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For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful 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.
• 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
RETURN TO MAIN MENU
LF- 72
11075, 11076, 11077
11209, 11210, 11211, 11227
11290, 11291, 11292, 11293
IP21
IEC 60974-5
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2005 Lincoln Global Inc.
IM847-B
December, 2005
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Table of Contents
Related Manuals for Lincoln Electric 11075
Summary of Contents for Lincoln Electric 11075
- Page 1 RETURN TO MAIN MENU IM847-B December, 2005 LF- 72 11075, 11076, 11077 For use with machines having Code Numbers: 11209, 11210, 11211, 11227 11290, 11291, 11292, 11293 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.
- 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 WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
- Page 6 The code number is especially important when identifying the correct replacement parts. On-Line Product Registration - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Glossary of Terms and General information ..............Section Glossary of Terms........................1 Definitions of Welding Modes ...................1 Common Welding Abbreviations ..................1 Product Description......................2 Recommended Processes and Required Equipment ............2 Base Model, Bench Model Standard Duty and Bench Model Heavy Duty .......3 Base Model and Standard Wire Drive Features ...............4 Technical Specifications ....................5 Typical System Configurations ..................6... -
Page 8: Table Of Contents
TABLE OF CONTENTS Page Maintenance ....................Section D Safety Precautions ....................D-1 Routine ........................D-1 Periodic........................D-1 Calibration Specification ..................D-1 ________________________________________________________________________ Troubleshooting ......................E Safety Precautions....................E-1 How To Use Troubleshooting Guide..............E-1 Troubleshooting .....................E-2, E-3 ________________________________________________________________________ Wiring Diagram and Dimension Prints ............Section F ________________________________________________________________________ Parts Lists ........................P501 ________________________________________________________________________ LF-72... -
Page 9: Glossary Of Terms
GLOSSARY OF TERMS COMMON WELDING ABBREVIATIONS • Wire Feed Speed • Constant Voltage GMAW (MIG) • Gas Metal Arc Welding FCAW (Cable Innershield or Outershield) • Flux Core Arc Welding LF-72... -
Page 10: Product Description
GENERAL INFORMATION PRODUCT DESCRIPTION PROCESS LIMITATIONS • Rated for up to 1/16(1.6 mm) solid electrode and General Physical Description 5/64 (2.0 mm) cored electrode. • The maximum WFS is 800 in/min (20.3 M/min). The LF-72 is optimized for .035 through .045 (0.9mm •... -
Page 11: Base Model, Bench Model Standard Duty And Bench Model Heavy Duty
GENERAL INFORMATION BASE MODEL BENCH MODEL STANDARD DUTY BENCH MODEL HEAVY DUTY LF-72... -
Page 12: Base Model And Standard Wire Drive Features
GENERAL INFORMATION BASE MODEL AND STANDARD WIRE DRIVE FEATURES DOOR AND HINGE REMOVED CALIBRATED STORAGE TRAY WIRE FEED SPEED KNOB PRESSURE ARM BALL BEARING REMOTE KIT PANEL INLET GUIDE BUSHING ASSEMBLY TIMER KIT PANEL 2 STEP TRIGGER INTERLOCK TOGGLE SWITCH DRIVE ROLLS COLD FEED GAS PURGE... -
Page 13: Technical Specifications
GENERAL INFORMATION TECHNICAL SPECIFICATIONS : LF-72 Wire Feeder SPEC.# TYPE WIRE FEED SPEED RANGE Wire Size LF-72 Speed Solid Cored K2327-1 Base Model K2327-4 K2327-2 Bench Model 50-800 IPM .023 - 1/16 in. .035 - 5/64 in Standard Duty (1.27-20.3 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm) K2327-3 Bench Mode... -
Page 14: Typical System Configurations
GENERAL INFORMATION TYPICAL SYSTEM CONFIGURATIONS The LF-72 is capable of welding with many different welding processes. These processes may require reconfig- uring the LF-72 with other products that may or may not be included with the model you purchased. Use the Table 1 below to identify the basic items which are included in the LF-72 to utilize the various Welding Processes that the machine is capable of controlling. -
Page 15: Installation
INSTALLATION SAFETY PRECAUTION MOUNTING ELECTRIC SHOCK can kill. For location and size, LF-72 Bench Model Rear • Only qualified personnel should Mounting Holes (See Figure A.1) and for Bottom perform this installation. Mounting Holes (See Figure A.2). • Turn off the input power to the power source at the disconnect switch or fuse box before working on this equipment. -
Page 16: Bench Mount
INSTALLATION BENCH MOUNT BOOM MOUNT When boom mounting, remove the wire reel stand (if The LF-72 mounts in a variety of configurations. As assembled) and secure the wire feeder directly to the shipped from the factory, the LF-72 is suitable for desired surface. -
Page 17: Safety Precautions
INSTALLATION SAFETY PRECAUTION ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn off the input power to the power source at the disconnect switch or fuse box before work- ing on this equipment. Turn off the input power to any other equipment connected to the weld- ing system at the disconnect switch or fuse box before working on this equipment. -
Page 18: Coaxial Weld Cables
INSTALLATION COAXIAL WELD CABLES A coaxial weld cable is constructed by 8 small leads wrapped around one large lead. The large inner lead Coaxial welding cables are specially designed welding connects to the electrode stud on the power source cables for pulse welding or STT welding. Coaxial weld and the electrode connection on the wire feeder. -
Page 19: Analog Control Cable Connection
INSTALLATION ANALOG CONTROL CABLE CONTROL CABLE CONNECTIONS • All control cables can be connected end to end to extend their length. The control cable connecting the wire feeder to the power source is specially made for the welding envi- ronment. The wire feeder power requires overcurrent protec- tion. -
Page 20: Analog Miller Control Cable Adapter
Arc Voltage feedback to feeder. Reserved for future use. Scaled 0-10V. 1 V = 10 Arc volts. Referenced to pin D. Electrode voltage to power source (67) Miller is a registered trademark not owned or licensed by The Lincoln Electric Company. LF-72... -
Page 21: High Frequency
INSTALLATION WELDING GUN/WIRE FEEDER TRIGGER REMOTE SENSE LEAD SPECIFICATIONS CONNECTOR Refer to the power source instruction manual for Wire Feeder Amphenol instructions for connecting the wire feeder for STT welding. Welding G un WIRE DRIVE SYSTEMS Trigger Lead Drive Roll Kits are designed to feed specific types and wire sizes. -
Page 22: Welding Guns, Torches And Accessories
INSTALLATION WELDING GUNS, TORCHES AND ACCES- 3. Fully insert the gun cable connector end into the gun receiver bushing and gently tighten the thumb SORIES screw as show in Figure A.5a below. GUN RECEIVER BUSHING 4. Connect the gun trigger connector to the trigger The LF-72 wire feeder comes with a K1500-2 gun receptacle. -
Page 23: Wire Drive Configuration
INSTALLATION PROCEDURE FOR CHANGING WIRE DRIVE CONFIGURATION DRIVE AND IDLE ROLL SETS (See Figure A.5) Changing the Gun Receiver Bushing (See Figure A.4 ) WARNING WARNING ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch or fuse box before •... -
Page 24: Pressure Arm Adjustment
A-10 A-10 INSTALLATION PRESSURE ARM ADJUSTMENT 7. Disconnect the shielding gas hose from the gun bushing, if required. WARNING 8. Connect the shielding gas hose to the new gun bushing, if required. ELECTRIC SHOCK can kill. 9. Rotate the gun bushing until the thumb screw hole •... -
Page 25: Wire Reel Loading
A-11 A-11 INSTALLATION WIRE REEL LOADING 3. Re-install the retaining collar. Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle. WARNING FIGURE A.8 • Keep hands, hair, clothing and tools away from rotating equipment. -
Page 26: Weld Wire Routing
A-12 A-12 INSTALLATION FIGURE A.9 WELD WIRE ROUTING The electrode supply may be either from reels, Readi- Reels, spools, or bulk packaged drums or reels. Observe the following precautions: a) The electrode must be routed to the wire drive unit so that the bends in the wire are at a 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. -
Page 27: Shielding Gas Connection
A-13 A-13 INSTALLATION 5. Attach one end of the inlet hose to the outlet fitting SHIELDING GAS CONNECTION of the flow regulator. Attach the other end to the welding system shielding gas inlet. Tighten the CYLINDER may explode if damaged. union nuts with a wrench. -
Page 28: Installing Electrode Conduit Kits
For best feeding results, "O" RING use the shortest conduit length possible and avoid sharp bends. (For Codes 11075, 11076, 11077) Tools required: (See Figure A.10a) • Snap Ring Pliers To install Lincoln conduit: 1. Turn off power at the welding power source. -
Page 29: Aluminum Wire Preparations
"O" RING To prevent scratching of the aluminum wire, remove the ball bearings from the ball housing as follows. (For Codes 11075, 11076, 11077) Tools required: (See Figure A.12a) • Snap Ring Pliers • 9/64" Hex key wrench 1. -
Page 30: Operation
Read this entire section of operating instructions responsibility of the builder/user. Many variables before operating the machine. beyond the control of The Lincoln Electric Company affect the results obtained in using the LF-72 wire WARNING feeder. These variables include, but are not limited... -
Page 31: Front Panel Controls And Connections
OPERATION FRONT PANEL CONTROLS AND CONNECTIONS CASE FRONT CONTROLS FIGURE B.1 ITEM DESCRIPTION Location for Optional Remote Voltage Control (See Accessory Section For Kit Number). Location for Optional Burnback and Postflow Timer Kit (See Accessory Section For Kit Number). Thermal LED, Motor Overload. Cold Feed - Gas Purge Switch, press the switch up to feed wire with weld output off. -
Page 32: Remote Voltage Control Kit (Optional
Perform regular maintenance and cleaning on the gun liner, conduit and gun. Always use quality electrode, such as L-50 or L-56 from Lincoln Electric. 4. COLD FEED/GAS PURGE SWITCH Cold Feed and Gas Purge are combined into a single spring centered toggle switch. -
Page 33: Wire Feed Speed Knob
OPERATION Trigger Interlock Trigger Interlock operation provides for operator com- fort when making long welds. When the gun trigger is first pulled, the welding power source energizes the output and the wire feeder feeds wire for welding. The gun trigger is then released while the weld is made. -
Page 34: Accessories
ACCESSORIES OPTIONAL KITS: Includes: 10k potentiometer, K2329-1 Remote Voltage Control Kit. harness, knob and decal with a 0-10 scale and mounting hardware. Includes: Panel and harness K2330-1 Timer Kit. for adjusting burnback and postflow times. Includes: Wire Reel Stand for K2328-1 Standard Duty Wire Reel Stand. - Page 35 ACCESSORIES OPTIONAL KITS: Includes: 14 pin to 14 pin wire K1797-xx Control Cable. feeder to power source control cable. Includes: Adapter control K2335-1 Adapter for Miller Power Sources. cable for connecting a Lincoln 42 VAC wire feeder to a 24 VAC Miller power source.
- Page 36 ACCESSORIES OPTIONAL KITS: K489-7 Gun Receiver Bushing (for Lincoln Includes: Gun receiver bush- Fast-Mate guns.) ing with trigger connector. K466-2 Magnum 200/300/400 to K1500-2 Includes: Gun adapter, cotter Adapter. pin, hex key wrench, wrench. K613-7 Magnum 550 to K1500-3 Adapter Includes: Trigger adapter, gun Lincoln Conduit.
- Page 37 ACCESSORIES OPTIONAL KITS: Includes: Cover, backing K1634-1 Plastic Wire Cover for 30-44 lb. plate, wire conduit, incoming (13.6 - 20.0 kg) Wire packages. bushing for .025 - 1/16" (0.6 - (For use with Standard Duty 1.6 mm) wire, incoming bush- Bench Models and Heavy Duty ing for 1/16"...
- Page 38 MAINTENANCE CALIBRATION SPECIFICATION MAINTENANCE WARNING Safety Precautions ELECTRIC SHOCK can kill. WARNING • Do not touch electrically live parts. ELECTRIC SHOCK can kill. • When inching with the gun trigger, electrode, wire drive motor and • Do not touch electrically live parts drive mechanism are "hot"...
- Page 39 MAINTENANCE FIGURE D.1 4. Open the idle arm. (For Codes above 11290 use 18) 5. Turn power on to the LF-72. 18. Replace P2 from the harness into connector J2. 6. Adjust the WFS knob to 300 ipm. Center the knob 19.
- Page 40 Observe all additional Safety Guidelines detailed throughout this manual. HOW TO USE TROUBLESHOOTING GUIDE 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.
- Page 41 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION OUTPUT PROBLEMS The wire feeder does not feed wire 1. Verify the power source is turned and the drive rolls do not spin. 2.
- Page 42 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION Variable or "hunting" arc. 1. Check for proper size contact. Make sure the contact tip is not worn, free of spatter and not melt- 2.
- Page 43 WIRING DIAGRAM Enhanced Wiring Diagram LF-72...
- Page 44 WIRING DIAGRAM LF-72...
- Page 45 DIAGRAMS LF-72...
- Page 46 DIMENSION PRINTS BENCH MODEL BENCH MODEL STANDARD DUTY LF-72...
- Page 47 DIMENSION PRINTS BENCH MODEL HEAVY DUTY LF-72...
- Page 48 NOTES LF-72...
- Page 49 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 bajo carga con la piel o ropa moja-...
- Page 50 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- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 51 • 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...