Lincoln Electric LN-10 HEADS & CONTROLS IM587-B Operator's Manual
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Lincoln Electric LN-10 HEADS & CONTROLS IM587-B Operator's Manual

Lincoln Electric LN-10 HEADS & CONTROLS IM587-B Operator's Manual

Heads & controls boom mount or bench models
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RETURN TO MAIN MENU
IM587-B
LN- 10 Heads & Controls
August, 2007
Boom Mount or Bench Models
For use with: LN-10 Control - Boom Mount Code 10442, 10831
10 Series Wire Drive - Boom Mount Code 10443, 10444, 10763, 10764, 10818, 10819
LN-10 Boom Package Code 10445, 10765, 10820
Synergic 7F Drive C C ode 10190, 10191
LN-10 - Bench Model Code 10440, 10441, 10761, 10762, 10816, 10817
LN-10 - Zipline Boom Package Code 10497, 10498 , 10771, 10772, 10824
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.
OPERATOR'S MANUAL
Copyright © 2007 Lincoln Global Inc.
• 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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Summary of Contents for Lincoln Electric LN-10 HEADS & CONTROLS IM587-B

  • Page 1 RETURN TO MAIN MENU IM587-B LN- 10 Heads & Controls August, 2007 Boom Mount or Bench Models For use with: LN-10 Control - Boom Mount Code 10442, 10831 10 Series Wire Drive - Boom Mount Code 10443, 10444, 10763, 10764, 10818, 10819 LN-10 Boom Package Code 10445, 10765, 10820 Synergic 7F Drive C C ode 10190, 10191 LN-10 - Bench Model Code 10440, 10441, 10761, 10762, 10816, 10817...

  • Page 2: California Proposition 65 Warnings

    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: Electric Shock Can Kill

    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.
  • Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 SAFETY Mar. ʻ93...
  • 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

    Installation ...Section A Technical Specifications ...A-1 General Description...A-1 Recommended Processes and Equipment ...A-2 Installation of the LN-10 Boom Mount Wire Feeder Components ...A-2 Mounting the LN-10 Wire Drive Unit ...A-2 Mounting Synergic 7F Wire Drive Unit (K679-1 or -2)...A-3 Mounting the LN-10 Control Box ...A-3 Connecting Wire Drive Unit to Control Box ...A-3 Electrode Routing...A-4 Wire Drive Speed Range Selection ...A-4...
  • Page 8 Diagrams ...Section F Wiring (LN-10 Control) ...F-1 Wiring (10 Series Wire Drive) ...F-2 Dimension Print...F-3 Parts List ...P311 Series TABLE OF CONTENTS Page...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS – LN-10 Heads & Controls WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO Speed K1563-1,-3 10 Series 35-500 IPM Std Drive Boom Mount (0.89-12.7 M/M) K1563-2,-4 10 Series 55 - 825 IPM Hi-Speed Boom Mount (1.40 - 21.0 M/M) K679-1 Synergic 7F* 50 - 770 IPM...

  • Page 10: Recommended Processes And Equipment

    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 recepta- cle.

  • Page 11: Mounting Synergic 7F Wire Drive Unit (K679-1

    5/16-18 THREAD 2.25 6.00 11.00 3.00 BOTTOM FRONT 10.50 14.50 FIGURE A.1 Mounting Synergic 7F Wire Drive Unit (K679-1 or -2) Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gearbox. Reference L9777 (included with Drive unit) to find the size and location of the mounting holes.

  • Page 12: Electrode Routing

    Electrode 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 13: Wire Feed Drive Roll Kits

    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.

  • Page 14: Gun And Cable Assemblies With Standard Connection

    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.

  • Page 15: Gun Cable Connection With Fast-Mate Connection

    • 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 elec- trical circuits.

  • Page 16: Electrical Installation

    ELECTRICAL INSTALLATION 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.

  • Page 17: Optional Features Installation

    When installed and properly configured, the K1561-1 Robotics Interface Module allows complete control of the welding process from the robot controller. The Lincoln Electric Companyʼs Automation Center should be contacted for questions regarding installa- tion or operation of the Robotics Interface Module.

  • Page 18: Operation

    "Other: Power Source Independent" power source selection dip switch setting: The LN-10 is designed to work with the following Lincoln Electric power sources: CV250, CV300-I, CV300, CV400-I, CV400, CV500-I, CV655, DC250, DC400, DC600, DC650 PRO, DC1000, Pulse Power 500 (non-pulse CV modes only), the V300 PRO, V350 PRO, and the DC655.

  • Page 19: Welding Power Source Selection

    Setting the DIP Switches The DIP switches are each labeled with an “ON” arrow showing the on direction for each of the 8 indi- vidual switches in each DIP switch (S1 and S2). The functions of these switches are also labeled and set as described below: Pwr Sources Head...

  • Page 20: Step Trigger Mode Operation Selection

    DC-250: * Pwr Sources DC-400: Pwr Sources DC-600: Pwr Sources DC-650 PRO: Pwr Sources DC-1000: * Pwr Sources Pulse Power 500: * Pwr Sources V300 PRO: Pwr Sources 10.0 TO 45.0 VOLT LINEAR PRESET (FOR POWER SOURCES WITH LINEAR VOLTAGE CONTROL PROTOCOL) Pwr Sources 0.0 TO 10.0 LINEAR PRESET:...

  • Page 21: Robotics Mode Selection

    S2 switch 2 ON = 4-Step without current interlock operation: M 4 S R + - 1) Closing Trigger initiates gas flow. 2) Opening Trigger initiates gas preflow timer fol- lowed 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).

  • Page 22: Minimum Limits Setting Mode Selection

    Minimum Limits Setting Mode Selection The LN-10 control is set up for allowing a minimum weld WFS and arc voltage setting for each procedure by set- ting S2 DIP Switch 6 (Labeled “-”). S2 switch 6 ON - Minimum Limits Setting mode ON M 4 S R + - When Minimum Limits Setting mode is selected, all keys except the procedure key are disabled.

  • Page 23: Keypad And Display Operation

    RUN-IN VOLTS / WFS SPOT BURNBACK POSTFLOW CONTROL TIMER THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A. Keypad and Display Description Keypad - Seven key, membrane type with "snap" tac- tile feel and embossed domes. Long life design. Spatter resistant surface.

  • Page 24: Trigger Mode Selection

    Trigger Mode Selection Trigger Mode Select key COLD FEED - enables operator to TRIGGER 2-STEP STD choose mode of operation 4-STEP LOCK shown by the indicator lights. Pressing key caus- SPOT mode sequence (top to bottom) starting from the current indicated selection.
  • Page 25 Control Select key - enables operator to CONTROL 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 dis- played. After Weld procedure is set, Run-in pro- cedure should be set to optimize arc starting.

  • Page 26: Maximum And Minimum Limits Setting Modes

    Maximum and Minimum Limits Setting Modes Limits setting modes are available for limiting the range for setting wire feed speed and voltage. The limits can be set independently for each procedure. The following steps should be followed for setting the maximum and minimum limits: 1.

  • Page 27: Dual Procedure Remote Control (K1449-1)

    B-10 DUAL PROCEDURE CONTROL (K1449-1) When this option is connected to the LN-10 Control Box receptacle, and the Procedure Key selects “REMOTE” the front panel knob controls and proce- dure selection is transferred to the knob encoder con- trols and Procedure Selector Switch of the remote, which function in the exact same manner.

  • Page 28: Feeding Electrode And Brake Adjustment

    B-11 To Mount a 50-60 Lb. (22.7-27.2 kg) Coil: (Using K1504-1 Coil Reel) (For 50-60 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" (51 mm) spindle (or with reel laying flat on the floor) loosen the spinner nut and remove the reel cover.

  • Page 29: Procedure For Setting Angle Of Feedplate

    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 LN- 10 Wire Feeder. 2) Properly connect the electrode and work leads for the correct electrode polarity.

  • Page 30: Wire Reel Changing

    B-13 WIRE REEL CHANGING At the end of a coil, remove the last of the old elec- trode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the follow- ing procedure: 1) Cut the end of the electrode off at the gun end.

  • Page 31: Explanation Of Prompting And Error Messages

    B-14 EXPLANATION OF PROMPTING AND ERROR MESSAGES Display Prompt or Error Displayed on Voltage display, indicates WFS display is showing acceleration setting, “1" to “5" (See “Acceleration Selection” in this sec- tion). Displayed on WFS and voltage displays; indi- cates limits for WFS or voltage are off for the displayed procedure.

  • Page 32: Accessories

    TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size Solid Steel Electrode 0.025” (0.6 mm) 0.030” (0.8 mm) 0.035” (0.9 mm) 0.040” (1.0 mm) 0.040” (1.0 mm) 0.045” (1.2 mm) 0.052” (1.4 mm) 1/16” (1.6 mm) 5/64” (2.0 mm) 3/32”...

  • Page 33: Input Cable Assemblies

    INPUT CABLE ASSEMBLIES: K1797-25 Consists of a 14-conductor control cable extension 25ʼ in length. K1797-50 Consists of a 14-conductor control cable extension 50ʼ in length. Note: Extensions can only be connected up to 100ʼ Maximum length. K1520-1 115V/42V TRANSFORMER KIT Required to use LN-10 with Lincoln Power Sources without 42VAC auxiliary and a 14-pin connector recep- tacle.

  • Page 34: Gun And Cable Assemblies

    Magnum 200/300/400 Guns The easiest and least expensive way to use Magnum 200/300/400 guns with the LN-10 wire feeder is to order them with the K466-2 connector kit, or to buy a completely assembled Magnum gun having the K466- 2 connector (such as the K497-21,-22,-23 dedicated Magnum 400 guns and the K497-20,-21 dedicated Magnum 200 guns).
  • Page 35 K1561-1 Robotics Interface Module allows com- plete control of the welding process from the robot controller. The Lincoln Electric Companyʼs Automation Center should be contacted for questions regarding installa- tion or operation of the Robotics Interface Module. K1557-1 SWIVEL MOUNT The K1557-1 Swivel mount attaches to the power source.

  • Page 36: Maintenance

    MAINTENANCE Safety Precautions 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.

  • Page 37: How To Use Troubleshooting Guide

    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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 38: Troubleshooting

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Rough wire feeding or wire not feed- ing, but drive rolls are turning. Variable or “hunting” arc. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 39 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Poor arc striking with sticking or “blast-offs”, weld porosity, narrow and ropy looking bead, or electrode stubbing into the plate while weld- ing. Tip seizes in the diffuser. Motor does not turn when trigger is pulled.
  • Page 40 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Speed does not change when weld current flows. Voltmeter does not function proper- ly. Welding may or may not vary from normal procedure. Wire feeds properly. Cold feed forward or cold feed reverse buttons on keypad do not work, but motor control otherwise functions properly.
  • Page 41 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Pressing the procedure key does not select between A - Remote - B. Pressing the timer or control key has no effect while not welding. Pressing the trigger key has no effect while not welding.
  • Page 42 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) One of the knobs changes the dis- play, but the other doesnʼt. Neither knob changes the display. Displays & LEDʼs on keypad are off. The green and red LEDʼs on the control p.c.
  • Page 43 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The K1449-1 remote control is not functioning when the Procedure LED is in the REMOTE position. Dual procedure switch is not func- tioning at the gun. Wire feed speed is consistent and adjustable, but operates at the wrong speed.
  • Page 44 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) ʻErʼ is displayed on power up. ʻGLPʼ is displayed. After pressing the trigger, wire feeds for a couple seconds, but stops. The voltage display reads less than 8.0 volts while the wire is feeding.

  • Page 45: 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 can kill. Lincoln Electric Field Service Shop. CAUTION...
  • Page 46 DIAGRAMS LN-10...
  • Page 47 DIAGRAMS LN-10...
  • Page 48 DIAGRAMS LN-10...

  • Page 49: Dimension Print

    DIAGRAMS DIMENSION PRINT LN-10...
  • Page 50 DIAGRAMS DIMENSION PRINT LN-10...
  • Page 51 DIAGRAMS DIMENSION PRINT LN-10...
  • Page 52 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 53 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 54 • 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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