Lincoln Electric IM812-A User's Manual
Contents
1. Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra eoo SS MARHE FRANEACRHEUCE OMIM PT APYSSeMRBE ATUBSHELTFEL e ER DEMBEBER amp e B RMI ERR SHES ae S4 se yya su 2749 HAS OMAR JUS gw Gall el jay oye daa dea ag iY d ily gS AA Gadi Jai JS aua ile woe Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos SODMTOBEEER MHI UL TREW EVA o iR aE L FRN o els 288 Hc AIX uie ya OSa JA ALIM Aal e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a2. Remove the hex head screw and clamping collar Remove the drive roll from the shaft The new roll to be installed is stamped for the size to be fed An A after the size indicates aluminum wire Remove the rolls from the kit and wipe them clean Wipe the output shaft and locating shoulder clean Use the drive key clamping collar and hex head screw to install the roll on the output shaft Certain size drive rolls consist of two roll halves and may contain a spacer If the drive roll you are installing contains a spacer the spacer fits between the two halves of the drive roll Tighten the hex head screw Back out the guide tube clamping screws Remove the old guide tubes if installed Insert the outgoing guide tube the one with the plastic insert into the front hole If the guide tube has a non symmetrical chisel end the larger radius must face the drive roll See Figure A 1 Push the guide tube back as far as it will go and tighten the clamping screw Insert the incoming guide tube as far back as it will go and tighten the clamping screw The clamping screws are dog points When the guide tubes are properly installed these dog points will lock into the annular grooves in each of the guide tubes Set the idle roll pressure as detailed in the Idle Roll Pressure Setting procedure detailed later in this section FIGURE A 1 INSTALLING DRIVE ROLLS ON A TWO ROLL FEEDER c CLAMPING COLLAR DRIVE LE SP
3. STORAGE 40 C to 85 C 40 F to 185 F LN 35 LINCOLN 2 INSTALLATION A 2 SAFETY PRECAUTIONS WARNING The electrode circuit including welding wire wire drive and welding gun is electrically hot when the welding power source is on The gun trigger controls wire feed only Disconnect or shut off welding power source before making connections or installations to the LN 35 The LN 35 should be positioned upright on a horizontal surface A WARNING ELECTRIC SHOCK can kill Do not touch metal portions of the LN 35 clamp when welding power source is on POWER SOURCE CONNECTION The LN 35 can be used with any DC welding power Source A constant voltage power source is recommended however the LN 35 can also be used with a constant current power source as long as the open circuit voltage is less than 110V DC The power source output will be electrically hot at all times when the power source is turned on See the power source instruction manual for proper power source connections and setting required WARNING 0 ELECTRIC SHOCK can kill Do not operate with covers removed Turn off power source before installing or servicing Do not touch electrically hot parts Turn the input power to the welding power source off at the fuse box before working in the terminal strip Only qualified personnel should install use or service this equipmen
4. 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 Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 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 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 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 ELECTRIC AND 3 mm MAGNETIC FIELDS S 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 w
5. Take at least two readings to assure repeatable accuracy WARNING Electrode will be electrically hot Do not allow fed wire to contact any metal common with welding work An alternate means to measure wire feed speed is as follows a Cut wire off at the end of the gun tip b Press trigger to feed wire for exactly 30 seconds CH Cut fed wire off at the end of the gun tip and accurately measure its length a Multiply the measured length by 2 to obtain the wire speed IN MIN e Repeat above steps to assure repeatable accu racy 4 Carefully slip speed knob onto potentiometer shaft so it points precisely to the wire speed measured in step 3 then secure the knob set screw without disturbing the position Recheck by repeating step 3 LN 35 LINCOLN 8 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual 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 label
6. 3199 1ndNI IHL 5 2018 YOLONGNOD WOY 53 09 HOLIMS ALIHV Od SHL OL QV31 49 IHL S3HOLIMS ANY LVLSO3HMH 40 WO SV SNOLLO3NNOO 38 LSNW 9019 HLOS SALON ER ALIHM HOVI8 gt H Ei po 2 5 ama La ders LL EN a 885 HOLIMS IAOW a334 ES tes ves A Movi8 31IHM qas ALAYO HOLO3NNOO x avo 1ndNI NNO 3 SS 9 HOLO3NNOO Vire vzo Ky Sr HOLIMS AUS Od LS 318VO AYYOM OL 9 ZLS 999 EC gt 009 Lps Hova ee 229 2 625 NH pzs o gt 605 o a EI M leg plo x x 9d IOHLNOO z ES M Ed titt sae l1V1SO3HMH lOHINOO G33ds an MAOL 19 21 geo zeo GE NT INVHOVIO 9NIHIM Ajuo 10 S SIUL ILON HOLIMS 0334 3HIM S HOLIMS ALIHV1Od LS AN3931 LN 35 LINCOLN E NOTES LN 35 LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO 5 BIR Chinese Korean Do nottouch electrically live parts or electrode with skin or wet clothing
7. ELE EEEE nene nose B 2 Loading Wire DIV 3 Idle Roll Pressure Setting EE B 3 Presetting Wire Feed Gpeed iii 4 M king a Weli 5 Procedure at End of I ERR RR RR RR RR RRRRRRRRRRRARKR NENE KEE KARE EKEE KERKEE B 6 Open Arc Welding with a Constant Current issus B 6 Automatic Protection Shutdown esses eene eene ee enne nennen esses sse s sensns sss B 7 ugs lect SECTION D eec D 1 Froutine EE D 1 Circuit Protection and Automatic Ghutdowm enne nnne nnn nnne D 1 Adjusting Speed Sensor Module D 2 Calibration of the LN 35 Wire Speed Dial sise D 2 TROUBLESHOOTING GUIDE rect eonun innt n rece EE an eu eaa Don Derek Rar tige SECTION E How to Use the Troubleshooting Guide iii E 1 Troubleshooting Guide E 2 E 3 Vd sil ies Peter Pic F 1 1 INSTALLATION TECHNICAL SPECIFICATIONS LN 35 K2281 1 Constant Voltage CV or 15 40 VDC 110VDC Maximum OCV Constant Current CC Rated current 500 Amps 60 Duty Cycle A 1 50 500 Inches Per Minute IPM 1270 12700 mm Min 7 64 Inches 2 78 mm CORED WIRE HEIGHT WEIGHT 27 Inches 14 25 Inches 33 Inches 686 mm 362 mm 838 mm TEMPERATURE RANGE OPERATION 40 C to 40 C 40 F to 104 F
8. WARNUNG ATENCAO Hx BIR Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 185 MM PBHO CL TRHOKRASME HTP SU MBA AU SERRA RRA SR EE T ECKE ECKE AZo SEE SIAD HAY Sigi AASE Zell abal gl quil ud AA Sal ag ls L LINCOLN 8 World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
9. eta A 59tEM d Feu Cru e c EUR E e SSeS S87I 8 HAMAL 5 HHPI Ash FAAAZI4 37 amp oe Saye dui ay e jul baa jaa yi aach Jaial e uu All Ge call us e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas X7TTLZA KR UAURBUD POR EF BRAT FE FTF e HENKE SHA AHS Aj aLi il SE alil e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e ID RALE CREATE LEWTFEU e iX HRHITDO SUUS Se S e do Gel tee OMAR Aga y Gils 13 jlgall l a Ja y e S i di Spanish AVISO DE PRECAUCION French ATTENTION German
10. IN MIN desired Refer to Setting Constant Wire Feed Speed Section For CC Set dial to value determined from the CC Wire Speed Graph for the DESIRED IN MIN and ARC VOLTS to be used Refer to Setting Arc Sensing Wire Feed Speed Section NOTE If procedure permits a range of acceptable arc voltage use the middle of the range to determine proper WIRE SPEED setting Be sure the proper contact tip for the wire size being used is in the gun and the gun is safe from work contact Turn on the welding power source WARNING The electrode is electrically hot when the power source is on The gun trigger controls wire feed only LINCOLN P B 6 OPERATION B 6 WARNING CYLINDER may explode if damaged 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 cylin der Keep cylinder away from welding or other live electrical circuits AA WARNING RAYS can burn not touch metal por tions of the LN 35 lead Clamp when welding power source is on L Cut the electrode within approximately 3 8 9 5mm of the end of the contact tip for solid wire and within approximately 3 4 19 1mm of the extension guide for cored wire b Position electrode over joint End of electrode should be slightly off the work c Lower welding helmet close gun trigger and begin wel
11. Innershield and gas metal arc welding GMAW satisfactory general purpose welding may be obtained using the LN 35 with a constant current CC power source for non critical commercial quality mild steel welding applications While welding with a continuously fed electrode weld current variations are continuously taking place There are many causes for these variations but predominantly they occur due to changes in electrical stickout operator hand movements nozzle tip contact variations etc and the dynamic metal transfer characteristics of the process or procedure being used short arc globular transfer etc When using a CV power source these current variations have essentially no effect on the welding arc stability since CV power sources can provide a wide range of weld current levels with virtually no change in average arc voltage These flat slope CV power sources therefore provide the arc power required to produce the best welding characteristics and ease of operation for most open arc constant wire feed speed welding processes LN 35 LINCOLN P B 7 OPERATION B 7 CC formerly VV power sources on the other hand permit the arc voltage to decrease with increases in welding current The output characteristics of these power sources can range from a drooping slope which provide minor arc voltage changes with weld current variations to steep slope which provide broad voltage changes with only minor curren
12. LN 35 B 1 The LN 35 provides constant wire feed speed for use with constant voltage CV power sources and arc sensing wire feed speed for use with constant current CC formerly variable voltage power sources Wire Speed is presettable on a calibrated dial The power sources recommended for use with the LN 35 include the DC 250 400 600 CV 400 and R3S type transformer machines and the SAM 400 650 engine welders as well as the SA 200 250 or SAE 300 400 with CV Adapter WELDING CAPABILITY The LN 35 will handle up to 500 Amp 60 duty cycle welding currents LN 35 INSTRUMENTS AND CONTROLS ELECTRODE POLARITY SWITCH The polarity switch is located on the center panel inside the LN 35 case Set the switch to the same polarity as the electrode lead connection to the power source If the switch is not set for the correct polarity the wire feeder will not operate WIRE FEED MODE SWITCH The CV VV CC Wire Feed Mode switch is located on the center panel inside the LN 35 case The forward CV switch position provides constant wire feed speed mode for use with constant voltage CV welding power sources The backward VV CC switch position provides arc sensing wire feed speed mode for use with constant current formerly variable voltage welding power sources WIRE FEED SPEED CONTROL This control sets the feed speed of the wire feeder Turn the knob to the left for slower speeds and to the right
13. PROTECTION SHUTDOWN The LN 35 control provides automatic electronic protection circuits which shut down the LN 35 for excessively high power source open circuit voltage or excessive motor overload OVERVOLTAGE SHUTDOWN If the power source open circuit voltage exceeds about 110 120 volts the LN 35 will not operate until the power source voltage drops below about 102 110 volts MOTOR OVERLOAD SHUTDOWN If excessive motor overload occurs due to prolonged excessive feeding force jammed drive rolls or shorted motor leads the LN 35 will shut down within a few seconds after the overload occurs The shutdown will reset automatically when the gun trigger is released but will reoccur if the overload situation is not remedied LN 35 LINCOLN P D 1 SAFETY PRECAUTIONS A WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not operate with covers removed Do not touch electrically live p
14. block on the front of the wire drive unit Make sure it is all the way in and tighten the hand wheel clamp Keep this connection clean and bright Connect the control cable polarized amphenol plug into the mating 5 cavity receptacle on the front panel of the wire feeder case LN 35 LINCOLN 4 WELD CABLE CONNECTION The size of the electrode cable and work cable must be sufficient for the maximum weld current and total cable length to be used Refer to table A 1 TABLE A 1 Total Cable Length 100 150 150 200 200 250 Weld Current 60 6 Duty Cycle 50 100 2 AWG 1 AWG 2 0 2 0 2 AWG 1 AWG 2 0 3 0 1 AWG 1 0 3 0 3 0 1 0 2 0 3 0 4 0 200Amps 300Amps 400Amps 500Amps ELECTRODE CABLE CONNECTION Route the electrode cable through the oval hole in the LN 35 rear panel Connect the electrode cable to the LN 35 using the bolt on the front of the wire drive WORK CABLE CONNECTION Connect a work lead of sufficient size between the proper output stud on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact Poor work lead connections can result in poor welding performance DRIVE ROLL INSTALLATION CHANGING DRIVE ROLLS FOR TWO ROLL WIRE FEEDERS To change drive rolls on a two roll wire feeder refer to Figure A 1 and perform the following steps INSTALLATION 1 4 Rotate the latch knob on the quick release arm
15. equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS can lt 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 fire 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 not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard 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 P
16. tangled coil will not feed It must be untangled or discarded 8 Cut and remove only the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires 9 Replace the reel on the wire feeder LN 35 LINCOLN P B 3 FIGURE B 1 LOADING A 50 OR 60 LB COIL SPINNER NUT D COVER eJ PLATE SLOTS CARDBOARD COIL LINER TIE WIRE REEL SPRING _ LOADED LOADING WIRE DRIVE a Turn the reel or spool until the free end of the electrode is accessible b While tightly holding the electrode cut off the bent end and straighten the first six inches Cut off the first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a birdnest c Insert the free end through the incoming guide tube to the drive roll d Turn on the welding power source WARNING The electrode circuit is electrically hot when the power source is on OPERATION B 3 e Press the gun trigger and push the electrode until it just enters the drive roll WARNING When inching with gun trigger the electrode and drive mechanism are always hot to work and ground f Inch the electrode through the gun IDLE ROLL PRESSURE SETTING The idle roll pressure is set at the factory backed out two turns from full p
17. vista ouvido corpo EU RER ARAOBFHRBAR ei 712 Sol Soares y due Lily us cl di en READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria
18. 0 IPM 17V 350 IPM 21V SETTING ARC SENSING WIRE FEED SPEED VV CC MODE When using a constant current formerly variable voltage power source welding performance is im proved using arc sensing wire feed speed VV CC mode In this wire feed mode the wire speed increases if arc voltage increases and decreases if arc voltage decreases but remains constant at any specific voltage level The LN 35 permits accurate VV CC mode presetting of the desired wire feed speed for the desired arc voltage to be used by setting the Wire Speed dial in the following manner before welding a Set Wire Feed Mode switch to VV CC position X T 150 200 250 300 350 400 450 500 550 600 650 700 FIGURE B 3 CC WIRE SPEED SETTING b Referring to the graph shown in Figure B 3 1 Select the horizontal line representing the DE SIRED IN MIN for the welding procedure See example arrow line for 375 in min 2 Select the diagonal line representing the ARC VOLTS to be used for the welding procedure See example arrow line for 29 volts 3 Determine the vertical line representing the CC WIRE SPEED SETTING where the above two lines cross See example arrow line for 450 c Set the Wire Speed dial to the value determined in Step 3 above 450 for example used The wire will feed at the DESIRED IN MIN speed when the welding power source is set to the arc voltage to be used for the w
19. 7 2 1974 idu PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER mue TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 pan talons sans revers et chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif 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 debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V V for selecting a QUALITY product by Lincoln Electric We want
20. ACER ROLL Ce gt FREAD HALVES OUTPUT GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE IDLE ROLL SMALL RADIUS INCOMING GUIDE TUBE LN 35 LINCOLN B 1 SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE WARNING ELECTRIC SHOCK can kill K Do not touch electrically live part or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulat ing gloves FUMES AND GASSES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away ARC RAYS can burn Wear eye ear and body protection GENERAL DESCRIPTION The LN 35 is a semiautomatic wire feeder designed for across the arc operation without a control cable on most any DC welding power source Simply connect the LN 35 to the electrode cable clip it to Work and it is ready to weld using up to 60 Ib coils or spools RECOMMENDED PROCESSES AND EQUIPMENT When combined with the quality drive roll kits and accessories available for use with the LN 35 a versatile welding system can be provided to meet the specific needs of Innershield or submerged arc welding applications within the wire feed capabilities of the LN 35 OPERATION
21. 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 to 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 ARC RAYS can burn 4 a Use a shield with the proper filter and cover p plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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 oth
22. LN 35 CV CC IM812 A SEMIAUTOMATIC WIRE FEEDER For use with machines having Code Numbers 11029 11250 RETURN TO MAIN MENU 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 809001 1 as A B Wwe Desig a Q nc LINCOLN fo Copyright 2005 Lincoln Global Inc World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com ABS Quality Eval to ISO 9001 Re CERTIFICATE NUMBER 30273 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A 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
23. N 35 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 The module is properly mounted to the gearbox as shipped from the factory If the device is ever removed or replaced proper mounting technique is as follows 1 Be sure all power to the LN 35 is shut off at the power source 2 Check that the module mounting plate is screwed securely to the side of the gearbox 3 Gently screw the module into the mounting plate until it just touches and stops against the rotating part inside the gearbox 4 Back the module out 1 2 turn then snug the module lock nut without rotating the module position Do not overtighten lock nut CALIBRATION OF LN 35 WIRE SPEED DIAL Calibration of the LN 35 Wire Speed dial is achieved by proper mounting of the dial knob to the speed potentiometer shaft Whenever the knob is removed the dial is recalibrated as follows NOTE Knob set screw does not seat on shaft flat 1 Be sure the Wire Speed potentiometer mounting nut is securely tightened then rotate the potentiometer shaft so its flat faces about to the 100 mark on the calibrated dial 2 Set WIRE FEED MODE switch to CV position 3 Press gun trigger to feed wire and measure the wire feed speed IN MIN using a Portable Digital Wire Feed Speed Meter Lincoln K283 Take at least two readings to assure repeat able accuracy Feed Speed Meter Lincoln K283
24. a 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 metallique 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 d 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 souder 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 prot 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 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser de
25. arts or electrode with skin or wet clothing Turn the input power to the welding power source off at the fuse box before working in the terminal strip Insulate yourself from work and ground Always wear dry insulating gloves See additional warning information throughout this operator s manual and the Engine manual as well 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 lu bricant out of the bearing The drive roll idle roll and guide tubes are stamped with the wire sizes they will feed If a wire size other than that stamped on the rolls is to be used the rolls and guide tubes must be changed The drive rolls for 035 through 052 cored electrode and 1 16 through 5 64 electrode have a double set of teeth so they can be reversed for additional life Drive rolls for 023 through 052 solid electrode and aluminum sizes have no teeth but use two grooves so they also can be reversed for additional life MAINTENANCE D 1 See Wire Feed Drive Roll and Guide Tube Kits Sec tion for roll changing instructions WIRE REEL SPINDLE No routine maintenance required Do not lubricate spindle CONTROL BOX Every six months open and inspect the control sec tion The accumulated dirt should be gently blown off all of the electrical components Be sure the air that
26. bjected to physical damage A 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 P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment 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 iv SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions 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 suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre l
27. d Connect SAM 650 lead to the Innershield stud desired c Set ELECTRODE POLARITY switch to constant voltage polarity required by electrode d Set toggle switch to Constant Voltage and set the Constant Voltage Control on welder and the portable field control on 5 for initial start SA 200 250 OR SAE 300 400 WITH CV ADAPTER a For electrode negative welding connect the electrode lead from the LN 35 to the output terminal on the CV Adapter and the work lead to the power source output terminal labeled POSITIVE For electrode positive welding interchange the above lead connections so the LN 35 electrode lead is then connected to the positive power source terminal b Place both switches on the CV Adapter to the CV INNERSHIELD position and make appropriate power source settings per the CV Adapter instruc tions provided for the power source being used c The output voltage is set with the voltage control on the CV Adapter NOTE Refer to the Instruction Manual provided with the machine for details on connection and operation of the LN 35 with the power source INVERTEC CV300 AND OTHER NEWER LINCOLN POWER SOURCES Refer to the instruction manual provided with the power source for details on connection and operation of the LN 35 with these newer machines GUN CABLE CONNECTION TO FEEDER Lay the cable out straight Insert the connector on the welding conductor cable into the brass conductor
28. ding Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used NOTE If the arc voltage is not within the proper procedure range adjust the power source output control The CC mode WIRE SPEED setting should not be changed from the preset procedure value for the proper arc voltage d To stop welding release the gun trigger and then pull the gun away from the work PROCEDURE AT END OF COIL When the wire on the reel is used up the following procedure is to be followed for removing the old wire from the gun cable and loading a new reel a Shut off power source if a Remote Output Control Option or internal contactor is not used b Cut the end of the electrode off at the gun end Do not break it off by hand since this puts a slight bend in the wire and makes it difficult or impossible to pull it back through the nozzle c Uncouple the gun conductor cable from the LN 35 d Lay the cable out straight e Using pliers to grip the wire pull it out of the cable from the connector end Do not pull it from the gun end f Put the conductor cable back on wire drive unit after the electrode has been removed g Load a new coil of wire and feed it through the cable as described in Loading Electrode Section OPEN ARC WELDING WITH A CONSTANT CURRENT formerly variable voltage POWER SOURCE Although a constant voltage CV power source is recommended for
29. ds often used when feeding smaller diameter electrode To adjust the brake position remove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a friction fit TO MOUNT A 50 OR 60 LB COIL 1 To remove the wire reel from its shaft 2 Lay the reel flat on the floor Loosen the spinner nut and remove the cover plate See Figure B 1 3 Place the coil of electrode on the reel so it unwinds as the reel rotates clockwise DO NOT cut the tie wires at this time 4 Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires 5 When loading 0 030 0 035 and 0 045 electrode be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil Sides needed for trouble free wire feeding 6 Put the cover plate on the reel so the four arms of the cover plate straddle and are in line with the spring loaded arms of the reel 7 Tighten the cover as much as possible by hand CAUTION DO NOT hammer on the spinner nut arms 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 back lashing of the coil which may tangle the wire A
30. ed PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 35 LINCOLN 8 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual open circuit voltage OCV present at weld terminals LN 35 work clamp may not be connected LN 35 polarity switch must match electrode polarity Jumper plug on control or option board may be loose or missing The power source O C V must be above 15 VDC But not more than 110 VDC The gun trigger may be faulty If all recommended possible areas Replace gun of misadjustment have been checked and the prob
31. eld procedure 375 in min at 29V for example used A chart representation of the VV CC wire speed setting graph is shown in Figure B 4 giving the Wire Speed dial setting required for the DESIRED IN MIN and ARC VOLTS used for the welding procedures LN 35 LINCOLN B 5 OPERATION B 5 Desired In Min Arc Volts Used 22 24 26 VV CC Speed Setting Desired IPM Arc Volts X 35 FIGURE 4 VV CC WIRE SPEED SETTING LN 35 a MAKING A WELD SETUP 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 Check that the LN 35 is properly connected to the power source for the polarity and process to be used and appropriate power source settings are made for the procedure to be used Refer to power source operating and connection instructions Place the LN 35 conveniently near the work area in a location to minimize exposure to weld spatter and to avoid sharp bends in the gun cable Connect the LN 35 Clamp Lead to work and set Polarity Switch to same polarity as electrode Set WIRE FEED MODE switch to CV or CC as appropriate for the power source then set the proper DIAL RANGE and WIRE SPEED dial set ting for the proper wire feed speed per the welding procedure For CV Set dial to the calibrated
32. er 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 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 prod ucts 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
33. for higher speeds The control is calibrated The nameplate shows the wire speed for the given setting of the control LINCOLN B 2 OPERATION B 2 WORK CLIP LEAD WARNING ELECTRIC SHOCK can kill o Do not touch metal por tions of the LN 35 lead clip when welding power source is WARNING IMPORTANT SAFETY NOTE To avoid possible electrical shock do not touch the metal portions of the LN 35 work lead clamp if the power source output is on The clamp will be electrically to work if the input electrode cable to the LN 35 is electrically HOT even if the gun trigger is off Care should be taken to only handle the LN 35 work clamp by its non metal insulated portions and or the welding power source should be turned off before handling the work clamp The 15 ft work clamp lead attached to the front panel of the LN 35 case must be connected directly to the work using the spring clamp on the end of the lead If not connected the LN 35 will not operate However the electrode will still be electrically when the clamp lead is disconnected WIRE REEL LOADING 50 AND 60 LB ADJUSTABLE WIRE REEL BRAKE The mount for standard 50 and 60 pound electrode coils includes a two position brake assembly Generally the brake should be at the inner position nearest to the wire reel shaft for wire feed speeds below 400 in min 10 m min It should be at the outer position for the faster wire spee
34. h set switch to Constant Voltage Innershield Initially set the output control on 6 DC 600 a Connect a jumper from 2 to 4 on the power source terminal strip so the output will be energized when the DC 600 is turned on For DC 600 below Code 8200 also jumper N to S b Connect the electrode cable to the output terminal of polarity required by electrode Connect work lead to other output terminal c Place Set to Same Polarity As Electrode Cable Connection switch at appropriate position d Place power source toggle switch in Output Control at DC 600 position unless a remote control is connected to 75 76 and 77 on the DC 600 terminal strip e Set mode switch to Constant Voltage Innershield Initially set output control on 4 R3S 325 a Connect a jumper from 4 to 32 on the power source terminal strip so that the output will be energized when the R3S 325 is turned on b Connect the electrode cable to the output terminal of polarity required by electrode Connect work lead to other output terminal c Set power source per its instruction manual NOTE Use of the optional Line Voltage Compensator available for the R3S 325 is recommended if input line voltage variation exceeds 3 SAM 400 650 a Connect a jumper from 2 to C4 on the power source terminal strip so the output will be energized when the SAM power source is on b Connect work lead to WORK stud Connect electrode to AUTO EQUIPMENT stu
35. hen 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 before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety nes 5 minimize exposure to fields from the welding circuit 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 coil the electrode lead around your body 1 f Do not put your hands near the engine fan ww Do not attempt to override the governor or idler by pushing on the
36. iping 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 oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode sr if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or su
37. is being used is dry Check that lead plugs are secure in their receptacles WIRE DRIVE MOTOR AND GEAR BOX Every year examine the gear box Paint the gear teeth with molydisulfide filled grease Lincoln specification E2322 Do not use a graphite grease Check the motor brushes Replace if they are worn down to 1 4 inch or less When ordering feed motor brushes give all information from the motor nameplate GUN AND CABLE MAINTENANCE See IM manual provided with the gun and cable as sembly CIRCUIT PROTECTION AND AUTOMATIC SHUTDOWN CONTROL PC BOARD FUSE On G1757 6 or higher part no P C Boards the 1 8 amp fuse was replaced with electronic protection for trigger circuit faults to electrode circuit On G1757 2 through 5 part no PC boards the 1 8 amp fuse interrupts the 500A lead to the trigger switch On G1757 1 PC boards a 5 amp fuse was used to interrupt the 667 lead The LN 35 will not operate if the fuse is blown AUTOMATIC PROTECTION SHUTDOWN See Automatic Protection Shutdown Section LN 35 LINCOLN D 2 MAINTENANCE D 2 ADJUSTING SPEED SENSOR MODULE The LN 35 Speed Sensor Module is a three lead Hall Effect switch device encased in an externally threaded housing which is screwed into a mounting plate on the motor side of the wire drive gearbox Proper positioning of this module is critical to proper operation of the LN 35 wire feed speed control If the device is not screwed in far enough the L
38. lem persists Wire feeds for a short time but 1 The drive motor may belContact your local Lincoln stops feeding When gun trigger is overloaded Check the wire Authorized Field Service Facility released and retriggered wire feeding system EX Drive roll feeding starts but stops again tension reel brake and gun cable liner Wire feeds OK but stubs or stops 1 If the power source is a constant current type supply the arc voltage may be dipping below 15 VDC causing the LN 35 to Stop or hesitate Connect a constant voltage type power supply to the LN 35 Make sure wire feed mode switch S3 is in the proper position Rough wire feeding or wire nol Gun cable kinked and or twisted feeding but drive rolls turning 2 Wire jammed in gun and cable 3 Incorrect size or installation of drive roll and guide tubes 4 Drive roll loose 5 Gun cable dirty 6 Worn drive roll 7 Electrode rusty and or dirty 8 Worn nozzle or cable liner 9 Partially flashed or melted contact tip 10 Incorrect idle roll pressure 11 Wire reel brake tension set too high CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 35 LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual 1 Worn and or me
39. lted contact tip Replace Worn work cable or poor work connection Loose electrode connect ions Check for loose or faulty connections Wrong electrode polarity for process being used Weld porosity narrow and ropey 1 Contaminated weld joint bead or electrode stubbing into improper procedures Clean plate when welding joint and check procedure wire If all recommended possible areas of speed and all voltage misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Motor feeds but there is no wire 1 Make sure all molex plugs and Field Service Facility feed speed control leads are securely connected to the control board Check speed sensor see maintenance section CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 35 LINCOLN F 1 DIAGRAMS Jequunu epoo 1ueuudinbe y e jueunredeg eui UM e qiGej s j sjeued y JO euo uo episui pejsed si epoo sejnomed e 5 siy Aq paJeAoo seuluoeui eq jou Aew 3 0211 S0 90 1 S6LSEYD 7400718 YOLONGNOD OL A119341Q SLOANNOO
40. ressure This is an approximate setting The optimum idle roll setting can be determined as follows 1 Press end of gun against a solid object that is electrically isolated from the welder output Press the gun trigger for several seconds 2 If the wire birdnests jams or breaks at the drive roll the idle roll pressure is too great Back the pressure setting out turn run new wire through gun and repeat above steps 3 If the only result is drive roll slippage shut off the power source then loosen the gun cable clamping screw in the gearbox conductor block and pull the gun cable forward about six inches There should be a slight waviness in the exposed wire If there is no waviness the pressure is too low Increase the pressure setting turn lock the gun cable in place and repeat the above steps LN 35 LINCOLN P B 4 OPERATION B 4 PRESETTING WIRE FEED SPEED The LN 35 permits accurate presetting of the desired wire feed speed before welding in both CV and CC wire feed modes SETTING CONSTANT WIRE FEED SPEED CV MODE a Set Wire Feed Mode switch to CV position b Set Wire Feed dial to the desired wire feed speed on the selected calibrated dial range The wire speed will remain constant at the value set independent of arc voltage changes as long as the arc voltage does not drop below the value per the chart below for the max wire feed speed shown Maximum Speed Minimum Arc Volts 250 IPM 15V 28
41. s 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 provoquer 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 fortement 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 11
42. t DC 250 a Connect a jumper from 2 to 4 on the power source terminal strip so the output will be energized when the DC 250 is turned on b Connect electrode cable to the Innershield GMAW output terminal of polarity required by electrode Connect work lead to other Innershield GMAW output terminal c Place Set to CV Electrode Cable Polarity switch at appropriate position d Place power source toggle switch in Output Control at DC 250 position unless a Remote Control is connected to 75 76 and 77 on the DC 250 terminal strip e Place mode switch in Innershield GMAW CV position Set CV arc control to 2 or NORMAL on some machines Initially set the output control on 7 DC 400 AND CV 400 a Connect a jumper from 2 to 4 on the power source terminal strip so the output will be energized when the power source is turned on NOTE DC 400 machines above Code 9200 have an output toggle switch to perform this function b Connect the electrode cable to the output terminal of polarity required by electrode Connect work lead to other output terminal LN 35 LINCOLN A 3 INSTALLATION A 3 c Place Set to Same Polarity As Electrode Cable Connection switch at appropriate position d Place power source toggle switch in Output Control at DC CV 400 position unless a remote control is connected to 75 76 and 77 on the power source terminal strip e If power source has a mode switc
43. t variations The steeper the slope the more difficult it becomes to maintain arc voltage stability with a constant wire speed open arc process To aid in stabilizing the arc voltage when welding on CC power sources the LN 35 is provided with a VV CC wire feed mode This arc voltage sensing feed mode decreases or increases the wire speed when the arc voltage decreases or increases However if the electrode shorts to the work the arc voltage will essentially drop to zero and the short circuit current supplied by the CC power source may not provide enough power to re establish the arc especially with steeper slope machines Under this condition the LN 35 feeder will stop as if the trigger was released and not restart until the short has been opened Arc shorting is more difficult to avoid when using a CC power source and requires a more refined operator technique than when using a CV power source Improved performance can be obtained on CC power source applications within the following guidelines 1 Flatter slope power sources with higher arc force short circuit current will improve performance over steep slope machines The steeper the slope the more critical it is to hold proper electrode stickout to maintain arc stability Welding techniques such as weaving will be more difficult to control Use the highest output current tap or setting capable of providing the voltage adjustment required for the procedure AUTOMATIC
44. tempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS vi Page INSTALLATION SECTION eege eege EE A Technical ee EE A 1 Safety PrECAULIONS oci esten US 2 Source E 2 Gun Cable Connection to Feeder A ie EE EES A 3 Weld Cable Conpechon nennen nennen senes sees esses 4 Electrode Cable Comme ctor A 4 Work Cable 4 Drive RGM instalation A 4 OPERATION m SECTION B Sri fe B 1 General Description 1 Recommended Processes and Equipment NENNEN B 1 ii EEE ENA AE a 1 EN 35 Instruments Controls Peu aat 1 Work Clip PET 2 Wire reel Loading 50 and 60
45. throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X K Connect the work cable to the workpiece as close as possible to the area being welded 1 9 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 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 or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic
46. you Thank You take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before at
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