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Lincoln Electric SVM143-A User's Manual

1.
2. 8 amp e x 8 S T 0 K Y P A D jej c 2 ia IN CLOCK A 18 ENABLE A COLD FEED FORW E fal nares a le 6 5 1448 475 5 JM sesh E Ses gt B 7 COLD FEED REVERSE 1 e C7 5 2 475 c 475 SIN C Gas PURGE i gt lt 1 1 RI 2 m 175 3 _ ng He X3 SS PL L FEEDER SC E SELEC 5 P D 454 F
3. 512 28 SREF L R34 512 56 20 812 Tes IW HE r REMO A 3 Ehe 2 4 OUTPUT B REMOTE 187 d pa 5 5 801 pL Ont 2 chi 05 505 178 5 2 6 8 1 4 275 ita A A 4 A ha _ 5128 ae v Se aly te Hart g in 186 5 1 4 2 amp o 3 92K S 40 z 5 208 e a 35 yke _ 50 aK cw REF raa gS 03 V 5 6 NN 130 REMOTE R55 E 3 0
4. en 912 un 9 0 8 2 ele EE 882 Loree _ _ FPEM x 2 X x lt ITEM REQ D PART DESCRIPTION REQ D PART NO DESCRIPTION A m A U 17 A Ul 2 117 R45 ROS R32 R86 897 12 518400 3321 3 32K 174W 18 5 022750 nn S PES 27 us Uu lt Ee 1116 R132 R160 R 169 1 is ee ulus a J R184 e XN S ple R18 AZO 824 R25 4 51 33 1 37 515668 11 71750 E LI D amp 9 eM 3n R22 R23 R36 R 105 8125 8142 B 81 22 C15 C16 C21 C23 d a v Z ER 5 15 NS
5. O 512 9 La BLACK A R189 6 yd EEK J6 J7 Q 9 se o 2 n B cm MOTOR REVERSING NS ole sy 8 CIRCUITRY 1 d ETT E BLUE Z T waite 5 Je J7 plz 2 s12 MOTOR 1 52 2 BLACK 512 E EV Rt 221K T gt 80 Vs RED zn V 500 TACH 2 e Em 332 7 512 S15 Proc 8 to is an e 186 4 TK ZIK 9 6 PROG A 2 DUAL PROCEDURE im a Er 33K hs 9 9 GUN 1 5 0 m d 10 c Eg PE c31 8 5201 Pi r ROO e oe E TOK 5 T tc 500 V 4 Ba 9 Tw 10K 512 49 505 ET 505 1 211 oOo A 1 s e SE ne 1 500 DUAL PROCEDURE 2 TER i S GUN 2 e e 9 4 ee 7 1 2 0 7 7 w E 512
6. B 5 2 POWerDOWN Save 22 oe keen bs B 5 5 Operation Keys sudeste mre ARR ae e 6 2 Trigger Mode Selection ssas adatas oaa ad daa D dna B 6 gt Display Control Keys 4 B 7 2 Digital Memory Voltmeter B 7 Acceleration Selection B 7 Security MOHS ve aaa uu kaq er dk qi Q ss sed aina w ied rud B 8 Dual Procedure Remote Control K1449 1 B 8 Wire Reel Loading Readi Reels Spools or Coils B 8 To Mount a 30 Ib 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter FIGURE B 1 B 8 To Mount 10 to 44 Ib 4 5 to 20 kg Spools 12 in 300 mm Diameter or 14 Ib 6 kg Innershield Coils B 9 To Mount a 50 to 60 Ib 22 7 to 27 2 kg Coil Using K1504 1 Reel 22 2 2 ehem ERE RERO Va B 9 Feeding Electrode and Brake Adjustment B 10 O Drive Roll Pressure 0
7. ul 1059 JO 107218d0 ur ynse1 pue y jo Ayrenb y sous pue seBeinoosip 91119811 ujoour AjUO 10 si siu 9119 9 u o3ur jou SJUSUO WOT pieog pejuug Enp pu Aueuem 1079e7 peog pieoq Bunins i se 1 10 Ayjiqisuodsas ou seuinsse 2u199 3 ujoour 1 1 661011 1 96 025 y 8X ZX 9X OX 26 2 6 8 006 15 1 01 006 15 X 9 IJH AGH G 82Z1S1S 2 ZX TX BEY BEY 001 0001 00961 5 8 LEY 9EY ZEYH Mp I 1061 007615 y TEY 8 2001 007615 GZH EZH 924 02H 61H STH 418 1 GLY 05 00 615 21 219 TIM BR o M TOOT 00 615 8 Leu Lu 94 EY Tu 22037 O 2037 22031 12027 020317 61 03 61031 O 81031 21037 91031 21 03 tc v1031 1
8. HEAD 1 HEAD 2 L 1 2 3 4 5 6 7 52 im 55 o o 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 HEAD 1 HEAD 2 1 2 3 4 5 6 7 52 52 Welding Power Source Selection The DH 10 Control is set up for proper presettable weld voltage control by setting 51 DIP switches 1 to 4 as appropriate per the following information for the welding power source being used 250 300 1 Pwr Sources _ M4 1 2 3 4 5 6 7 Si o S1 300 400 1 Pwr Sources Security _ 4 2 3 4 5 6 7 51 51 400 500 1 Sources Security nr M 4 ON 1 4 5 6 7 8 51 2 L
9. 1499 2 10 Bench with Left Head 35 500 0 89 12 7 m m amp Right Head 55 825 IPM 1 40 21 0 m m Low Speed Ratio set S2 DIP switch as follows HEAD 1 HEAD 2 1 2 3 4 5 6 7 52 1 0 Ll For 1497 2 DH 10 Boom 1499 2 DH 10 Bench with Left Head 50 750 IPM 1 25 19 0 m m amp Right Head 80 1250 IPM 2 00 31 8 m m High Speed Ratio set S2 DIP switch as follows initial fac tory setting HEAD1 2 1 1 2 3 4 5 6 7 52 s2 DH 10 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o lt a gt gle 5 2 1 Return to Section Return to Master TOC B 3 OPERATION 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 HEAD 1 HEAD 2 1 2 3 4 5 6 7 52 H S2 Li 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
10. 888 lt 0 3925 25 gt 05 05 50 GEARBOX RIGHT WIRE DRIVE RECEPTACLE Return to Master TOC x gt gt Return to Section ELECTRODE CABLE HEAD TO HEAD a er a 21 gt ao lt O a gt zs gt 609 198 n CE gt sa 19g gt 098 223 028 2 olo O o 5 o PEN 1 LEFT WIRE DRIVE RECEPTACLE GEARBOX A 18N3SSV QV3H DUAL PROCEDURE TRIGGER AND SWITCH LEFT GUN RECEPTACLE ELECTRODE WIRE DRIVE HEAD ONLY N B WHITE LEADS 560 AND 561 MAY NOT BE LABELED ON N A REVERSING PLUG ASSEMBLY REQUIRED FOR THE RIGHT EARLIER WIRE DRIVES NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine DH 10 LINCOLN M17871 1 1 21 97J Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC G 2 5 o 2 2 Return to Section TOC Return to Master TOC Q D 5 8 4 8 4 Cont
11. 9 2 Zw 3 g LABELS o 233 9 9 L w SUPPLY VOLTAGE NET PROTECT 2 T La m cjo lm s APRES Lers x 8 w Le SHEET 2 OF 2 9 gt BLUE LEE We S 750 Lw2o0 80V ice 50 S 9 57 500 9 S us 2 FILE 68040 2BA EARTH GROUND CONNECTION v N 500 GRAM M 5 228 ST gig NS A GOMADN 5 2 07 5 5 488 MES N G3040 2 4 N B PRESENT ON THE DH12 MODELS ONLY NOTE Lincoln Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail pocas LINCOLN able from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design result in danger to the Machine Technician board repairs could result in damage to the machine DH 10 Return to Section TOC Return to Master TOC Return to Section TOC o Ele G amp a gt 8 8 c 515 a Return to Section TOC Return to Master TOC Return to Master TOC G 6 ELECTRICAL DIAGRAMS G 6 Display Board Schematic L10138
12. B 10 Procedure for Setting Angle of Feedplate B 10 2 Gas Guard Regulator Setting B 10 Making WEI a ictus alea qa dr add a das d atc e dat m Coeds a Je M atat aee B 10 Wire Beel u u scere hex t RR X PRIE Sus a ORE n dea 11 Loss of Voltage Sense Shutdown B 11 5 Wire Feed Overload IPIOIGOHDIN uidi ne ddp Ro Vido dre od d B 11 2 Grounding Lead Protector s tre uka ut 12 Explanation of Prompting and Error Messages B 12 5 9 gt 8 E d DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o F w 9 a gt 212 EIS 2 1 Return to Section Return to Master TOC B 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can 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
13. Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger elec trode 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 con nected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should per form this installation Observe all additional Safety Guidelines detailed throughout this manual ROUTINE MAINTENANCE Drive Rolls and Guide Tubes After feeding every coil of wire inspect the drive roll section Clean it as necessary Do not use a solvent for cleaning the idle roll because it may wash the lubricant out of the bearing The driver roll and guide tubes are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll s is to be used the roll s and guide tubes must be changed The drive rolls for 0 035 in 0 9 mm through 0 052 in 1 3 mm cored electrode and 1 16 in 1 6 mm through 3 32 in 2 4 mm electrode have a double set MAINTENANCE D 2 of teeth so they can be reversed for additional life Drive rolls for 0 023 in 0 6 mm through 0 052 in 1 3 mm solid electrodes and aluminum sizes have no teeth but use two grooves so they also ca
14. e eV u3002N3 AHV1OH 7921140 ELECTRICAL DIAGRAMS DH 10 LINCOLN amp Encoder Board Schematic 522066 LP 2 GLY 20 QHVO8 1081 03 10 SL S M M gr ra G 7 DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N DOL J91Se N 01 UuunjeH DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes 0 8 ELECTRICAL DIAGRAMS G 8 Control Board Layout G3041 2
15. 1 R5 1 R68 RB 1 R83 9 1500 150 1 4W EE iul 85 ter A r Me A 22 1 3 UNDERVOLT SENSING CIR 55 86 R110 R157 im a S 0021 oH E zu 8 HAt Du p sa X24 1 8 ROM SP1 12 813 R14 RI5 R 124 5 19400 2671 2 87K 174 up ee Cent ut nr LS 2 5 X25 1 7 OS MPU A D 10 819 821 849 R52 R54 25 19400 4751 4 75K Y X26 X27 2 16 HV DRIVE 55 R58 RB 1 R73 R74 87 R94 18 e UR X28 1 4 8 PIN IC R38 R102 R106 8112 8115 x29 1 3 T SINK ASBLY R130 R131 8143 R 149 R 155 X30 X31 2 R 162 R 163 No 0 2 26 8162 8163 R236 Yi 1 5 8 0 MHZ CAPACITORS MFD VOLTS RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED INDUCTANCE HENRYS G 30412 OJO Fle ci a 9 5 im G3041 2 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail 2 20 98M able from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine DH 10 G 9
16. 827 R28 R28 R 108 R 109 8 51 475 C28 C32 C34 C36 E 22 A 2 lt R147 8153 C41 C42 C43 46 7 74 0 R55 RIS R127 R159 R161 515 3 92K 1 4 3 T Xo 5 X R37 R4 1 R43 R53 33 Sis 10K 174W seq 5 x _ X R71 872 R100 8 118 R 3 x 36 R144 R208 R209 R2 2 X R2 11 R2 12 R2 13 R2 14 R2 5 g Be R224 R225 8226 8227 R C44 C45 C48 C52 C6 1 C62 6 i Oe 17 7 230 231 R235 8242 56 C78 2 E 1 o 1 72 2 681 1 4W 1 1 20 ohm 5 watt 1 Fle Li gt 746 1744 1 Y ES JI RSS R114 R133 R171 12 2 21K 1744 2 g T R173 R186 R 188 R232 R233 1 Oo 7 8234 1 R42 1 T1 1 6 eb gh 844 546 2 TT 6015 8 E R50 1 fs CRI 1 o z 5s suu R59 182 2 51 Aq 2 T PA R60 R62 R66 R67 R89 870 7 51 01 02 03 D4 05 06 07 DS DS 38 FEF E ne 5 BAKEN R182 210 011 D12 D13 D14 D15 9 aS RULES 239 21274 e ELEN A 3 R88 S 1 21K 1743 016 017 D 18 019 5 48 BAIE 4 0 49 B mu 2 8 8 RSSB gk 8 5 619 174W 028 029 030 031 032 4r 18 E 2 TT E 51 2 43K 1 4 043 044 045 046 N Z jor DHT 88 2 T T 51 3
17. 1 Return to Section Return to Master TOC 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 2 Feeder Lights Indicate the wire feed head selected for procedure mode FEEDER timer and cold feed functions settings The feeder may be selected by press D ing the Feeder select key or by the last feeder gun trigger that was closed ETC 1 is selected for the selected feeder and procedure for PROCEDURE Feeder 1 is independently set from A and B Procedure for Feeder 2 The Procedure select key selects if REMOTE Light is selected the cedure selection light is controlled by connection of an optional Dual Procedure gun switch K683 1 3 or Dual Procedure Remote Control 1449 1 COLD FEED Cold Feed Keys energize mm the wire feeder but not the power source or gas sole noid valve Cold Feed Forward speed is factory set at 200 but is adjustable with WFS encoder knob and displayed on WFS display with
18. Return to Master TOC Return to Section TOC Return to Master TOC O10 O o EE lt iz 5 a a Return to Section TOC Return to Master TOC F 24 TROUBLESHOOTING AND REPAIR F 24 KEYPAD RESISTANCE TEST continued FIGURE F 3 KEYPAD RESISTANCE TEST DISPLAY TEST PROCEDURE 5 Remove input power to the 10 unit Using the 5 16 in nutdriver remove the two screws from the top of the control panel See Figure 3 Carefully lower the control panel Remove plug J11 from the display board Perform the Display Board Removal DH 10 LINCOLN 5 10 Check the keypad resistances referenc ing Figure F 3 and Table 1 The resistances are checked at plug J10 on the keypad See Figure F 3 If any of the resistances are not correct the keypad may be faulty When test is complete carefully install the display board and connect plugs 410 and 11 Reassemble the front panel 25 TROUBLESHOOTING REPAIR F 25 KEYPAD RESISTANCE TEST continued NOTE There should not be continuity between pins until a key is pressed on the keypad TABLE F 1 KEYPAD RESISTANCE TEST Return to Section TOC Return to Master TOC MAXIMUM TEST POINTS ALLOWABLE RESISTANCE FROMPIN KEY PRESSED TYPICAL RESISTANCE GAS PURGE 100 OHMS 50 OHMS TYPICAL
19. 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected t
20. i I lt o 2 lt DOL 4 1 01 NOL 4 1 01 DOL 4 1 01 NOL 4 1 01 DOL uonoes DOL uonoes DOL uonoes DOL uonoes SECTION 1 SECTION 1 9 TABLE OF CONTENTS n OPERATION SECTION 8 Operations 12424 SS regii dS Yum e ___________ 2 Duty PEE 2 5 DH 10 Control Switch Setup B 2 2 Setup DIP Switch Access n lcm aid ae d 2 Setting the DIP Switches 1 B 2 Wire Drive Head Selection 1 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 4 B 5 o Keypad and Display
21. 8 lt ROS 2007 T 512 4 p 1 00K 500 Lo a 9 1 J 512 s LT 23 4 E lt SWITCHING 3 E amp 5 Qe 058 088 SOLENOID lt O16 POWER SUPPLY uk ipm uds 2 SOLENOID GAS SOLENOID 1 d pr Naga i T 500 TRIGGER Wan 4 4 DRIVER o e 8 0 5 7e 5 5 7 500 cs s 128 DC dn PT SOLENOID 255 D34 o N A 025 048 505 J8 FAULT2 e 9 a 184936 4 o gt Se Lx n 257 512 z Z vo R182 gt 813 A s ET 7 w INTERFACE lt lt gu 1200 re Sr P C BOARD TRIGGER 2 WHITE 15V a ee S 50 50 980 512 TEN 30K gt TRIG2 N 4 4 L Soop d GAS SOLENOID 2 rota WHITE s j SOLENOID Sum 2 Ei 0018 S e e TS eu 32 DRIVER A Els Es amp g 087 V7 500 7 zd 184938 GAS iE ete snm Sola ESS ARC D51 V 500 500A 5 x CURRENT WHITE 5 gt e gt CURRENT 2 SENSE oe a 2 D50 WHITE R232 TK 505 00 V 4 o ib B js e 4 4 GENERAL INFORMATION mem m 0 515 GROUND 8
22. Cid 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 caspur Gas Purge key energizes the gas solenoid valve but not the wire feeder or power source OPERATION B 6 Trigger Mode Selection Trigger Mode Select key mes enables operator to choose oe mode of operation shown by e tov the indicator lights Pressing e key causes mode lights to sequence top to bottom starting from the current indi cated selection o oio COLD FEED 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 Trigger Mode Operation Sel
23. Encoder PC Board Test ius uu oaa eda ke eee yd dried de Gas Solenoid Test Component Replacement Procedures Display PC Board Removal and Replacement Gas Solenoid Removal and Replacement Encoder PC Board Removal and Replacement Wire Drive Motor and Gear Box Removal and Replacement Retest After DH 10 LINCOLN 5 Section F F 2 F 3 F 5 F 17 F 17 F 19 F 23 F 27 F 29 F 31 F 31 F 33 F 35 F 37 F 41 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 5 Return to Section Return to Master TOC Q 2 0 TROUBLESHOOTING REPAIR F 2 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 throu
24. power source and the DH 10 may be defective Perform the Adjustment and Feedback Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o F F w 9 a gt elg EIS 1 Return to Section Return to Master TOC F 14 TROUBLESHOOTING AND REPAIR F 14 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS The wire is feeding rough or not feeding but the drive rolls are turning The contact tip seizes in the gun liner FEEDING PROBLEMS Check for mechanical restric tions in the wire feed path Make sure the gun liner is cor rect for the electrode wire being used Check the contact tip Make sure the drive rolls are installed correctly Make sure the DIP switches on the control board are set correctly The tip may be overheated because of prolonged or excessive high current and or duty cycle POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION 1 If the drive rolls are turning erratically perform the wire Drive Motor Test Adjustment
25. Activate the gun trigger Make sure the motor is running Check for the pres ence of approximately 5 0 VDC from blue lead 555 to black lead 500 The 5 0 VDC represents the correct feedback voltage from the hall effect device to the control board If the above voltage reading is not cor rect the hall effect device may need to be adjusted or replaced See Tach Adjustment Procedure ral TROUBLESHOOTING AND REPAIR EM TACH ADJUSTMENT AND FEEDBACK TEST continued TACH ADJUSTMENT 3 Using the 9 16 in wrench loosen the PROCEDURE locking nut 4 Gently screw the hall effect module into the mounting plate until it just touches and stops against the rotating part inside the gearbox See Figure F 2 Proper positioning of the module is critical to the proper operation the DH 10 wire feeder If the device is not screwed in far enough the motor speed could be unstable or run at full speed with no control If screwed in too far it will rub a moving part inside the gearbox Return to Section TOC Return to Master TOC 5 Back the module out 1 2 turn Using the 9 16 in wrench and carefully snug the locknut without rotating the module 1 Remove input power to the DH 10 wire position f 6 Install the wire drive cover 2 Make sure the module is securely attached to the gearbox Return to Section TOC Return to Master TOC O10 o lt a gt gle 5 1
26. More detailed dimensions and weight information found in Section F of this manual A 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 WIRE DRIVE HEADS BOOM SPEC TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Speed Solid Cored Speed Solid Cored 1497 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 20 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
27. Return to Section Return to Master TOC DH 10 LINCOLN 5 g NIOINIT Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 20 4 SALON 20 4 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O F a gt 8 8 5 Return to Section Return to Master TOC F 23 TROUBLESHOOTING AND REPAIR KEYPAD RESISTANCE TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory war ranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if any key is not functioning properly MATERIALS NEEDED 5 16 in nutdriver Analog Volt Ohmmeter Small screwdriver DH 10 LINCOLN 5 F 23 Return to Section
28. wire drive cover Disconnect the 67 lead at the quick connect See Figure F 9 Disconnect the gas hose from the brass gun connector Disconnect the tach hall effect device leads DH 10 LINCOLN 5 TACH LEADS 3 4 in NUT GAS HOSE FITTING Disconnect the motor armature leads Remove any necessary cable ties Using the 3 4 in wrench remove the electrode cable from the wire feed assembly Using the 7 16 in socket wrench and extension remove four mounting screws lock washers and flat washers The motor gear box and feed head assembly are now free from the DH 10 unit Remove the wire feed assembly Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O lt a gt 8 8 5 1 Return to Section Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR F 39 WIRE DRIVE MOTOR AND GEAR BOX REMOVAL REPLACEMENT FIGURE F 10 DRIVE MOTOR AND WIRE DRIVE ASSEMBLY REMOVAL DRIVE MOTOR GEAR BOX TO REMOVE THE DRIVE MOTOR FROM THE GEAR BOX 12 13 14 15 Using the slot head screwdriver and 7 16 in wrench remove the gear box inspection cover nearest to the drive motor See Figure 10 Using the 5 16 in wrench remove the motor mounting screw located inside the gear box Using the slot head screwdriver remove
29. 24 B Nm n V gx 505 4 48 V sea TU J T d 3i 8 amp NE u v a CE m 500 3 78 Vi ee ale sh L Is 508 8 15 sean V D atl vas 52 7 9 18 ETE 3 a 18 reu 77 48 LR 22 28 3 4 Reset 4 619 R59 5 V X2 ve 4 3 pce p g 3 10 ec al T RE TRIG lt b EN j 8 ze v 76 3 5 47 3 2 x pna lt PE 8 la zY e paz FT 25 _ 2755 ja pc E LT F 267 Da i e a stre 3 502 828 CIS S 50 Le QUE R5 4 sina 85 3L p ce ce 3 7 g 33 6 E ha 26 t ET aye le QUI R3 9 32 6 a 2 Y 267 02 a BER VOLTS 517 5 05 PB4 s s 9 x TRIM OO 2 oe 2 RIZ 267 267K 2 m Lo m 8 eo zara E 22 267 5 85 522 vas pog 9018 RE 5 508 LE He LT 267 92 R Pus x 2 215 z g Les 774 t 7 6 4 N 5 2 4 Ed 505 6 VE 4 N S O F 1242 il a 10400 S Ivi 4 sea x V sao 48 val 1 lt 202 DHi2 lt p 4 8248
30. 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 Return to Master Return to Master TOC Q gt Return to Master iv SAFETY iv PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metalli
31. 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 Made 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 connec tion Also Tweco 5 GUN AND CABLE ASSEMBLIES The following Lincoln gun and cable assemblies are compatible with DH Wire Feed heads with appropriate K1500 Gun Adapter K126 Requires K1500 1 Innershield gun and cable assemblies are rated at 350 amps 60 duty cycle Consult sales specifications for appropriate models K115 Requires K1500 1 Innershield gun and cable assemblies are rated at 450 amps 60 duty cycle Consult sales specifications for appropriate models K470 With K466 9 requires K1500 2 Magnum 300 GMAW gun and cable assemblies are rated 300 amps 6096 duty cycle Consult sales specifications for appropriate models K471 With K466 9 requires K1500 2 Magnum 400 GMAW gun and cable assemblies are rated 400 amps 6096 duty cycle Consult sales specifications for appropriate models 5 K497 With K466 9 requires 1500 2 Magnum 200 GMAW gun and cable assemblies are rated 200 amps 60 duty cycle Co
32. O10 O F a gt 8 8 5 Return to Section Return to Master TOC F 35 TROUBLESHOOTING AND REPAIR ENCODER PC BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory war ranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of either the WFS or Volts control encoder boards MATERIALS NEEDED 5 16 in nutdriver 5 64 in Allen wrench 1 2 in wrench DH 10 LINCOLN 5 F 35 F 36 TROUBLESHOOTING AND REPAIR F 36 9 ENCODER PC BOARD REMOVAL AND REPLACEMENT continued Je 5 5 FIGURE 8 PC BOARD REMOVAL AND REPLACEMENT 518 gt 212 ala QE ENCODER PC BOARD olo 5 Q olg 2 212 513 WASHER NUT FELT WASHER SPA
33. Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or unable to form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The procedure will aid the technician in the removal and replacement of either the motor or gear box These instructions are applicable for either the left or right side wire feed assemblies MATERIALS NEEDED Return to Section TOC Return to Master TOC 5 16 in nutdriver Pliers 3 16 in Allen wrench 7 16 in socket wrench and extension 3 4 in wrench 5 16 in wrench Slot head screwdriver O10 OJO E a gt 8 8 5 Return to Section Return to Master TOC DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o Fle lt 9 a gt Gje EIS 1 Return to Section Return to Master TOC TROUBLESHOOTING AND REPAIR F 38 WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT continued FIGURE F 9 WIRE FEED ASSEMBLY REMOVAL MOTOR ARMATURE LEADS CAP SCREW LOCK WASHER PROCEDURE Remove input power to the DH 10 unit Remove the electrode wire from the wire drive Using the 5 16 in nutdriver remove the
34. Return to Section TOC Return to Master TOC O10 o lt a gt 212 5 Return to Section Return to Master TOC DH 10 LINCOLN 5 g NIOINIT Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 92 4 SALON 92 4 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O lt a gt 8 8 5 1 Return to Section Return to Master TOC F 27 TROUBLESHOOTING AND REPAIR ENCODER PC BOARD TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory war ranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the encoder PC boards are functioning
35. should activate then deactivate when the key is released 2 Press the Cold Feed Forward key Check that the direction of rotation of the drive roll is correct to feed wire out of the front of the machine Check that the drive roll shaft stops abruptly when the key is released 3 Press the Cold Feed Reverse key Check that the direction of rotation of the drive roll is correct to retract the electrode wire back into the machine Check that the drive roll shaft stops abruptly when the key is released DH 10 LINCOLN 5 Check the Feeder selection and Procedure keys for proper operation 1 Press the Trigger key The LEDs should toggle through the various trig ger selections as the key is pressed and released 2 Press the Timer key The LEDs should toggle through the various modes as the key is pressed and released 3 Press the Control key The Run In Volts WFS LED should light up Press the Control key again The LED should turn off The Volts and WFS control must function and change the appropriate display CHECK WIRE FEED SPEED RANGE DH 10 with low speed gear installed 35 500 IPM DH 10 with high speed gear installed 50 750 IPM 42 9 sf 5 LL NOL 4 1 01 DOL 4 1 01 NOL 4 1 01 NOL 4 1 01 DOL uonoes DOL uonoes uinjeg DOL uonoes DOL uonoes
36. 2 SOLENOID 2 lt P ces L J2 10 DIR lt tp CN R2 1 m 217 2 REMOTE lt 2 Ps 84 2 MOTOR lt 2 05 505 505 L vB2 TACHS F A als A LI lt 5 50 110 Rae J3 z 74HC373 1 i gt 9 505 FES 08 5 A Ip Jo p 828 3 MISO JIN 554 n DISPLAY SG V 275 T 55 553 A vs 5 BOARD 301 g 8 m 23 552 cs EE lt p T 55 k 0 5REF LATCH x 1 AR R27 551 1 15 520 Tin oe nie fou i2 500 5 al Ne 2 Z 505 gt 5 5 1 X oo 50 vaa v85 ss x25 n d els 3 5 ANS El zlels 5 E SIS 8 Joe 888 16 ANT M gleoc pers ANS 35 VBE 512 8217 zj 1 ba us 4 5 d 1 ana 5 p 74H05 a 7490151 24x B 2 145051 Vs E ile 500 100 5 03 REIS 04 3 u o5 REL vB us 4 756 1004 ES 2 V 3 3 1 5 159 488 ui 7 50 95 21 7 _STROB 1 CH 2 512 A 1 505 3 9 9 4 k GENERAL INFORMATION 20 2 vaa 26 vec 8 2 bv 4 2 ELECTRICAL T n cis n x30 X31 ru CAPACITORS ce x x2 4
37. 31 8 m m 0 6 1 2 mm 0 9 1 2 mm K679 1 Synergic 7 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 0 9 2 0 mm K679 2 Synergic 7F x 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 Excluding Wire Reel More detailed dimensions and weight information can be found in Section F of this manual n Included in K1521 1 2 3 DH 10 Boom Packages 9 Included 1521 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 DH 10 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 5 Return to Section Return to Master TOC Q 2 0 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
38. 5 0 120 in 3 0 mm 1505 120 2 d Aluminum Electrode 0 035 in 0 9 mm KP1507 035A KP656 035A 0 040 in 1 0 mm KP1507 040A 7 3 64 1 2 1507 3 64A 656 3 64 1 16 in 1 6 mm KP1507 1 16A KP656 1 16A 3 32 in 2 2 mm 1507 3 32 olo Aluminum Electrode For use with Binzel Guns Only 8 0 040 in 1 0mm 647 040 gt 3 64 1 2mm 647 3 64 918 1 16 in 1 6mm KP647 1 16 dc DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 OJO CIS a gt gle 5 1 Return to Section Return to Master TOC C 4 INPUT CABLE ASSEMBLIES One required per DH 10 Control Box K1501 Control Cable Only Consists of a 9 conduc tor control cable with a 14 pin control cable plug with out electrode cable and is available in lengths of 10 ft 8 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 mm 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 80 m is also available with a 4 0 107 mm elec trode cable K1503 Consists of a 9 conductor con
39. 7 TROUBLESHOOTING AND REPAIR F 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued The wire feed speed does 1 The run in and weld wire 1 Check the current sensing reed Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o F F w 9 a gt elg EIS 1 Return to Section Return to Master TOC change when welding current is established The voltmeter does not function properly The welding may vary from normal performance The wire feeds properly feed speeds may be set at the same value Check the current sensing reed Switch leads and connectors for loose or faulty corrections See the Wiring Diagram Make sure the dip switch set tings on the control board are correct for the power source being used See Welding Power Source Selection Make sure the voltage sense leads are connected A Lead 67 has continuity zero ohms to the electrode B Lead 21 has continuity zero ohms to the work piece switch for proper operation A While not welding the volt age at pins 3Jl to 4J1 should be approximately 12 VDC The reed switch should be open If the 12 VDC is miss ing either the reed switch is stuck closed or the control board is defective While wel
40. 9353 WELD DESCRIPTION This will aid the technician in the removal and replacement of the display PC board MATERIALS NEEDED Return to Section TOC Return to Master TOC 5 16 in nutdriver Small screwdriver O10 O F a gt 8 8 5 Return to Section Return to Master TOC DH 10 LINCOLN 5 F 32 TROUBLESHOOTING AND REPAIR ES DISPLAY PC BOARD REMOVAL AND REPLACEMENT continued FIGURE F 6 DISPLAY PC BOARD REMOVAL AND REPLACEMENT Return to Section TOC Return to Master TOC DISPLAY PC BOARD MOUNTING PIN Return to Section Return to Master TOC O10 o lt a gt 8 8 5 1 Return to Section Return to Master TOC panel Lower the control panel Locate and remove plug 411 from the display board Observe static electricity precautions See Figure 6 Carefully pry the display board from the six mounting pins Note that the keypad is still attached to the display board via plug J10 Carefully remove plug 410 from the dis play board DH 10 LINCOLN 5 REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1 Remove input power to the DH 10 unit 1 Install plug J10 into the new display board 2 Using the 5 16 in nutdriver remove the two screws from the top of the control 2 Mount the display board onto the six mounting pins I
41. DH 10 front panel when the remote is connected and selected by the DH 10 Procedure Key ACCESSORIES C 4 K1450 L Extension cables are available in lengths L of 12 16 or 25 ft 3 6 4 9 or 7 6 m to match the control to Feeder cable length 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 con nection 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 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 con trol 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 K683 3 DUAL PROCEDURE SWITCH One per gun Kit includes gun switch and mountings for Lincoln Innershield and Magnum guns wi
42. HEDUI EL RD alp 475 SIE 70H 18 4 m E J DUAL PROCEDURE 2 15 5 R13 510 sa 10 475 8 GND 8 18 BANK4 yg 7 x z z Z 3 2 74 165 5 BANKS gt E 515 F_ TRIGGER MODE SELEC AWIG V E alm 2 R14 5 zo 75 3 BANK2 44 A le Jg 2 viz TIMER SELECT BANKI 225 17 5 19 175 4 BANK 7 L JU CONTRO 2 DATA IN ss UE H CON L SELECT 2 gt R26 L CLOCK 475 4 54 lt lt V COM s gt 520 Pd ONTR D ROARI 5 UIN TI 554 150 i 3 R2 S 475 25 gt lt 17 L So 278 2 x 3 7 8 E m EDS LED8 2 5522 SCK 5 5 RIB 5 ve oe v 475 2 M VE n d 5 el 2 gt BANKS 5 gt 9 2 DATA IN vss tb LED2 LEDS LEDS 2 5 20 ENABLE 8129 We et 23 1 cLock 3 VE Y 52 553 y MOSI 5 18 OU Rx 8 1 1 Qs 475 MC14489 8 M LED3 LED7 1 NIS S EIS D Le f Y o i m EOD bd ED4 LEON 02 7 500 4 L i v 5 ITI 832 2 gt 100 gt Vdo 8 1 5128 2 z C 96 x5 m x 8 ME 4 29 ES 8 L ble LEDI2 LEDIG LE
43. Procedures F 31 Electrical Diagrams Section G Parts Manual i uo mw ER P 288 DH 10 LINCOLN 5 SECTION 1 INSTALLATION SECTION 1 9 TABLE OF CONTENTS n INSTALLATION SECTION 3 INStANAUON rr T Section A Technical Specifications DH 10 Complete Units or Controls 8 Heads A 2 General Description 34454 96 02242 0 A 3 5 Models 3 2 Recommended Processes 3 Safety Precautions mnt ex mets due de e arp Rr 4 Installation of the DH 10 Boom Mount Wire Feeder Components 4 Mounting the DH Double Header Wire Drive Unit K1497 1 2 4 Mounting Single Head Wire Drive Unit K679 1 or 2 4 Mounting the DH 10 Control Box 1496 1 4 Connecting Wire Drive Unit to Control BOX A 5 Electrode ROUNO aceto Rane tha et dapes Me EUR Rd ud RUE A 5 Wire Drive Speed Range Selection A 5 Control Speed Range 0 A 5 Double Header DH
44. Wire Feed Heads and Receptacles DH 10 LINCOLN 8 SECTION E 1 THEORY OF OPERATION SECTION E 1 Section E E 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o lt a gt 8 8 5 1 Return to Section Return to Master TOC E 2 THEORY OF OPERATION E 2 FIGURE E 1 GENERAL DESCRIPTION TO GUN TRIGGER AND DUAL PROCEDURE LEFT WIRE WIRE DRIVE DRIVE RECEPTACLE MOTOR TACH FEEDBACK TO GUN TRIGGER AND DUAL PROCEDURE WIRE DRIVE MOTOR CURRENT SENSING REED SWITCH GROUND LEAD PROTECTOR RIGHT WIRE DRIVE RECEPTACLE TACH FEEDBACK __ CONTROL BOARD DISPLAY BOARD KEYPAD GENERAL DESCRIPTION offered are four independently selectable gun trigger modes for each head procedure cold feed 2 step and The DH 10 is a 42 dual head 4 roll wire feeder 8tep trigger and spot weld The user can also pre A single control for each head is utilized with dual set timers for each head procedure prellow procedure of wire feed speed and arc burnback and SPOL ids voltage The DH 10 models have controls providing feed acceleration rates can be used to optimize arc keypad or remote selectability of wire drive head and starting Refer to Figure E 1 either one or two procedures for e
45. 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 protec tion 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 HOO 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 n the Maintenance section DH 10 LINCOLN P Return to Section Return to Master TO
46. box using the 5 16 in wrench Install the gear box inspection cover and secure it with the slot head screws and nut previously removed DH 10 LINCOLN 5 8 Place the entire assembly into the DH 10 unit Align the mounting holes with wire feeder base Secure the assembly to the wire feeder base using the four screws lock wash ers and flat washers previously removed Connect the gas hose to the brass gun conductor block Connect the motor armature leads Connect the tach hall effect device leads Connect lead 67 quick connects together Connect the electrode cable to the to the wire feed assembly Replace any cut or removed cable ties Install the wire drive cover Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o Fle lt 9 a gt 818 EIS 1 Return to Section Return to Master TOC TROUBLESHOOTING AND REPAIR F 41 RETEST AFTER REPAIR If failed test indicates that any mechanical part which could affect the machine s elec trical characteristics must be replaced or if any electrical components are repaired or replaced the machine must be retested and meet the following standards Apply the correct input power 42 VAC to the DH 10 unit The following checks should be performed for both wire drive units left and right 1 Press the Purge key The gas solenoid
47. feedback information from the active wire feed head as to the wire feed speed and the arc volt age The control board compares the feedback infor mation with the user command signals and generates the appropriate signals to control wire feed speed arc voltage and gas flow The current sensing switch and ground lead protector are connected to the control board via plug J1 The current sensing reed switch closes when welding cur rent is established which signals the control board to change from the run in welding parameters to the pre set welding wire feed speed and arc voltage If the ground lead protector is activated the trigger circuit will be disabled and the WFS display will show GLP DH 10 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 F F w 9 1 gt 2 2 EIS 2 1 Return to Section Return to Master TOC E 4 THEORY OF OPERATION E 4 FIGURE 3 WIRE FEED HEADS AND RECEPTACLES SOLENOID 0 TO GUN TRIGGER AND DUAL PROCEDURE WIRE LEFT INPUT CABLE WIRE FEED HEADS AND RECEPTACLES The leads to the drive motor gas solenoid and the tach hall effect device are brought into the control box via the wire drive receptacles These two 14 pin receptacles also house the gun trigger leads the elec trode voltage sense lead and the leads for the option al remote with dual procedure capabili
48. is missing or low check the leads and connections between the solenoid and the control board See the Wiring Diagram If the leads and con nections are OK the control board may be faulty If the 10 VDC is present at the solenoid leads and the solenoid does not activate the solenoid may be faulty Normal solenoid coil resistance is approximately 22 ohms The solenoid s can be further checked by disconnecting the solenoid leads from the DH 10 wiring harness and applying an external 12 VDC supply to the leads If the solenoid does not acti vate the solenoid is faulty Reconnect all disconnected leads Install the wire drive cover 31 TROUBLESHOOTING REPAIR F 31 COMPONENT REPLACEMENT PROCEDURES DISPLAY PC BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory war ranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833
49. kit con nect 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 quick connects are provided with the kit for installation on 3 16 in 5 mm 1 0 hose Customer to provide appro priate clamps The feeder connectors self seal when disconnected DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o F F w a gt 212 EIS 1 Return to Section Return to Master TOC A 9 Shielding Gas WARNING 28 CYLINDER may explode if damaged e 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 electri cal circuits 3 SEE AMERICAN NATIONAL STANDARD 2 49 1 SAFETY WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY BUILDUP OF SHIELDING GAS may harm health or kill Shut off shielding gas supply when not in use The customer must provide a cylinder of shielding gas a pressure regulato
50. 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 CAUTION 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 SPINNER NUT ZA rTrIE WIRE SPRING LOADED ARM DH 10 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O o F F w 9 a gt 21e EIS 1 Return to Section Return to Master TOC 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 jam causing a birdnest 3 Insert the free en
51. result in damage to the machine SQUARE WAVE TIG 275 7 ur pjnoo 10 0161900 eu u Aew pue jo y eouis pue jaaa pieoq 2u199 3 ujoour JO pepi o4d si Stu 9H159 3 U OOUI jou 5149804 2 pieog M 5 jag 1 01510089 ou seunsse 9119811 0901 JALON 522066 4 7 95 990228 S6 L 7 NOLLJ3NNOJ NOWWOI AN 031312395 3SIMH3H10 53730 00991 530010 u38W N 3003 NOWWOJ V O9NIAVH S OHINOJ 30 AULINIHII HO NOIL23NNO2 ONNOHO HlIHV3 INIOd dans 031319395 3SIMH3H10 53791 1 5 0 590151539 SLNANOdWO9 129 3 3Hl MOHS LON ASW NVHOVIO SIHL 031319395 3SIMH3H10 SS37Nn 08 220 1030 5901199999 04908 31379002 9 JO 111189 JHL NOIL23NNOO LAN 3991310 A ddns y 16613 610845 6214123713 9 1133449 LNOHLIM 39NVH2 AYW 09908 11028412 O31NIHd Y NO ABIID2HIJ HO SIN3NOdWO3 JINIS 813891 NOILYWYOSNI 1983N39 PTS
52. running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 ELECTRIC AND um MAGNETIC FIELDS ES may be dangerous 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 vaporiz ing 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 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving HP Exposure to EMF fields welding have other health parts when starting operating or repairing equipment effects which are now not known welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit In some cases it m
53. setup or changing drive roll and or guide tubes Welding power source must be con nected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should operate this Equipment Observe all additional Safety Guidelines detailed throughout this manual DUTY CYCLE The DH 10 models are rated at 6096 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 com ponents being used and for general operator prefer ences 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 OPERATION Setting the DIP Switches The DIP switches are each labeled with an arrow showing the on direction for each of the 8 indi vidual switches in each DIP switch 81 and S2 The functions of these switches are also labeled and set as described below Pwr Sources Security HEAD1 HEAD 2
54. ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 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 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 Also see item 1 b Mar 95 Return to Master Return to Master TOC Q gt SAFETY ili 7 WELDING SPARKS gt 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 fi
55. 0331 z1031 11 03 at 810310 5 01037 6031 8037 037 9034 TD He lt 31 03H 9 G9ET 8031 037 037 2031 1031 He 8 086025 1 tet se H3093H 5 082025 1 orr lt 845 10 45 10 94810 lt 9145 10 2 466 15 1 645104510 10 24810 19 48 10 P SBEZIS I 14510 tr 1 661211 2 zg 1d 82 059615 c 112 89 O 0S 49007 v 9 899915 13 99 562 09 1 LI S g 01 3 69 29 T9 9 NOLLVOIHLLN3QI ON Lud Q 03H L 1 a LX 18 5 a eeu 4431 9031 S031 o Op 1 m h gt gx 1 5 2 m gt 45 n y 166107 5 AVIdSIQ H G 9 DOL 18 0 uunjeH SOL uin1 ti DH 10 LINCOLN D A R J 33 83 7031 O 10870 EJ DOL 4 0 uunjeH SOL DOL 0 uunjeH SOL uonoesg DOL 0 uunjeH SOL uonoesg 31ON L10139 1 5 2 97 Board Layout 17797 1 Return to Section Return to Master TOC ENCODER po 027 210 r E olo 3 2 E M ARN 5 5 N N 55 17 HE AI S gt I TNAM 5 5 dE i O PEE E R e 0
56. 2 8 VDC is present the display board may be faulty The control board may be defective The control board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 5 F 11 TROUBLESHOOTING AND REPAIR F 11 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued The wire feeds for a few seconds 1 Make sure the electrode and 1 Make sure the 21 lead has Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o F F w 9 a gt elg EIS 1 Return to Section Return to Master TOC and stops The voltage display reads less than 8 VDC while the wire is feeding The dual procedure switch is not functioning at the gun on either side of the DH 10 The dual procedure switch func tions properly when attached to one side of the DH 10 but will not operate on the other side work cables are connected securely and properly Make sure the 21 lead is con nected correctly at the power source Make sure the power source is operating correctly and capable of pu
57. 2 x18 C x25 7 TA lt i xs RESISTORS Ohms SAV pel 5av Bev T4 T4 8 Sov e 58 50 ET Sav 7ARCIBI Sov DIODES 1A 488 MC14505 68HC71E9 a 744373 74HC373 485 0 seg B Vas Vss 5 d i d PRINTED CIRCUIT h 57 COMMON CONNECTION NGEABILITY OF COMPLE GRAM MAY SHEE gt m S OR CIRCUITRY DF CON MMON CODE SHEET 10F 2 FRAME CONNECTION NUMBER LT EARTH GROUND CONNECTION V NB PRESENT DN THE Dr12 MODELS 989 5026 5 2 97 G3040 1 5 2 97 DH 10 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail able from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LINCOLN P 0 5 ELECTRICAL DIAGRAMS G 5 Control Board Schematic Sheet 2 G3040 2
58. 3 9 DRIVE ROLL AND GUIDE TUBE KITS 5 5 Table 2 gives a listing of all of the Drive Roll and d Guide Tube Kits that are available for the DH 10 p Dual Head Wire Feeder TABLE 2 DRIVE ROLL AND GUIDE KITS e Wire Size 4 Roll 4 Roll DH Drive Single Drive 4 Driven 2 Driven Solid Steel Electrode 0 023 in 0 025 in 0 6 mm 1505 0305 655 0255 0 030 0 8 1505 0305 655 0305 0 035 0 9 mm 1505 0355 655 0355 O 0 040 in 1 0 mm 1505 0455 655 0355 5 r 0 045 in 1 2 mm KP1505 045S KP655 052S 8 0 052 in 1 4 mm KP1505 052S KP655 052S 9 gt 1 16 in 1 6 mm KP1505 1 165 KP655 1 16 8 8 5 64 2 0 1505 5 64 655 3 32 5 5 3 32 in 2 4 mm KP1505 3 3 3 c 2 Cored Electrode 0 030 in 0 8 mm KP1505 035C C 0 035 0 9 1505 035 655 035 0 040 1 0 1505 045 655 035 0 045 1 2 1505 045 655 052 0 052 1 4 mm KP1505 052C KP655 052C 1 16 in 1 6 mm KP1505 1 16C KP655 1 16 9 9 0 068 1 7 1505 068 655 3 32 5 5 5 64 2 0 1505 5 64 655 3 32 3 32 2 4 KP1505 3 22 gt 7 64 in Lincore Hard Facing 2 8 mm 1505 7 64H 8 7 64 in 2 8 mm KP1505 7 64 5
59. 3 17797 1 slg 515 518 ITEM REQ D PART NO DESCRIPTION 9 61 8668 11 1 52 3a 212 2 513490 19 1 8 20 01 02 03 04 4 12705 23 1 5818 E 619555 8 RIGHT ANGLE HEADER 1 82 2 51 3400 4750 475 1 4W 4 7 95 17797 1 NOTE Lincoln Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine DH 10 LINCOLN amp M17797 1 n Return to Section TOC Return to Master TOC 5 DH 10 LINCOLN amp DOL J91Se N 01 UuunjeH DOL J91Se N 01 UuunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 Winey DOL uonoes 0 DOL uonoes 0 uumeg DOL uonoes untu DOL uonoes uumeg
60. 501 Control Cable Only Consists of a 9 conductor control cable with 14 control cable plug without electrode cable and is available in lengths of 10 ft 3 m 17 ft b 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 mm 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 mm elec trode cable DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 F a gt 8 8 5 Return to Section Return to Master TOC A 10 K1503 Consists of a 9 conductor control cable with a 14 pin plug and 2 0 67 mm 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 mm 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
61. 8 2 1 4W 05 1 052 053 D 18 m 1 Hi 51 39 2 1 051 4 05 STAARE Fely wr E 51 75 1744 042 047 3 o FESI I 950 5 Biv l 4 97 l 04 8111 8119 8135 51 100 i 4W 02 1 022 023 024 026 13 CT k 1 a LH M R141 R 151 R200 R2 036 037 038 039 040 dQ0 9 38i8 5 A R202 04 8205 048 E 4 LS 2 esr sau O R207 82 16 R2 17 R2 18 R2 20 9919 esy 57 O T R220 R221 8222 R223 07 1 072 2 Fam BEN of pra Em a R107 R148 R 178 023 074 075 076 4 dat Gi B 8 R113 R145 R183 R189 027 028 079 3 6 G x 90 esm 5 8123 BEN 1 980 E su z 3 1 2 Tel EE ali R120 R121 R167 R168 R177 NB 2 M A 180 sur ord R N B 1 p mur Ci 37 R 178 N B 1 1 Gi TT 619 Teal ea 8139 8140 E 1 4W N B 2 1 4 Satu dm R W 2500 OHM RESISTOR N B 1 C8 Hat 1 R152 R154 15 1 4W e 229 b ri C F out te dur hs R156 R158 05 3 3 En d 2E 620 ta sa 8164 8170 R175 7332 1 44 3 13 at 1 zy SE UM Hu j 8155 8172 44 2 1 4W 2 u Leg 204 134 Y t R 100K 1 4W sat 15 m T a R 5 W
62. ANCE SECTION D 1 9 TABLE OF CONTENTS MAINTENANCE SECTION 0 Maintenance aede dabei deba ect RR kai es Section D o Safety Preca tfionS a EL a A a a a D 2 Routine Maintenance oup VOTE EE RM PAR aaa 0 2 5 Drive Rolls and Guide Tubes D 2 2 Wire Reel Mounting Readi Reels and 10 to 30 Ib 4 5 to 14 kg Spools D 2 Avoiding Wire Feeding Problems D 2 Periodic Maintenance 2 55 awed EAR D D 3 Wire Drive Motor and Gearbox D 3 Gun and Cable Maintenance D 3 Procedure for Removing Feedplate from Wire Feeder D 3 O 0 9 5 O 0 8 5 O 0 8 2 10 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 OJo lt a gt 212 5 Return to Section Return to Master TOC D 2 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill
63. ATT 0 5 OHM RESISTOR 21 L 880 i 180 1 4 CT 4 OCIS 8 SOLID STATE RELAY l E eid x l 9818 F 8 5 11 1 4W o vm 1028 4 457 T gt 3185 8187 5 gt OJO SIRE 809 a CL EX XX LOX 1 SI 52 SPST SLIDE SWITCH PACKAGE a eI lt x 260 4 2N4401 ozs 1 TRANSFORMER 1 NPN IRANSISTOR sp cma 1 2 N CHANNEL FET SS o ES ps Ean XI Be 1 TPI 1 T13640 16 2 244403 ar X g el tot 1 EX 010 Hoah i X J 4 5 T 1 1 4 Late CSS 2 TRAI oot x x 1 X2 1 2 5 Le MCU SS 1 H S o z i 18 ae 2 1 1 8 14 PIN SS Len uu HA aX Ce X4 X17 X18 3 24 QUAD 2 INPUT SCHMITT TRIG NAND 55 R RB R47 8 2870 257 174 o X XK X x d H X5 X7 X10 X16 2 11 14 PIN QUAD COMPARATUR R6 1 4752 47 5K 1 4W Up 4 RM TTT Like slt 1 4 1 224 R7 R35 R39 R75 876 R90 R95 13 1001 IK 1 4W c E ji 2 zi x8 X9 2 5 LIRI STATE OCTAL LATCH SS R101 R129 R134 8138 8240 8 L P EU TTTTT i 4 Xii 1 4 TC CMOS XCVR ELA485 55 R241 3 8 Da 211511 61 18r def qat is mL X12 1 20 AMPLIFIER R10 2 1004 IM 174 EIE Wa 86118118 1981 1811814181 ar 080 21 1 10
64. C Return to Section TOC O10 OJo F CIS a gt g 2 5 1 Return to Section Return to Master TOC Return to Master TOC 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 touch es the wire feeder frame while the electrode is electri cally 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 sec onds See Display Control Keys this section Displayed WFS display indicates that the Grounding Lead Protector circuit was activated due to excessive current flow into the wire feeder fram
65. CER lt gt wm di SCREW olo m PROCEDURE 6 Carefully remove the PC board from 912 the front panel Q 9 1 Remove input power to the DH 10 unit 7 Remove the harness plug from the 2 Using the 5 16 nutdriver remove the encoder PC board 515 two screws from the top of the control 2 2 panel 8 Install the harness plug into the new encoder PC board 3 Lower the control panel 9 Assemble the PC board into the front 4 Using the 5 64 in Allen wrench remove panel and secure with the washer and the control knob spacer and felt nut previously removed washer from the encoder board that is to be removed See Figure F 8 10 Assemble the felt washer spacer and control knob onto the shaft and secure 5 Using the 1 2 in wrench remove the with the 5 64 in Allen wrench nut and washer from the control shaft 11 Replace the control panel Return to Section TOC Return to Master TOC DH 10 LINCOLN 5 37 TROUBLESHOOTING REPAIR F 37 WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory war ranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual
66. DIB LED22 s o 334 prp AU Qn 100 ND 4HC165 5 V MC14489 5 14489 5av 5 LE oe Te roc gt gt N N M 558 335 8 Su J 100 39V 2 L d N 0 500 55 Lee 5 5V B LED13 LEDI7 1155 Vs 588 D E V9 C VE VE 100 v 18 DATA OUT x 8 gt 837 Le A x MC14489 o dr 100 5 B EDM 020 528446 q R38 p d N 2 522104 120 8 8 28 4 Was ilg VE N a x 839 4 Vdd 3 Vad 3 5 S Bal SS zs o 1 2 2 4 Lg Lg gaz 8 OUT 7 3 2 23 8 S 85 AT 4 201 g 88 8 RC GND HEXINV 1717 meissa Sav 1 Ss 7 500 27552 c8 50 Ma NG 5 de Le m E AL m rj Vss 4 5 4 LC 5 5 p en 5 gt BS 500 sea 500 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail pre LINCOLN able from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could
67. E SENSE gt TO BRASS BLOCK VOLTAGE SENSE NOTES TO SOLENOID gt TO SOLENOID N A S ADS THE JUMPER SHOWN 8s TO SOLENOID SHIELDED SHIELDED SOLENOID THE OPTIONAL REMOTE SWITCH INTERFACE TO DUAL PROCEDURE SWITCH Y TEC E TO DUAL PROCEDURE SWITCH o MODULE NOT SHOWN MUST BE INSTALLED TO DUAL PROCEDURE SWITCH TO DUAL PROCEDURE SWITCH 2 O J5 ON THE CONTROL BOARD FOR TO TRIGGER TO TRIGGER THE DH 10 TO TO TRIGGER CONTROL TO TRIGGER c G3041 1 CONTROL P C BOARDS DO NOT CABLE 9159 5 5 8 5 5 NEWER MODELS o N C WHITE LEADS 560 AND 561 MAY NOT BE 0919 LABELED EARLIER MODELS EJE L10218 ala 11 21 97J a NOTE This diagram is for reference only may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclo sure panels of your machine DH 10 ELECTRICAL DIAGRAMS ES Wiring Diagram Wire Drive M17871 P5 11 21 97J 0000000 2992222 Return to Section Return to Master TOC 55 Qv3H SEQUENCE DUAL PROCEDURE TRIGGER AND SWITCH RIGHT GUN RECEPTACLE ozs o gt 009 gt 615 595 619 108 4 199 gt 099 gt S gt 099 19 9 a gt 8 8 gt n e n gt gt gt 668
68. ENDED MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued An message is displayed when the DH 10 is powered up message is displayed When the gun trigger is activated the wire feeds and arc voltage is present but gas does not flow 1 This indicates an error has been detected Press any key to return to normal operation Check all the settings to make sure they are within the acceptable ranges If the Er message is still displayed remove the input power While pressing the Timer and Control keys turn on the input power The message Ln should be displayed Leave on for 5 sec onds Remove the input power Note All the settings will be removed The Ground Lead Protector cir cuit has activated due to exces sive current flow in the wire feeder frame This can be caused be the electrode coming in contact with the wire feeder frame or poor connections in the work cable circuit The wire feeder will be disabled Remedy the grounding problem and resume normal operations by releasing the gun trigger and then closing the gun trigger Make sure the gas supply is adequate and connected cor rectly to the DH 10 1 The control board may be faulty The GLP reed switch may be faulty This switch is normally open and should only close when current is flowing through the green lead and wire feeder frame It may be stuck closed See the Wiring Diagr
69. LTs WIRE SPEED TMER CONTROL THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA 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 DH 10 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo o F F w 9 a gt elg EIS
70. ON 1 2 3 4 5 6 7 S1 2 3 4 5 6 7 S2 o 51 52 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 follow ing 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 5 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 HEAD 1 HEAD 2 4 1 2 3 4 5 6 7 52 52 For 1497 1 DH 10 Boom 1499 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 settin HEAD 1 HEAD 2 9 n 1234567 52 Oo 2 1497 2 10
71. Q gt Return to Master i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 1 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 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 FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be
72. R 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 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 025 116 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 Excluding Wire Reel More detailed dimensions and weight information can be found in Section F of this manual 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 CONTROLS BOOM MOUNT SPEC TYPE INPUT POWER PHYSICAL SIZE TEMPERATURE RATING Dimensions Height Width Depth Weight Operating Storage K1496 1A DH 10 40 42 10 14 80 in 14 20 in 4 20 in 18 0 108 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 40 Excluding Wire Reel
73. Return to Master Return to Master TOC O O o 9 gt E 2 5 Return to Master View Safety Info View Safety Info gt 2 2 o 2 gt View Safety Info DH 1 0 Heads amp Controls RETURN TO MAIN INDEX SVM143 A March 1999 Boom Mount or Bench Models 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 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 LINCOLN amp World s Leader in Welding and Cutting Products ELECTRIC Sales 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 Premier Manufacturer of Industrial Motors Return to Master Return to Master TOC
74. Return to Section TOC Return to Master TOC O10 o Fle lt 9 a gt Gje EIS 1 Return to Section Return to Master TOC CLAMPS NOTE WIRE FEEDER SHOWN WITH DRIVE MOTOR ASSEMBLY REMOVED FOR CLARITY PROCEDURE Remove input power to the DH 10 unit Using the 5 16 in nutdriver remove the wire drive cover Locate the gas solenoid assembly and remove the input gas lines See Figure 7 Label and remove the four leads two for each solenoid connected to the solenoids Remove the two rubber hoses and clamps from the gas solenoids Be careful not to damage the rubber hoses Using the 5 16 in wrench remove the two screws that mount the solenoid assembly to the rear panel of the wire feeder DH 10 LINCOLN 8 SOLENOIDS MOUNT Remove the solenoid assembly from the DH 10 unit Using the Phillips head screwdriver remove the two screws holding the solenoid to the bracket Remove the solenoid Mount the new solenoid onto the bracket using the two Phillips head screws Install the solenoid assembly into the DH 10 Connect the two gas hoses Connect the four wires previously removed Be sure the leads are connected to the correct solenoid Install the wire drive cover and connect the input gas lines Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
75. SVM REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to addi tional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 Return to Master Return to Master TOC o 0 E Return to Master ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section u u u u u u Section G Wiring Diagram Control ET02 18 2 tre tree reete tee e ap t ree tege G 2 Wiring Diagram Wire Drive M17871 ui G 3 Control Board Schmatic Sheet 1 03040 1 G 4 Control Board Schmatic Sheet 2 G3040 2 su G 5 Display Board Schematic 10138 tert eden tr inerte Esos G 6 Encoder Board Schematic 522066 G 7 Control Board Layout G3041 2 nnne nns G 8 Display Board Lay
76. The voltage displayed while weld ing 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 Ifa 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 con nect 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 Metric English Wire Feed Speed Display Selection 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 S1 switch 6 OFF z IPM as shipped Pwr Sources Security 1 2 3 4 5 6 7 51 51 switch 6 m min Pwr Sources Security ON 1 2 3 4 5 6 7 Si 51 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 set ting 51 switch 7 Labeled 4 When 4 Step trigger mode is selected on the DH 10 keypad See Keypad and Display Operati
77. UNCTION PROBLEMS Continued The DH 10 is dead The displays and LEDs on the keypad are off The green and red LEDs on the control board are not lit The displays and LEDs on the key pad are off The green and red LEDs on the control board are both blinking normally at about one sec ond intervals The displays and LEDs on the key pad are off The green and or red LEDs on the control board are blinking at a very fast or erratic rate The wire feed is consistent and adjustable but operates at the wrong speed 1 Make sure the DH 10 is con nected properly to the power source Make sure 42 VAC is being applied to the DH 10 at the input receptacle terminals A and B Check the wires and connectors 411 and J3 between the dis play board and the control board for loose or faulty connec tions Make sure the DH 10 is con nected properly to the power source Make sure 42 is being applied to the DH 10 at the input receptacle terminals A and B Make certain the DIP switch S1 is correctly set for the wire drive and gear ratio See Head Selection 1 The input rectifier bridge may be faulty Check for 42 VAC at the red leads Also check for at least 42 VDC at leads 542 to 500 See the Wiring Diagram The control board may be faulty Check leads 512 1J3 to 500 343 for the presence of 12 8 VDC If the 12 8 VDC is not present the control board may be faulty If the 1
78. Wire Drive Ratio Selection 5 5 Wire Feed Roll Kits u a nce pede ed c e 6 2 Procedure to Install Drive Roll and Wire Guides es runa astres A 6 gt Single Drive 4 Roll Kits KP655 KP656 7 2 DH Drive Roll Kit Installation 1505 1507 A 7 Gun and Cable Assemblies with Standard Connection A 7 GMAW GUNS senem na dear i ie dade a d 4 mos p aoa 7 Guns 7 Gun Cable Connection with Standard Connection 8 Gun and Cable Assemblies with Fast Mate Connection 8 GMAW GUNS a a a ana aa Eea ar d d G aea aa rte a A 8 Gun Cable Connection with Fast Mate Connection A 8 DH Double Head Drives Water Connections For Water Cooled 5 A 8 DH Double Head Driv s EO aed RU 8 Single Head Drives 679 A 8 GMAW Shielding A 9 Electrical Installati
79. a jumper plug or a K1558 1 remote switch interface module must be installed into connector J5 on the control board Check the connections between the drive motor and the control board See the Wiring Diagram Check the tach leads between the tach hall effect device and the control board See the Wiring Diagram 1 For feeders using the Remote Switch Interface Module make sure there is continuity zero ohms in the circuit connecting the two terminals marked 1A on the remote switch interface P C board Also check that there is continuity in the circuit connect ing the two terminals marked 2A Make sure the gun trigger cir cuits are working properly See the Wiring Diagram Perform the Wire Drive Motor The control board may be faulty Perform the Wire Drive Motor The control board may be faulty Perform the Tach Adjustment and Feedback Test Perform the Wire Drive Motor CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 5 F 6 TROUBLESHOOTING AND REPAIR F 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued No control
80. ach between the control box and the wire drive unit 1 Drill the required holes in the mounting surface par tially install 1 4 20 screws 2 Mount the box 3 Tighten the screws not be bent sharply as it comes from the unit See FIGURE A 2 Procedure for setting angle of Feed Plate lin the z 10 50 Operation section of this manual zo CLEARANCE V P i PAS 1 FIGURE 1 D 27 1 5 16 18 THREAD 2 25 lt 1 i 1 3408 13 75 12 75 6 00 10 00 11 00 1 FEED PLATE DOOR OPEN 2 3 00 tot Z 1 Y Y BOTTOM FRONT f 10 50 gt lt 500 2 68 ma 263 ra 18 50 5 25 14 50 DH 10 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 OJo 5 a gt gle 5 1 Return to Section Return to Master TOC 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 con nected 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
81. ach head Also DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo o F F w 9 gt 212 EIS 1 Return to Section Return to Master TOC E 3 THEORY OF OPERATION E 3 FIGURE 2 INPUT RECEPTACLE CONTROL BOARD AND OPERATOR CONTROLS SOLENOID GUN TRIGGER AND DUAL PROCEDURE WIRE DRIVE MOTOR LEFT TACH FEEDBACK INPUT CABLE WIRE DRIVE RECEPTACLE RECEPTACLE CONTROL BOARD 22 SOLENOID TO GUN TRIGGER AND DUAL PROCEDURE WIRE RIGHT WIRE DRIVE RECEPTACLE DRIVE 1 MOTOR TACH FEEDBACK CURRENT SENSING REED SWITCH GROUND LEAD PROTECTOR IN VOLTS WFS DISPLAY ENCODER ENCODER BOARD INPUT RECEPTACLE CONTROL BOARD AND OPERATOR CONTROLS The 42 VAC input voltage is applied to the DH 10 through a 9 pin amphenol type receptacle The remote control and trigger leads are also accessed through this 9 pin receptacle The 42 VAC is rectified by a full wave bridge and sent to the control board This DC voltage is coupled to an onboard switching power supply The switching power supply manufac tures regulated 12 8 VDC and 5 0 VDC regulated supplies for the control board Refer to Figure E 2 The control board receives commands from the user operated controls such as the volts encoder the wire KEYPAD feed speed WFS encoder and the keypad It also receives
82. acle 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 con trol 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 instruc tions shipped with the kit INSTALLATION A 11 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 attop Attach gas supply to 5 8 18 female inlet of reg ulator Shielding Gas jn this section K1449 1 Dual Procedure Remote Control Provides remote rotat
83. am The control board may be faulty Perform the Gas Solenoid Test The control board may be faulty CAUTION DH 10 LINCOLN 5 If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o F F w 9 a gt elg EIS 1 Return to Section Return to Master TOC F 13 TROUBLESHOOTING AND REPAIR F 13 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued The preset arc voltage does not match the actual voltage The preset WFS does not match the actual WFS Make sure the power source is set for remote voltage control Make sure the DIP switches on the DH 10 control board are set correctly for the power source being used Check the wiring and connec tions between the tachometer and the control board See the Wiring Diagram Make sure the DIP switches on the DH 10 control board are set correctly The control board may be faulty 1 The control board may be faulty The control cable between the
84. and Feedback Apply a light coating of high temperature anti seize lubricant such as Lincoln Electric E2067 graphite grease to the tip s threads CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 5 F 15 TROUBLESHOOTING AND REPAIR F 15 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS The welding arc is variable or 1 The electrode or work cables 1 1 the drive rolls are turning hunting may have faulty connections erratically perform the Make sure the welding proce dures are correct for be process being used Return to Section TOC Return to Master TOC Make sure the switches on the control board are set correctly The gas shielding may not sufficient or contaminated The power source may be faulty Poor arc striking with sticking or 1 Make sure the welding proce 1 If the drive rolls are turning plast offs The bead may be nar dures are correct for the erratically perform the row ropey and have porosity process being used Drive Motor Test Return to Section TOC Return to Master TOC Adjustment and Feedback The gas s
85. 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 mat ing receptacles on the back of the wire feed unit connection box Feeder Head 1 uses the left recep tacle 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 Atthe control box end connect the 14 pin connec tors 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 Atthe 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 Readi Reels s
86. ate 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 INSTALLATION 4 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 con venient location close to the wire drive unit which will enable the desired control cable to re
87. ay 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never the electrode lead around your body 1 f Do not put your hands near the engine fan Do not to override the idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode work cables If the electrode cable is on your right side the work cable should also be on your right side AR Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 LINCOLN 5 Return to Master TOC Return to Master TOC Q 0 Return to Master SAFETY 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
88. ble friction brake for control of overrun Two 2 in spindles standard on DH 10 Bench models When a 2 in 51 mm spindle is used with Readi Reels or coils not on 12 in 305 mm O D spools an adapter is required Coil Adapter K1504 1 Permits 50 to 60 Ib 22 7 to 27 2 kg coils to be mounted on 2 in 51 mm O D spindles K435 Permits 14 Ib 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 Ib 14 kg and 22 10 kg to a 2 in 51 mm spin dle Durable molded plastic one piece construction Designed for easy loading adapter remains on spin dle for quick changeover K438 Adapts Lincoln Readi Reel coils of electrode 50 to 60 Ib 22 7 to 27 2 kg to a 2 in 51 mm spindle K1634 1 Wire Reel Enclosure Kit Provides the neces sary parts to cover the wire and protect if from exces sive dirt and contamination This kit is not for use with 60 Ib coils most 30 Ib 15 kg 44 Ib 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 DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 5 Return to S
89. cond Light indicates spot time is being displayed settable 0 0 as shipped to 199 9 seconds 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 Third Light indicates burnback time is being dis played 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 dis played 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 dis played and set by the appropriate encoder knob Conirol 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 RUN IN Speed and Voltage are displayed VOLTS WFS After Weld procedure is set Run in procedure should be set to optimize arc starting CONTROL 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
90. contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 RETURN MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety 22225250209 Re Installation 24 Section Technical Specifications DH 10 Complete Units Controls amp Heads A 2 General Description 3 Recommended Processes and Equipment 3 Safety Precautions A 4 Installation of the DH 10 Boom Mount W
91. d 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 A WARNING 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 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 posi tion 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 set ting 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 OPERATION B 10 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 st
92. ding current is flowing the voltage at pins 3J1 to 4J1 should be approximately 0 VDC The reed switch should be closed If the voltage is not at or near OVDC the reed Switch is faulty The control board may be faulty The control board may be faulty The display board may be defective CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 5 Return to Section Return to Master TOC Q 2 0 TROUBLESHOOTING REPAIR Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued The Cold Feed Forward and or the Cold Feed Reverse buttons do not function properly Both motors operate properly in other modes The Gas Purge button does not activate the gas solenoid The gas solenoid operates properly in other modes The Feeder button does not func tion The feeder head can be selected by pulling the appropriate gun tr
93. down B 11 Wire Feed Overload Protection B 11 Grounding Lead Protector B 12 Explanation of Prompting and Error Messages B 12 2 2442 enira C 2 Section D Safety Precautions D 2 Routine Maintenance D 2 Wire Reel Mounting Readi Reels and 10 to 30 Ib 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 5 Test Procedures F 17 Component Replacement
94. e When the GLP circuit OPERATION DH 10 LINCOLN P B 12 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 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 n 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 Displayed on WFS display indicates wire feed overload XX indicates time remaining in seconds before unit resets automatically See Wire Feed Overload Protection n this section and Avoiding Wire Feeding Problems the Maintenance section 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
95. e 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 5 S1 switch 8 ON Low Security mode ON Pwr Sources Security L 4 2 3 4 5 6 7 8 Si 51 switch 8 OFF Low Security mode OFF as shipped 51 Pwr Sources Security r M4 Inr 3 45 6 7 51 S1 A 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 Pwr Sources Security m M 4 2 3 4 5 6 7 Si 51 51 switch 5 OFF High Security mode OFF as shipped i Pwr Sources m M 4 1 2 3 4 5 6 7 51 00808 5 OPERATION B 5 KEYPAD AND DISPLAY OPERATION LINCOLN DOUBLE HEADER DH 10 V vo
96. e is required for each head K1498 L Includes a control cable with 14 pin ms style connection on each end and INSTALLATION A 3 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 1497 1 16 ft 4 9 m Control Cable Same as 681 16 16 ft 4 9 m Control and Weld Cable Same as K1498 16 K1521 2 includes DH 10 Control Same as 1496 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 Innershield processes The wire type and size range for the wire drive used and gear ratio change selected are given in the Specifications Recom
97. ection Return to Master TOC Q 2 0 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 466 1 Connection Kit or Magnum 550 with 613 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 recept
98. ection 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 Keyslin this section If set to 0 0 seconds spot mode light selection will be skipped Trigger closure ener gizes 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 sole noid 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 Keyslin this section DH 10 LINCOLN P Return to Section Return to Master TOC Return to Section TOC O10 o F F lt 9 a gt elm EIS 1 Return to Section Return to Master TOC Return to Master TOC Display Control Keys TIMER 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 dis played on the speed display The times are set using the Voltage encoder knob 4 PREFLOW 5 ft see o 5 2 Se
99. ecurity Head 1 or Head 2 connector Both settings are con 4 figured the same way 123456 7 8 51 DH 10 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o lt a gt gle 5 1 Return to Section Return to Master TOC Pulse Power 500 Pwr Sources Security M4 1 2 3 4 5 6 7 8 51 Pwr Sources Security M4 1 2 3 4 5 6 7 51 Also 51 Other Power Source Independent Pwr Sources security M4 V300 PRO 1 2 3 4 5 6 7 51 51 Set the switches as shown for all other power sources which can be controlled with a 10 poten tiometer circuit DH 10 features operate as described elsewhere 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 increments of 0 02 The number 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 actu al arc voltage
100. ecurity 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 51 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 proce dures for both Feeders Then setting 51 DIP switch 8 inside the DH 10 Control Box ON or OFF and restor ing 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 nor mally 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 Selectionlin this section High Security mode can only be activated or deacti vated by shutting off the input power to the DH 10 with all settings as desired for both Procedures for both Fe
101. eders Then setting S1 DIP Switch 5 inside the DH 10 Control Box ON or OFF and restoring input power See High Security Mode Selection in this section OPERATION 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 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 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 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 Ib 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter FIGURE The Spindle should be located in the LOWER mount ing 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 re
102. eps 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 set ting 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 reg ulator flow adjusting Key should be set to maxi mum 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 con stant 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 in this section DH 10 LINCOLN 5 Return to Section Return to Mas
103. es to the power source This kit includes a feeder adapter plate that allows the feeder to rotate on top of the power source The feeder can be easily separated from the swivel mount at any time This option is compatible with the K1556 1 Light Duty Caster Kit DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O lt a gt gle 5 1 Return to Section Return to Master TOC C 6 ACCESSORIES K1556 1 LIGHT DUTY CASTER KIT This option provides 4 casters and required hard ware to mount it to the Power Feed 10 This option is compatible with the K1557 1 Swivel Mount K1555 1 INSULATED LIFT HOOK For applications where an insulated lift hook is required This kit provides an easily installed heavy duty insulated lift eye that mounts to the wire reel stand mast See the instructions provided with the kit for installation 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 Ib coils most 30 15 kg 44 10 fiber spools and smaller coils will work The kit includes a 2 part reel cover a Magnum conduit adapter for the incoming end of the wire feeder feed plate and a short length of Magnum conduit to go between the reel cover and the feedplate DH 10 LINCOLN 5 SECTION D 1 MAINTEN
104. eter or 14 Ib 6 kg Innershield Coils FIGURE B 1 The Spindle should be located in the LOWER mount ing hole For 8 in 200 mm spools a K468 spindle adapter must first be slipped onto spindle For 13 14 Ib 6 kg Innershield coils a K435 Coil Adapter must be 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 OPERATION B 9 To Mount a 50 to 60 Ib 22 7 to 27 2 kg Coil Using K1504 1 Coil Reel For 50 to 60 Ib 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 elec trode 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
105. eturn to Master TOC Check the wiring and plug con nections between the encoder boards and the control board Plug J2 See the Wiring Diagram Neither encoder control knob 1 Make sure the DIP switches on 1 Perform the Encoder Board functions the control board are NOT set for the high security mode The high security mode disables the 2 The control board may be encoder controls See the faulty Operation Section olo O o F F w PEN a gt em EIS 1 Check the wiring plug nections between the encoder boards and the control board Plug J2 See the Wiring Diagram CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 5 Return to Section Return to Master TOC Q 2 0 5 10 TROUBLESHOOTING REPAIR F 10 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION F
106. ew on right face of feedplate Install gear onto output shaft and secure with flat washer lock washer and Phillips head screw which were previously removed Tighten the screw on lower right face of feed plate Install gear onto output shaft and secure with flat washer lock washer and Phillips head screw which were previously removed Re attach feedplate to wire feeder if removed in Step 2 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 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 A 6 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 in Accessories These kits are common with those used fo
107. for posi tive 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 GAS PURGE CONTROL 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 feed er and procedure 1 is the slowest acceleration and 5 is the fastest DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O o EE CIS a gt 8 8 5 Return to Section Return to Master TOC 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 S
108. ghout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories function problems feeding prob lems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled RECOMMENDED COURSE OF ACTION lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chap ter Refer to the Troubleshoo
109. hielding may not be sufficient or contaminated Make certain weld procedures Make sure the set screw in the and parameters are correct for connector block is in place and the process being performed tightened against the liner bushing Weld procedures and or para meters incorrect for process being performed The power source may be faulty olo O o F F w 9 a gt elg EIS 1 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC DH 10 LINCOLN 5 16 sf 5 J21SEMN J21SEMN 1 DOL uonoes UNY DOL uonoes DOL uonoes UNY uonoes 17 TROUBLESHOOTING REPAIR F 17 TEST PROCEDURES WIRE DRIVE MOTOR TEST WARNING Service and repair should only be performed by Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory warran ty For your safety and to avoid electrical shock please observe al
110. hing 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 Selection in this section and or Run In speed Refer to Display Control Keys n this section OPERATION 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 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 Loading 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
111. i 3 51 CV 655 DC 655 initial factory setting _ Pwr Sources Security M4 For K1563 2 LN 10 Boom 80 1250 IPM 2 00 31 8 2 3 4 5 6 7 81 High Speed Ratio set 52 Switch fol daB lows initial factory setting DC 250 HEAD 1 HEAD 2 Pur Sources 1 ON 12 3 4 5 6 7 8 82 1 51 400 ecurity For K679 1 Single Head Boom with 50 770 IPM pico MEM 1 27 19 5 m m Low Speed Ratio set S2 DIP Switch 123456758151 as follows bi HEAD ON 2 3 4 5 6 7 8192 DC 600 1 Pwr Sources o 2 3 4 5 6 7 51 For 679 2 Single Head Boom with 80 1200 2 00 30 5 m m High Speed Ratio set 52 DIP Switch as follows DC 650 PRO HEAD 1 HEAD 2 Pwr Sources vt 1 rN 2 3 4 5 6 7 91 L1 A Bau A NOTE Any single drive may be connected to the DE 1000 TA S
112. igger The Procedure button does not function properly 1 Check the connectors and wires between the display board and the control board for loose or faulty connections J11 and J3 Check the connector J10 between the keypad and the display board for loose corrections Check the connectors and wires between the display board and the control board for loose or faulty connections J11 and J3 Check the connector J10 between the keypad and the display board for loose connections Check the connectors and wires between the display board and the control board for loose or faulty connections J11 and J3 Check the connector J10 between the keypad and the display board for loose connections Check the connectors and wires between the display board and the control board for loose or faulty connections J11 and J3 Check the connector J10 between the keypad and the display board for loose connections 1 Perform the Keypad Resis The display board may be faulty The control board may be faulty Perform the Keypad Resis The display board may be faulty The control board may be faulty the Keypad Resis The display board may be faulty The control board may be faulty Perform the Keypad Resis The display board may be faulty The control board may be faulty CAUTION If for any reason you do not understand the test
113. in speed setting of 100 IPM or less is recommended for optimum starting Factory setting is near min rated speed B 7 OPERATION B 7 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 dis play 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 load ing 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 DH 10 display reads actual welding voltage from 0 0 to 60 0 VDC with automatic polarity indication
114. ing signal is NOT the Volts encoder board may be faulty Also check the lead and plug connections between the encoder board and the control board See the Wiring Diagram 8 While slowly rotating the WFS control check for a pulsing 0 to 5 signal from 3J2 lead 526 to 7J2 lead 527 If the 5 VDC supply IS present at the encoder board and the pulsing signal is NOT the WFS encoder board may be faulty Also check the lead and plug connections between the encoder board and the control board See the Wiring Diagram NOTE Pulsing means that as the control is rotated the signal will fluctuate from 0 to 5 VDC 9 Remove input power to the DH 10 unit 10 Reassemble the control panel Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O F a gt 8 8 5 Return to Section Return to Master TOC F 29 TROUBLESHOOTING AND REPAIR GAS SOLENOID TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory war ranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per f
115. ing 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 1450 4 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 exter nal equipment fume extractor etc To the module s isolated relay contacts which actuate when the feeder welding gas solenoid is activated representing weld ing 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 DH 10 LINCOLN 5 12 lt oF
116. ire Feeder Components 4 Wire Drive Speed Range Selection 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 Operati f uuu Section B Safety Precautions 2 Duty 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 Weldi x Sus ER debat ee B 10 Wire Reel Changing B 11 Loss of Voltage Sense Shut
117. kit See Gun and Cable Assemblies with Fast Mate this section for details Innershield Guns 126 and 115 gun and cable assemblies are avail able 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 DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 5 Return to Section Return to Master TOC Q 2 0 5 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 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 i
118. l safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the wire drive motor is receiving the correct voltage and is capable of running properly Either motor can be checked with this procedure MATERIALS NEEDED Return to Section TOC Return to Master TOC 5 16 in nutdriver Volt Ohmmeter O10 o F a gt 8 8 5 Return to Section Return to Master TOC DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo o F Cc 1 iz gle 5 1 Return to Section Return to Master TOC F 18 TROUBLESHOOTING AND REPAIR F 18 WIRE DRIVE MOTOR TEST continued FIGURE F 1 WIRE DRIVE MOTOR TEST TEST PROCEDURE Remove input power to the DH 10 unit Using the 5 16 in nutdriver remove the wire drive cover Locate the motor armature leads for the motor to be tested one black lead and one white lead Do not discon nect the leads See Figure 1 Apply the correc
119. llowing this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legiti mate PC board warranty claims Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o F F w 9 a gt els EIS 1 Return to Section Return to Master TOC F 5 TROUBLESHOOTING AND REPAIR TROUBLESHOOTING GUIDE F 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION drive motor turns when the gun triggers are activated The dis plays are lit and the correct input voltage 42 is applied to the DH 10 One side s drive motor does not turn although the arc voltage is present and the gas solenoid works and the gun trigger is acti vated There is NO control of wire feed Speed on one side only Both motors turn both gas solenoids operate and arc voltage is present The WFS can be preset FUNCTION PROBLEMS an error message appears on the wire feed 416 play the unit may be over loaded The indicates the time remaining in seconds before the unit automatically resets Make certain the dip switches are set correctly for the power source being used See Welding Power Source If the control board is G3041 2 or later
120. mended power sources are Lincoln Electric Company constant voltage power sources with 42 VAC auxiliary power and a 14 pin connector recepta cle At the time of printing these include CV 250 00 CV 300 400 CV 400 500 DC 400 655 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 DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo o F F w PEN a gt ele EIS 1 Return to Section Return to Master TOC A 4 SAFETY PRECAUTIONS WARNING 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 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 locat ed on the bottom of the DH drive connection box See Figure A 1 for the size and location of the mount ing holes The feed plate assembly is electrically hot when the gun trigger is pressed Therefore make certain the feed pl
121. n and tighten the hand clamp Keep this connection clean and bright Connect the trigger control cable polar ized 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 1 0 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 M Adapter Kit used with the DH K1500 1 Gun Adapter GMAW Guns An expanding line of Magnum Fast Mate M air cooled and water cooled gun and cable assemblies are avail able 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 litera ture 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 req
122. n be reversed for additional life See Procedure to Install Drive Roll and Guide Tubes in the Installation section for roll changing instructions WIRE REEL MOUNTING READI REELS AND 10 TO 30 Ib 4 5 TO 14 kg SPOOLS No routine maintenance required Do not lubricate 2 in 51 mm spindle AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling and feeder set up procedures a Do not kink or pull cable around sharp corners b Keep the electrode cable as straight as possible when welding or loading electrode through cable c Do not allow dolly wheels or trucks to run over cables d Keep cable clean by following maintenance instructions e Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication f Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed 0 Do not use excessive wire spindle brake settings h Use proper drive rolls guide tubes and drive roll pressure settings DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O lt a gt gle 5 1 Return to Section Return to Master TOC PERIODIC MAINTENANCE D 3 MAINTENANCE D 3 PROCEDURE FOR REMOVING FEEDPLATE FROM WIRE FEEDER Wire Drive Motor and Gearbox 1 Every year inspec
123. nstall plug J11 into the new display board Reinstall the control panel Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O lt a gt 8 8 5 1 Return to Section Return to Master TOC F 33 TROUBLESHOOTING AND REPAIR GAS SOLENOID REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory war ranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of either of the gas solenoids MATERIALS NEEDED 5 16 in nutdriver 5 16 in wrench Pliers Phillips head screwdriver DH 10 LINCOLN 5 F 33 F 34 TROUBLESHOOTING AND REPAIR F 34 GAS SOLENOID REMOVAL AND REPLACEMENT continued FIGURE 7 GAS SOLENOID REMOVAL AND REPLACEMENT Return to Section TOC Return to Master TOC
124. nsult sales specifications for appropriate models K541 With K466 9 requires K1500 2 Magnum 400 Short Neck GMAW gun and cable assemblies rated 400 amps 60 duty cycle Consult sales specifications for appropriate models K598 With K613 7 requires K1500 3 Magnum 550 GMAW gun and cable assemblies are rated 550 amps 60 duty cycle Consult sales specifications for appropriate models The following Lincoln gun and cable assemblies equipped with Fast Mate connector They can be used with DH wire feed models by installing a K489 7 Adapter or a K489 2 Fast Mate adapter kit and K1500 1 Lincoln Gun adapter K684 Magnum Super Cool FM water cooled GMAW gun and cable assemblies are rated 450 amps 100 duty cycle CO Consult sales specifications for appropriate models K498 Magnum 200 FM GMAW gun and cable assem blies are rated for 200 amps 60 duty cycle Consult sales specifications for appropriate models K534 Magnum 250L FM GMAW gun and cable assemblies are rated for 250 amps 3096 duty cycle Consult sales specifications for appropriate models K478 Magnum 300 FM GMAW gun and cable assem blies are rated for 300 amps 60 duty cycle Consult sales specifications for appropriate models K479 Magnum 400 FM GMAW gun and cable assem blies are rated for 400 amps 60 duty cycle Consult sales specifications for appropriate models K1557 1 SWIVEL MOUNT The K1557 1 Swivel mount attach
125. o of the DH drive 1 Pull open the Pressure Door 2 Remove the Phillips head screw retaining the pin ion 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 DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O o F F w 9 a gt og 5 a Return to Section Return to Master TOC A 6 INSTALLATION To remove feedplate 3 10 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 dicular 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 Loosen but do not remove the screw on the lower right face of the feedplate with a 3 16 in Allen wrench Remove the screw on the left face of the feed plate 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 scr
126. o two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 5 ARC RAYS can burn 4 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 287 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 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 2 FUMES AND GASES can be dangerous 0 5 Welding may produce fumes 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
127. of wire feed speed on 1 Check the tach leads between Return to Section TOC Return to Master TOC Return to Section TOC o F F w 9 a gt elg EIS 1 Return to Section Return to Master TOC Return to Master TOC both sides Both motors run both solenoids operate and arc voltage is present The WFS can be preset on both sides The wire feeds and the gas sole noid operates but no arc voltage is present the tach hall effect devices and the control board See the Wiring Diagram Make certain the electrode and work cables are connected correctly Make certain the control cable between the DH 10 and the power source is in good working condition Make certain the power source is operating properly and capa ble of producing welding voltage and current Perform the Tach Adjustment and Feedback Test Perform the The control board may be defective Check the continuity zero ohms of leads 2 and 4 between the input cable recep tacle and plug j8 on the control board See the Wiring Diagram The control board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 5 F
128. on es drm sb s a EE NE 9 ps Input Cable DH 10 Control to Power A 9 2 Optional Features Installation A 10 gt 8 5 9 gt 8 10 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC O10 o F F w a gt 212 EIS 1 Return to Section Return to Master TOC Return to Master TOC 2 INSTALLATION 2 TECHNICAL SPECIFICATIONS DH 10 Complete Units Controls amp Heads 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 CONTROLS SECTION OF COMPLETE UNITS TYPE INPUT POWER PHYSICAL SIZE TEMPERATURE RATING Dimensions Height Width Depth Weight Operating Storage K1499 1 Double Head 40 42 10 20 50 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 38 3 40 C to 40 to 20 40 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 WIRE DRIVE SPECIFICATIONS FO
129. on in this section 51 DIP switch setting determines the 4 step trigger operation S1 switch 7 OFF 4 Step with current interlock operation As shipped Pwr Sources Security 1 2 34567 51 51 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 DH 10 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo o F F w 9 a gt elm EIS 1 Return to Section Return to Master TOC S1 switch 7 ON 4 Step without current interlock operation Santi Pwr Sources M4 ON 1 2 3 4 5 6 7 51 51 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 break ing arc stops th
130. orm the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This procedure will help determine if the gas solenoids are receiving the correct volt ages and if the solenoids are functional This test can be used for either gas solenoid MATERIALS NEEDED 5 16 in nutdriver Volt Ohmmeter 12 VDC 1 amp power source DH 10 LINCOLN 5 F 29 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O o Fle lt 9 a gt Gje EIS 1 Return to Section Return to Master TOC F 30 TROUBLESHOOTING AND REPAIR F 30 GAS SOLENOID TEST continued FIGURE F 5 GAS SOLENOID TEST GAS SOLENOID LEADS NOTE WIRE FEEDER SHOWN WITH DRIVE MOTOR ASSEMBLY REMOVED FOR CLARITY TEST PROCEDURE Remove input power to the DH 10 unit Using the 5 16 in nutdriver remove the wire drive cover Locate the gas solenoids and lead quick connects See Figure F 5 Do not disconnect the leads Apply the correct input power 42 VAC to the DH 10 unit While pressing the gas purge button or activating the appropriate gun trigger check for approximately 10 VDC at the solenoid leads If the 10 VDC is present the gas solenoid should activate DH 10 LINCOLN 5 6 SOLENOID If the 10 VDC
131. out E10199 1 oie otras eiee G 9 Encoder Board Layout 7 retta cepe reuse Potes G 10 DH 10 LINCOLN G 2 ELECTRICAL DIAGRAMS G 2 Wiring Diagram Control L10218 WIRING DIAGRAM DH 10 CONTROL ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE PIN NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD COMPONENT SIDE OF P C BOARD Return to Section Return to Master TOC 7 CONNECTOR CAVITY NUMBERING SEQUENCE 0000000 EE NON LEAD SIDE OF CONNECTOR Es Us2 CASE GROUNDING P10 P17 nis STUD P11 J19 y PROTECTOR 2 PIN 1 PIN 1 19 512 Ke ko T ER Le 2 5 o 2 3 Return to Master 512 500 AULT1 FAULT2 CR1 WFS 98 gt N B E Y lo 10 20 L Fle R F CHOKE m es sls OPTIONAL REMOTE s CONTROL KIT 9 8 aoma pale HIRE DAVE HITE ORE um 8 9 RECEPTACLE RECEPTACLE pes us 212 CABLE TO RIGHT CABLE TO LEFT WIRE DRIVE TO MOTOR 0 gt SHIELDED SHIELDED F TO MOTOR TACHOMETER TO MOTOR TACHOMETER n u N TO MOTOR TACHOMETER BRASS BLOCK VOLTAG
132. pools 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 INSTALLATION A 5 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 set ting 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 the front of this section The following procedure is for changing rati
133. 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 for ward 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 dri ven roll drives housed together in a single combina tion mounting and connection box Gun adapters are available to permit use with a variety of standard weld ing guns AVAILABLE MODELS The DH 10 Wire Feeder system is available config ured 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 cabl
134. procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 5 F 9 TROUBLESHOOTING AND REPAIR F 9 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued The Timer Control and or 1 Make certain the switches 1 Perform the Resis Trigger buttons do not function on the control board are not set correctly for the security mode DIP switch S1 position 5 and posi 2 The display board may be tion 8 must be in the OFF posi faulty tion Return to Section TOC Return to Master TOC 3 The control board may be Check the connectors and wires faulty between the display board and the control board for loose or faulty connections J11 and J3 Check the connector J10 between the keypad and the display board for loose connections One of the encoder control knobs 1 The unit maybe in a mode that 1 Perform the Encoder Board functions but the other one does utilizes only one display To not check if this is the problem make sure that both knobs 2 The control board may be change the display when both faulty displays are showing a number and the high security mode is disabled Return to Section TOC R
135. proceed SECTION 1 ACCESSORIES SECTION C 1 9 TABLE OF CONTENTS n ACCESSORIES SECTION 0 ACCOSSOTIOS General PUTET 2 Drive Rolland Guide Tube Kits spe cee un eae he Susa HER FOR 3 5 Input Cable Assemblies C 4 2 22191116 52 10 611 OOo pie ad CA ra vdd e Eos d C 4 Gun Adapters For DH Wire Drive Heads C 5 Gun and Cable Assemblies C 5 O 0 9 5 tc o O 0 8 5 tc o O 0 8 2 10 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o F F w 9 gt 212 EIS 1 Return to Section Return to Master TOC 2 ACCESSORIES C 2 GENERAL The following is a list of all the accessories that can be used with the DH 10 Dual Head Wire Feeder A description of each item is given later in the section TABLE C 1 DH 10 DUAL HEAD WIRE FEEDER ACCESSORIES EXTENSION CABLE 17 REPRESENTS 12 16 OR 25 FT 3 6 4 9 OR 7 6M MAGNUM SUPER COOL FM WATER COOLED GMAW GUN AND CABLE ASSEMBLY DH 10 LINCOLN 5 3 ACCESSORIES
136. properly MATERIALS NEEDED 5 16 in nutdriver Volt Ohmmeter analog recommended DH 10 LINCOLN 5 F 27 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o Fle lt 9 a gt Gje EIS 1 Return to Section Return to Master TOC F 28 TROUBLESHOOTING AND REPAIR F 28 ENCODER PC BOARD TEST continued FIGURE F 4 ENCODER PC BOARD TEST 3 500 TEST PROCEDURE Remove input power to the DH 10 unit Using the 5 16 in nutdriver remove the two screws from the top of the control panel Carefully lower the control panel Locate plug J2 on the control board See Figure F 4 Do not remove the plug from the control board Apply the correct input power 42 VAC to the DH 10 unit Carefully check or the presence of 5 VDC from 542 lead 8505 to 4J2 lead 500 This is the supply voltage from the control board to both encoder boards Volts and WFS If this voltage is missing or low the control board may be defective Also make certain the 5 VDC supply is being applied to the encoder boards via leads 4505 and 3 500 See the Wiring Diagram DH 10 LINCOLN 5 ENCODER PC BOARDS 7 While slowly rotating the Volts control check for a pulsing 0 to 5 signal from 8J2 lead 516 to 6J2 lead 517 If the 5 VDC supply IS present at the encoder board and the puls
137. ptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the sus pect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures DH 10 LINCOLN 5 PC BOARD TROUBLESHOOTING PROCEDURES PC board can be damaged by static electricity 5 static charge before ATTENTION opening the static Static Sensitive shielding bag Wear an Devices anti static wrist strap Handle only at For safety use a 1 Meg Static Safe ohm resistive cord con Workstations nected to a grounded part of the equipment frame Reusable Container Do Not Destroy f you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board cannot be installed immediately put it back in the static shielding bag If the PC board uses protective shorting jumpers don
138. que ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR 3 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER Bonis TRANSFORMATEUR ET soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provo
139. quer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides
140. r 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 INSTALLATION ELECTRICAL INSTALLATION A WARNING 9 ELECTRIC 5 kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger elec trode 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 con nected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should per form this installation Observe all additional Safety Guidelines detailed throughout this manual Input Cable DH 10 Control to Power Source Available Cable Assemblies K1
141. r 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 in Accessories Each head requires a separate drive roll kit PROCEDURE TO INSTALL DRIVE ROLL AND WIRE GUIDES WARNING 9 ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger elec trode 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 con nected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should per form this installation Observe all additional Safety Guidelines detailed throughout this manual DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o E iz 8 8 5 Return to Section Return to Master TOC A 7 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
142. re extinguisher readily available 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 When 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 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 Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear 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 Connect the work cable to the work as close to the welding area as practical Work cables connec
143. rol Board Schematic Sheet 1 G3040 1 ELECTRICAL DIAGRAMS
144. s detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the hall effect module tach is functioning correctly Either tach can be checked using this procedure MATERIALS NEEDED 5 16 in nutdriver Volt Ohmmeter 9 16 in wrench DH 10 LINCOLN 5 F 19 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o Fle lt 9 a gt 818 EIS 1 Return to Section Return to Master TOC TROUBLESHOOTING AND REPAIR F 20 TACH ADJUSTMENT AND FEEDBACK TEST continued FIGURE F 2 TACH FEEDBACK TEST 555 BLUE TEST PROCEDURE Remove input power to the DH 10 unit Using the 5 16 in nutdriver remove the wire drive cover Locate the three hall effect leads blue red and black See Figure F 2 Apply the correct input power 42 VAC to the DH 10 Check for approximately 12 VDC from red lead 512 to black lead 500 If the 12 VDC is NOT present or low DH 10 LINCOLN 5 512 HALL EFFECT DEVICE TACH the control board or associated leads or plugs may be faulty See the Wiring Diagram
145. ssure 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 INSTALLATION 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 dle Roll Pressure in Operation GUN AND CABLE ASSEMBLIES WITH STANDARD CONNECTION The DH Wire Drive Heads each require a K1500 Gun Adapter installed See Gun Adapters in Accessories section GMAW Guns An expanding line of Magnum gun and cable assem blies 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 7 6 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
146. t input power 42 VAC to the DH 10 Activate the gun trigger With the motor running check the armature voltage at the black and white leads The normal voltage range is approximately 1 to 25 VDC depending on motor speed When the armature voltage is increased the motor speed should also increase DH 10 LINCOLN 5 WHITE If the correct voltages are NOT present at the armature motor leads check the associated leads and plugs for loose or faulty connections See the Wiring Diagram the leads and connections are OK the control board may be faulty If the correct voltages are present at the motor armature leads and the motor does not run and vary speed with changes in armature voltage the motor or gear box may be faulty See Install the wire drive cover Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O F a gt 8 8 5 Return to Section Return to Master TOC F 19 TROUBLESHOOTING AND REPAIR TACH ADJUSTMENT AND FEEDBACK TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dan ger to the technician or machine operator and will invalidate your factory war ranty For your safety and to avoid electrical shock please observe all safety notes and precaution
147. t remove them until installation is complete f you return a PC board to the Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 O o Fle lt 9 a gt 9 8 EIS 1 Return to Section Return to Master TOC TROUBLESHOOTING AND REPAIR F 4 4 Test the machine to determine if the fail ure symptom has been corrected by the replacement PC board NOTE is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reap pear by substituting the original board then the PC board was not the problem Continue to look for bad DH 10 LINCOLN 5 connections in the control wiring har ness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Fo
148. t the coat the gear teeth with a moly disulfide filled grease Do not use graphite grease Every six months check the motor brushes Replace them if they are less than 1 4 in long 2 Gun and Cable Maintenance See appropriate 5 Manual DH 10 LINCOLN 8 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 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 4 LINCOLN B MAINTENANCE DH 10 4 DOL 4 1 01 DOL 4 1 01 DOL 4 1 01 NOL 4 1 01 DOL uonoeg 0 DOL 5 0 DOL uonoeg 0 DOL uonoeg 0 Return to Master TOC Return to Master TOC o 2 0 E OF OPERATION Theory of Operation sea sami REESE T4 ES rra y General Description Input Receptacle Control Board and Operator Controls
149. taining 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 DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o F a gt 8 8 5 Return to Section Return to Master TOC B 9 CAUTION 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 elec trode 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 2 IN O D SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR GROOVES READI REEL INSIDE CAGE WIRES RELEASE BAR To Mount 10 to 44 Ib 4 5 to 20 kg Spools 12 in 300 mm Diam
150. ted 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 5 CYLINDER may explode if damaged Ta 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in
151. ter TOC Return to Section TOC Return to Master TOC O10 o F F w a gt 212 EIS 1 Return to Section Return to Master TOC 11 4 Use Control Select 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 Display Control Keys Kans n this section 5 Adjust the wire feed acceleration if desired for each feeder and procedure Refer to Acceleration Selection n this section 6 Use Timer Select and Voltage Encoder knob to set desired timers Refer to Trigger Mode Selection n 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 WARNING When using an Open Arc process it is 2 necessary to use correct eye head body protection 9 If used be sure shielding gas valve is turned on 10 Position electrode over joint End of electrode may be lightly touc
152. th 15 ft 4 5 m control cable and 5 pin plug with two leads to connect to gun trigger SPINDLE ADAPTERS K162H Not required for DH 10 Bench Models Spindle for boom mounting Readi Reels and 2 in 51 mm 1 0 spools with 60 Ib 27 2 kg capacity User mounted to appropriately prepared boom frame work Includes an easily adjustable friction brake for control of overrun When a 2 in 51 mm spindle is used with Readi Reels or coils not on 12 in 305 mm O D spools an adapter is required Coil Adapters K1504 1 Permits 50 Ib to 60 Ib 22 7 27 2 kg Coils to be mounted on 2 in 51 mm O D spindles K435 Permits 14 Ib 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 DH 10 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o F a gt 8 8 5 Return to Section Return to Master TOC C 5 ACCESSORIES Readi Reel Adapters K363P Adapts Lincoln Readi Reel coils of electrode 30 Ib 14 kg and 22 Ib 10 kg to a 2 in 51 mm spin dle Durable molded plastic one piece construction Designed for easy loading adapter remains on spin dle for quick changeover K438 Adapts Lincoln Readi Reel coils of electrode 50 to 60 Ib 22 7 to 27 2 kg to a 2 in 51 mm spindle GUN ADAPTERS
153. 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 cur rent sensor cover Work Cable Connect a work lead of sufficient size and length per the following table between the proper output termi nal 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 00 67 mm Current 60 Duty Cycle 400 Amps 500 Amps 000 85 mm 600 Amps 000 85 mm INSTALLATION A 10 OPTIONAL FEATURES INSTALLATION K1501 K1502 and K1503 Input Cable Assemblies See Electrical Installation 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 installa tion instructions included with the kit Spindle Adapters K162H Spindle for boom mounting Readi Reels and 2 in 51 mm 1 0 spools with 60 Ib 27 2 kg capacity User mounted to appropriately prepared boom frame work Includes an easily adjusta
154. the open positions 3 Remove clamping screw amp 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 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 amp 4 7 Center the middle guide between the two drive rolls and tighten in place 8 Back out the screws for the incoming and outgo ing 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 Roll Pressure Setting in Operation DH Drive Roll Kit Installation KP1505 and KP1507 1 Turn OFF Welding Power Source 2 Pull open Pre
155. the two screws mounting the top of the motor to the gear box Carefully remove the drive motor from the gear box assembly Note motor lead placement for reassembly DH 10 LINCOLN 5 GEAR BOX INSPECTION COVER WIRE DRIVE ASSEMBLY ALLEN SCREWS TO REMOVE THE WIRE DRIVE ASSEMBLY FROM THE GEAR BOX 16 Using the 3 16 in Allen wrench loosen the two Allen screws located at the bot tom of the wire drive unit Remove lead 67 from the conductor block Carefully slide and remove the wire drive assembly from the gear box assembly Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o Fle lt 9 a gt 818 EIS 1 Return to Section Return to Master TOC F 40 TROUBLESHOOTING AND REPAIR F 40 WIRE DRIVE MOTOR AND GEAR BOX REMOVAL REPLACEMENT continued REPLACEMENT PROCEDURES 1 Carefully slide the wire drive assembly and gear box together Tighten the two Allen type screws at the bottom of the wire drive unit using the 3 16 in Allen wrench Attach lead 67 to the conductor block Carefully slide the drive motor into the gear box assembly Be sure to position the motor leads so that they can be properly connected Install the slot head screws that mount the top of the drive motor to the gear box Install the mounting screw located inside the gear
156. ting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo o F F w 9 a gt elg EIS 1 Return to Section Return to Master TOC TROUBLESHOOTING AND REPAIR F 3 A WARNING ELECTRIC SHOCK Have electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid problems when trou bleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure sym
157. trol cable with a 14 pin plug and 2 0 67 mm electrode cable with Twist Mate M connector It is rated at 500 amps 60 duty cycle and is available in lengths of 10 ft 3 m 17 ft b 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 mm electrode cable K1520 1 115V 42V TRANSFORMER KIT Required to use DH 10 with Lincoln Power Sources without 42VAC 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 K590 4 WATER CONNECTION KIT One per gun Includes water cooled gun tube fittings and self sealing outlet and inlet quick connectors for mounting into the DH wire drive connection box K659 1 GAS GUARD REGULATOR One per gun Adjustable flow regulator with remov able adjustor key for and Argon blend gases Mounts onto wire drive gas inlet and reduces gas waste and arc start blow by reducing surge caused by excess pressure in supply hose K1449 1 DUAL PROCEDURE REMOTE CONTROL One per DH 10 Control Box Includes a remote con trol box with a 16 ft 5 m length control cable with 4 pin plug for the mating receptacle on the bottom of the DH 10 control box The remote control box con tains a procedure selector switch and 2 rotating knob encoders one controls arc voltage and the other con trols wire feed speed which function the same as comparable controls on the
158. tting out more than 8 VDC Make sure the dual procedure switch is installed and connect ed properly The Remote LED on the keypad must be lit and the toggle switch on the remote control if used must be in the gun position Check the connections and wiring between the dual procedure switch and the gun trigger connector Check the connections and wiring between the wire drive unit and the control box Check leads 519 and 520 through the shielded cable to the control board See the Wiring Diagram continuity zero ohms to the workpiece and 67 lead has continuity zero ohms to the electrode wire See the Wiring Diagram The control board may be faulty The control board may be faulty The control board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 DH 10 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo o F F w 9 a gt elg EIS 1 Return to Section Return to Master TOC F 12 TROUBLESHOOTING AND REPAIR F 12 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF RECOMM
159. ty Refer to Figure E 3 WIRE DRIVE DRIVE 3 RECEPTACLE MOTOR TACH FEEDBACK CONTROL BOARD 2 SOLENOID TO GUN TRIGGER AND DUAL PROCEDURE WIRE DRIVE RIGHT WIRE DRIVE RECEPTACLE TACH FEEDBACK CURRENT SENSING REED SWITCH GROUND LEAD PROTECTOR DISPLAY BOARD KEYPAD When the gun trigger is activated the control board energizes the gas solenoid then the welding drive motor and welding power source The control board receives tach feedback information and adjusts the motor armature voltage to match the preset wire feed speed DH 10 LINCOLN 8 Return to Master TOC Return to Master TOC Q 2 0 E F 1 TROUBLESHOOTING AND REPAIR TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR SECTION Troubleshooting and Repair How to Use Troubleshooting Guide 2 PC Board Troubleshooting Procedures Troubleshooting Guide yl Test Proc dures mte eem mte eek RR pode etie Rer 9 Roe X a ee ACT eu Wire Drive Motor Test 1 Tach Adjustment and Feedback Keypad Resistance Test
160. uire the use of either the K173 1 or K184 vacuum units Requires S14927 8 connector hose and an S20591 hose adapter INSTALLATION A 8 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 quick connects L E Part No 519663 are provided in the Kit for installation on 3 16 in 5 mm 1 0 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

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