Lincoln Electric SVM143-A Manual de usuario

DH-10 Heads & Controls

Boom Mount or Bench Models

OPERATOR’S MANUAL

SVM143-A

March, 1999

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.

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.)

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

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FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

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.

____________________________________________________

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.

____________________________________________________

1.e. 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.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. 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.

SAFETY

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 & Cutting - ANSI Standard Z49.1” 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.

WARNING

Mar ‘95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

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

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

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.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

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FUMES AND GASES

can be dangerous.

5.a.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.

5.b.

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

form phosgene, a highly toxic gas, and other irritating

products.

5.c. 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.

5.d. 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.

5.e. Also see item 1.b.

SAFETY

ARC RAYS can burn.

4.a. 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 Z87. I 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.

4.c. 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.

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 DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. 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.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. 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.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

Mar ‘95

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CYLINDER may explode

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.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. 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.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding 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.

6.b. 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.

6.c. 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.

6.d. 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).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

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.

6.g. 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.

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instruc-

tions et les précautions de sûreté specifiques qui parraissent

dans ce manuel aussi bien que les précautions de sûreté

générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés 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 couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

d. Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud-

er parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-

téger contre les chutes dans le cas ou on recoit un choc. Ne

jamais enrouler le câble-électrode autour de n’importe quelle

partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du

rayonnement de l’arc et des projections quand on soude

ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflamma-

bles.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection

libres de l’huile, tels que les gants en cuir, chemise épaisse,

pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les

vapeurs du solvant pour produire du phosgéne (gas forte-

ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code

de l’électricité et aux recommendations du fabricant. Le dis-

positif de montage ou la piece à souder doit être branché à

une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste

seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la

debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

Mar. ‘93

DH-10

MASTERTABLE OF CONTENTS FOR ALL SECTIONS

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Technical Specifications — DH-10 Complete Units or Controls & Heads A-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . A-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Installation of the DH-10 Boom Mount Wire Feeder Components . . . . . A-4

Wire Drive Speed Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-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

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Wire Reel Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Loss of Voltage Sense Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Grounding Lead Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Explanation of Prompting and Error Messages . . . . . . . . . . . . . . . . . . . B-12

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Wire Reel Mounting - Readi-Reels and

10 to 30 lb (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . F-31

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-288

RETURNTOMAIN INDEX

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SECTION A-1

INSTALLATION

DH-10

SECTION A-1

TABLE OF CONTENTS

-INSTALLATION SECTION-

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

Technical Specifications — DH-10 Complete Units or Controls & Heads . . . . . . . . . . . . . . . . . . . . A-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Available Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Installation of the DH-10 Boom Mount Wire Feeder Components . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Mounting the DH Double Header Wire Drive Unit (K1497-1 or -2) . . . . . . . . . . . . . . . . . . . . . . . A-4

Mounting Single Head Wire Drive Unit (K679-1 or -2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Mounting the DH-10 Control Box (K1496-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Connecting Wire Drive Unit to Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Wire Drive Speed Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Control Speed Range Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Double Header (DH) Wire Drive Ratio Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Wire Feed Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Procedure to Install Drive Roll and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Single Drive 4-Roll Kits (KP655 and KP656) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

DH Drive Roll Kit Installation (KP1505 and KP1507) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Gun and Cable Assemblies with Standard Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

GMAW Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Innershield Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Gun Cable Connection with Standard Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Gun and Cable Assemblies with Fast-Mate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

GMAW Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Gun Cable Connection with Fast-Mate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

DH Double Head Drives Water Connections (For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . . A-8

DH Double Head Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Single Head Drives (K679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

GMAW Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Input Cable: DH-10 Control to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Optional Features Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

A-2

INSTALLATION

DH-10

A-2

TECHNICAL SPECIFICATIONS – DH-10 Complete Units or Controls & Heads

WIRE DRIVE HEADS (BOOM MOUNT)•

SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO

Wire Size Wire Size

Speed Solid Cored Speed Solid Cored

K1497-1

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)

K1497-2◊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 - 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 - 31.8 m/m) (0.6 - 1.2 mm) (0.9 - 1.2 mm)

K679-1* Synergic 7F 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 mm) (0.9 - 2.0 mm)

K679-2* Synergic 7F --- --- --- 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)

CONTROLS SECTION OF COMPLETE UNITS

SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING

Dimensions

Height Width Depth Weight Operating Storage

K1499-1 Double Head 40 - 42 Vac + 10% 20.50 in. 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 mm) (38.3 kg) +40°C to +40°C to

-20°C -40°C

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.

CONTROLS (BOOM MOUNT)

SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING

Dimensions

Height Width Depth Weight Operating Storage

K1496-1∆DH-10 40 - 42 Vac + 10% 14.80 in. 14.20 in. 4.20 in. 18.0 lbs +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°C -40°C

• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual.

∆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

• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual.

¤ Included in K1521-1,-2,-3 DH-10 Boom Packages.

◊Included in K1521-4,-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)

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:

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:

WIRE DRIVE SPECIFICATIONS FOR 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 - 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)

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A-3

INSTALLATION

DH-10

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 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 cable is required for each head:

K1498-“L” Includes a control cable with a 14-pin

ms style connection on each end, and

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 K1497-1)

• 16 ft (4.9 m) Control Cable (Same as K681-16)

•16 ft (4.9 m) Control and Weld Cable (Same as

K1498-16)

K1521-2 includes:

• DH-10 Control (Same as K1496-1)

•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 or Innershield processes.

The wire type and size range for the wire drive used,

and gear ratio change selected, are given in the

Specifications.

Recommended power sources are Lincoln Electric

Company constant voltage power sources with 42

VAC auxiliary power and a 14-pin connector recepta-

cle. At the time of printing these include: CV 250,

CV300-I, CV-300, CV400-I, CV-400, CV500-I, DC-

400, CV-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.

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A-4

INSTALLATION

DH-10

A-4

SAFETY PRECAUTIONS

INSTALLATION OFTHE DH-10

BOOM MOUNTWIRE FEEDER

COMPONENTS

Mounting the DH Double HeaderWire

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 plate 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

not be bent sharply as it comes from the unit. See

Procedure for setting angle of Feed Plate

in the

Operation

section of this manual.

Mounting Single HeadWire 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 reach 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.

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.

----------------------------------------------------------------------------------------

WARNING

FIGURE A.1

5/16-18 THREAD 2.25

FEED PLATE

DOOR OPEN

5.00

10.50

18.50

3.00

6.00

11.00

BOTTOM FRONT

FIGURE A.2

CLEARANCE

FOR 1/4 BOLT

2.63

12.75

14.50

13.75

5.25

CLEARANCE

FOR 1/4 BOLT

10.50 .50

10.00

2.63

14.00

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