 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION ʻErʼ is displayed on power up. 1. EEPROM error detected. 2. Damaged control p.c. board. ʻGLPʼ is displayed. 1. Ground Loop Protection fault occurred.

  • Page 48: Procedure For Replacing Pc Boards

    If PC board is visibly damaged mechanically, inspect for cause, then remedy before installing a replacement PC board. If there is damage to the PC board or if replacing PC board corrects problem, return it to the local Lincoln Electric Field Service Shop. DH-10...
  • Page 49 DIAGRAMS DH-10...
  • Page 50 DIAGRAMS DH-10...
  • Page 51 DIAGRAMS DH-10...
  • Page 52 DIAGRAMS DIMENSION PRINT DH-10...
  • Page 53 DIAGRAMS DIMENSION PRINT DH-10...
  • Page 54 DIAGRAMS 10.92 .141 5.25 2.80 4.27 2.63 14.65 13.75 12.75 10.10 4.58 5-2-97 14.67 18299 17869-1. K1496-1 Control Unit Unit Weight: 18.0 lbs. (8.2 kg.) 2.90 7.00 11.25 7.69 6.75 1.00 4.67 6.67 6.25 7.16 7.50 8.06 1.00 .281 6.21 1.31 3.36 3.18...
  • Page 55 DIAGRAMS 18.1 1 5.25 7.81 6.55 4.44 2.16 12.74 10.40 2.25 4.08 3.00 3.00 K1563-[ ] LN-10 WIRE DRIVE UNIT 11.0 0 UNIT WEIGHT: 25 LBS. (11.3 kg) 3.00 7-2000 M18034 5/16-18UNC-2B (6 L 14.71 5.25 7.81 6.55 4.44 2.42 12.74 10.40 2.25...
  • Page 56 NOTES DH-10...
  • Page 57 NOTES DH-10...
  • Page 58 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 59 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • Page 60 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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