Lincoln Electric Welder SVM154 A User Manual
RETURN TO MAIN INDEX  
SVM154-A  
LN-10 Heads & Controls  
September, 2002  
Boom Mount or Bench Models  
For use with: LN-10 Control - Boom Mount Code 10442  
10 Series Wire Drive - Boom Mount Code 10443, 10444, 10763, 10764  
LN-10 Boom Package Code 10445, 10765  
Synergic 7F Drive Code 10190, 10191  
LN-10 - Bench Model Code 10440, 10441, 10761, 10762  
LN-10 - Zipline Boom Package Code 10497, 10498 , 10771, 10772  
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.  
SERVICE MANUAL  
Copyright © 2001 Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
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.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
• AC Welder with Reduced Voltage Control.  
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.  
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.  
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 to  
form phosgene, a highly toxic gas, and other irritating  
products.  
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.  
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.  
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.  
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.  
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.  
5.e. Also see item 1.b.  
Mar ‘95  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
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.  
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.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
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.  
•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.  
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).  
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.  
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.  
FOR ELECTRICALLY  
powered equipment.  
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.  
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.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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iv  
iv  
SAFETY  
5. Toujours porter des lunettes de sécurité dans la zone de  
PRÉCAUTIONS DE SÛRETÉ  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Pour votre propre protection lire et observer toutes les instruc-  
tions et les précautions de sûreté specifiques qui parraissent  
dans ce manuel aussi bien que les précautions de sûreté  
générales suivantes:  
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.  
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.  
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.  
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.  
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.  
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.  
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.  
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.  
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.  
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.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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.  
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.  
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.  
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. 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.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
Mar ‘93  
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RETURN TO MAIN INDEX  
v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
Page  
i-iv  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D  
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E  
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F  
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . .  
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .  
Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
F-2  
F-3  
F-5  
F-17  
F-31  
F-43  
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G  
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
P-311  
LN-10  
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SECTION A-1  
SECTION A-1  
INSTALLATION  
TABLE OF CONTENTS  
-INSTALLATION SECTION-  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A  
Technical Specifications — LN-10 Head and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installation of the LN-10 Boom Mount Wire Feeder Components . . . . . . . . . . . . . . . . . . . . . . . . . .  
Mounting of Synergic 7F Wire Drive Unit (K679-1 or -2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Mounting the LN-10 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Connecting Wire Drive Unit to Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Speed Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Control Speed Range Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
10 Series Wire Drive Ratio Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Feed Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Procedure to Install Drive Roll and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Synergic 7F Wire Drive 4-Roll Kits (KP655 & KP656) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
10 Series Wire Drive Roll Kit Installation (KP1505 and KP1507) . . . . . . . . . . . . . . . . . . . . . . . .  
Gun and Cable Assemblies with Standard Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
GMAW Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Innershield Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun Cable Connection with Standard Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun and Cable Assemblies with Fast-Mate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
GMAW Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun Cable Connection with Fast-Mate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
10 Series Wire Drive Water Connections (For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . . . .  
10 Series Wire Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Synergic 7F Wire Drive (K679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
GMAW Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Cable: LN-10 Control to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Optional Features Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Dual Procedure Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Boom and Bench Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
A-2  
A-2  
A-3  
A-3  
A-3  
A-4  
A-4  
A-4  
A-5  
A-5  
A-5  
A-5  
A-6  
A-6  
A-6  
A-6  
A-7  
A-7  
A-7  
A-7  
A-7  
A-7  
A-8  
A-8  
A-8  
A-8  
A-8  
A-9  
A-9  
A-9  
A-10  
A-10  
A-10  
LN-10  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS – LN-10 Head & Control  
WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER  
SPEC.# TYPE  
LOW SPEED RATIO  
HIGH SPEED RATIO  
Speed  
Wire Size  
Solid  
Speed  
Wire Size  
Solid  
Cored  
Cored  
K1563-1 10 Series  
Std Drive Boom Mount  
35-500 IPM  
(0.89-12.7 M/M)  
.025 - 3/32 in.  
(0.6 - 2.4 mm)  
.035 - .120 in  
(0.9 - 3.0 mm)  
.50 - 750 IPM  
(1.25 - 19.0 M/M)  
.025 - 1/16 in.  
(0.6 - 1.6 mm)  
.035 - 5/64 in.  
(0.9 - 2.0 mm)  
K1563-2 10 Series  
Hi-Speed Boom Mount  
55 - 825 IPM  
(1.40 - 21.0 M/M) (0.6 - 1.6 mm)  
.025 - 1/16 in.  
.035 - 5/64 in.  
(0.9 - 2.0 mm)  
80 - 1250 IPM  
(2.00 - 31.8 M/M)  
.025 - .045 in.  
(0.6 - 1.2 mm)  
.035 - .045 in.  
(0.9 - 1.2 mm)  
K679-1 Synergic 7F*  
Std Drive Boom Mount  
50 - 770 IPM  
(1.27 - 19.5 M/M) (0.6 - 1.6 mm)  
.025 - 1/16 in.  
.035 - 5/64 in.  
(0.9 - 2.0 mm)  
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---  
---  
K679-2 Synergic 7F*  
Hi-Speed Boom Mount  
---  
---  
---  
80 - 1200 IPM  
(2.00 - 30.5 M/M)  
.025 - .045 in.  
(0.6 - 1.2 mm)  
.035 - .045 in.  
(0.9 - 1.2 mm)  
K1559-1 LN-10  
Std Drive Bench Model  
35-500 IPM  
(0.89-12.7 M/M)  
.025 - 3/32 in.  
(0.6 - 2.4 mm)  
.035 - .120 in.  
(0.9 - 3.0 mm)  
50 - 750 IPM  
(1.25 - 19.0 M/M)  
.025 - 1/16 in.  
(0.6 - 1.6 mm)  
.035 - 5/64 in.  
(0.9 - 2.0 mm)  
K1559-2 LN-10  
Hi-Speed Bench Model  
55 - 825 IPM  
(1.40 - 21.0 M/M) (0.6 - 1.6 mm)  
.025 - 1/16 in.  
.035 - 5/64 in.  
(0.9 - 2.0 mm)  
80 - 1250 IPM  
(2.00 - 31.8 M/M)  
.025 - .045 in.  
(0.6 - 1.2 mm)  
.035 - .045 in.  
(0.9 - 1.2 mm)  
CONTROLS, HEADS AND COMPLETE UNITS  
INPUT POWER PHYSICAL SIZE•  
SPEC.# TYPE  
TEMPERATURE RATING  
Dimensions  
Width  
14.20 “  
Height  
14.80 “  
Depth  
4.20 “  
Weight  
18.0 Lbs  
Operating  
Storage  
K1562-1∆ LN-10  
40-42 Vac + 10%  
Control  
Controls  
4.0 Amps 50/60 Hz (375.9 mm) ( 360.7mm) (106.7 mm) (8.2 Kg)  
K1563-1∆ 10 Series  
7.81 “  
14.71 “  
11.00“  
25.0 Lbs  
Std Drive  
Boom Mount  
(198.4 mm) (373.6 mm) (27.94 mm) (11.3 Kg)  
K1563-2 10 Series  
Hi-Speed  
Boom Mount  
+40°C  
to  
+40°C  
to  
K679-1  
Synergic 7F*  
11.5“  
7.16“  
8.06“  
16.5 Lbs  
-20°C  
-40°C  
Std Drive Boom Mount  
( 285.8mm) (181.9 mm) (204.7mm) (7.5 Kg.)  
K679-2  
Hi-Speed  
Synergic 7F*  
Boom Mount  
K1559-1 LN-10  
40-42 Vac + 10%  
20.46 “  
14.73 “  
30.35 “  
65.0 Lbs  
Std Drive Bench Model 4.0 Amps 50/60 Hz (519.7 mm) (366.5 mm) (770.9 mm) (29.5 Kg)  
K1559-2 LN-10  
Hi-Speed  
Bench Model  
• Excluding Wire Reel  
∆ Included with K1561-Series, LN-10 Boom Packages  
*Synergic 7F wire drives use 4-roll drives with 2 driven rolls(Drive roll kits not common with 10 Series heads)  
GENERAL DESCRIPTION  
Also, 4 selectable, presettable timers for each procedure;  
preflow, postflow, burnback and spot weld time.  
The LN-10 is a modular line of 42VAC input 4-roll wire feed-  
ers. A single control with dual procedure presettability of  
wire feed speed (in IPM or M/min) and arc voltage is used  
with a single DC welding power source.  
Arc starting can be optimized for each procedure with 5  
selectable wire feed acceleration rates, and independent  
control of slower run-in procedure.  
The LN-10 models have controls providing keypad or  
remote selectability of either of two procedures.  
A gas purge key is provided, as well as cold feed forward  
and reverse keys with independently adjustable forward  
feed speed setting.  
The units offer 4 independently selectable gun trigger  
modes for each procedure; cold feed, 2 step and 4-step trig-  
ger and spot weld mode.  
LN-10  
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A-3  
A-3  
INSTALLATION  
All of these features are selected with a tactile-feel keypad,  
and are set independently using one of two rotating knob  
encoders, setting levels are displayed on one of two digital  
LED displays.  
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 and DC-650 PRO.  
The 10 Series Wire Drive assemblies include a heavy duty  
head with externally changeable gear ratio and 4 driven roll  
drives housed together in a single combination mounting  
and connection box. Gun adapters are available to permit  
use with a variety of standard welding guns.  
Available Models:  
The DC-250, DC-600, DC-1000 and the Pulse Power  
500 (CV mode only) may also be used with the LN-10  
if the optional K1520-1 115V / 42V Transformer Kit is  
used.  
The LN-10 Wire Feeder system is available configured in  
both Bench and Boom models.  
Bench Models consists of an LN-10 control and a 10  
Series wire drive assembly premounted on a platform  
with a dual 2" O.D. spindle mounting.  
SAFETY PRECAUTIONS  
ELECTRIC SHOCK can  
Boom Models consist of an LN-10 control and a choice of  
wire drives designed to be mounted separately and joined  
by available head to control cable assemblies.  
kill.  
• Turn the input power off at the power source  
disconnect switch before attempting to connect  
the input power to the LN-10 Control.  
The head to control cable assemblies are available in  
two types; one control cable is required for each head:  
• Only qualified personnel should perform this installation.  
----------------------------------------------------------------------------------------  
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)  
INSTALLATION OF THE LN-10  
BOOM MOUNT WIRE FEEDER  
COMPONENTS  
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).  
Mounting the 10 Series Wire Drive  
Mount the 10 Series wire drive to the boom or struc-  
ture using the four 5/16-18 threaded mounting holes  
located on the bottom of the 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.  
LN-10 Boom Packages (K1564-Series) are also avail-  
able which include:  
• LN-10 Control Box  
• 10 Series Wire Drive  
• Appropriate length Control and Weld Cables to  
connect Control to Wire Drive  
• Accessories specific to the Boom package  
ordered  
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.  
RECOMMENDED PROCESSES  
AND EQUIPMENT  
The LN-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.  
LN-10  
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A-4  
A-4  
INSTALLATION  
CLEARANCE  
FOR 1/4 BOLT  
5/16-18 THREAD  
2.25  
10.50  
.50  
6.00  
11.00  
FEED PLATE  
DOOR OPEN  
CLEARANCE  
FOR 1/4 BOLT  
3.00  
BOTTOM FRONT  
5.00  
2.63  
10.50  
14.50  
2.63  
5.25  
14.50  
FIGURE A.2  
FIGURE A.1  
Mounting Synergic 7F Wire Drive Unit  
(K679-1 or -2)  
Connecting Wire Drive Unit to Control Box  
One head to control cable assembly is required. The  
Head to Control cable assemblies are available in two  
types:  
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.  
K1498-"L" -Includes a control cable with 14-pin ms-style  
connectors on each end, and a 3/0 weld  
cable (rated 600 amps, 60% duty cycle) to  
route between the wire drive and the control  
box. Available in lengths "" of 16 ft. (4.9 m),  
20 ft. (6.1 m) and 25 ft. (7.6 m)  
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.  
K681-"L" - Same as K1498, but does not include weld  
cable. Available in lengths "L" of 12 ft (3.6 m),  
16 ft (4.9 m) and 25 ft. (7.6 m).  
a) Making certain the cables are protected from any  
sharp corners which may damage their jackets,  
mount the cable assembly along the boom so the end  
with the female amphenol connector pins is at the  
wire feed unit.  
Mounting the LN-10 Control Box  
The same control box is used for both a 10 Series drive,  
or a Synergic 7F drive. 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 convenient 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.  
b) Connect the 14-socket cable connectors to the mating  
receptacles on the back of the wire feed unit connec-  
tion box.  
c) At the same end, connect the electrode lead to the  
1/2" connection bolt on the front of the left wire drive  
head feed plate.  
a) Drill the required holes in the mounting surface,  
partially install 1/4-20 screws.  
d) At the control box end, connect the 14 pin connectors  
of the cable to the mating receptacle on the bottom of  
the control box.  
b) Mount the box.  
c) Tighten the screws.  
e) At the control box current sensor, slip the cover box  
up off the sensor and connect the electrode cable(s)  
to the top bolt connection.  
LN-10  
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A-5  
A-5  
INSTALLATION  
Electrode Routing  
a) Loosen the clamping collar screw using a  
3/16" Allen wrench. The clamping collar  
screw is accessed from the bottom of the  
feedplate. It is the screw which is perpen-  
dicular to the feeding direction.  
The electrode supply may be either from reels, Readi-  
Reels, spools, or bulk packaged drums or reels.  
Observe the following precautions:  
a) The electrode must be routed to the wire drive unit  
so that the bends in the wire are at a minimum,  
and also that the force required to pull the wire  
from the reel into the wire drive unit is kept at a  
minimum.  
b) Loosen the retaining screw, which is also  
accessed from bottom of feeder, using a  
3/16" Allen wrench. Continue to loosen  
the screw until the feedplate can be easily  
pulled off of the wire feeder.  
b) The electrode is "hot" when the gun trigger is  
pressed and must be insulated from the boom and  
structure.  
3) Loosen, but do not remove, the screw on the lower  
right face of the feedplate with a 3/16" Allen  
wrench.  
c) If more than one wire feed unit shares the same  
boom and are not sharing the some power source  
output stud, their wire and reels must be insulated  
from each other as well as insulated from their  
mounting structure.  
4) Remove the screw on the left face of the feedplate.  
If changing from high speed (larger gear) to low  
speed (smaller gear), line the lower hole on the left  
face of the feedplate with the threads on the  
clamping collar. Line the upper hole with the  
threads to install larger gear for high speed feeder.  
If feedplate does not rotate to allow holes to line  
up, further loosen the screw on right face of feed-  
plate.  
WIRE DRIVE SPEED RANGE  
SELECTION  
The rated speed and wire size range for each wire  
drive head is shown in the SPECIFICATIONS in the  
front of this section.  
5) Install gear onto output shaft and secure with flat  
washer, lock washer, and Phillips head screw  
which were previously removed.  
6) Tighten the screw on lower right face of feedplate.  
Control Speed Range Setting  
7) Re-attach feedplate to wire feeder if removed in  
Step 2.  
The speed range is set up to match the wire feed  
head connected to the LN-10 control by properly set-  
ting the switch (S1) code on the control board inside  
the control box. See OPERATION “Setting the DIP  
Switches” for setting instructions.  
8) Feedplate will be rotated out-of-position due to the  
gear change. To re-adjust angle of feedplate:  
a) Loosen the clamping collar using a 3/16"  
Allen wrench. The clamping collar screw  
is accessed from the bottom of the feed-  
plate. It is the screw which is perpendicu-  
lar to the feeding direction.  
10 Series Wire Drive Ratio Selection  
The 10 Series type drives include two external gear  
sizes; a 1" dia. gear and a 1-1/2" dia. gear. The  
smaller gear provides the low speed range ratio, and  
the larger gear provides the high speed range ratio  
per the SPECIFICATIONS in the front of this section.  
b) Rotate feedplate to the desired angle and  
tighten clamping collar screw.  
The following procedure is for changing ratio of the 10  
Series wire drive:  
9) Make sure to properly set the switch (S2) code on  
the control board inside the control box for the  
new gear size installed. See OPERATION  
“Setting the DIP Switch” for setting instructions.  
1) Pull open the Pressure Door.  
2) Remove the Phillips head screw retaining the pin-  
ion gear to be changed and remove the gear. If  
the gear is not easily accessible or difficult to  
remove, remove the feedplate from the gearbox.  
To remove feedplate:  
LN-10  
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A-6  
A-6  
INSTALLATION  
3) Remove clamping screw & clamping collar from  
the drive shaft closest to the incoming side of the  
feeder.  
WIRE FEED DRIVE ROLL KITS  
NOTE: The maximum rated solid and cored wire  
sizes for each wire drive head and selected  
drive ratio is shown on the SPECIFICATIONS  
in the front of this section.  
4) Install drive roll onto keyed shaft. (Do not exceed  
the maximum wire size rating of the wire drive.)  
Replace collar and tighten clamping screw.  
5) Back out the set screw for the middle guide tube.  
Install the middle guide tube and slide it up against  
the drive roll. DO NOT TIGHTEN THE MIDDLE  
GUIDE AT THIS TIME.  
The electrode sizes that can be fed with each roll and  
guide tube are stenciled on each part. Check the kit  
for proper components.  
Synergic 7F Wire Drives (K679) use 4-Roll drive roll  
kits with 2 driven rolls, per Table C.1 in ACCES-  
SORIES Section. These kits are common with those  
used for the 4-Roll LN-7 GMA and LN-9 GMA Lincoln  
Wire Feeders, but are not common with those used  
with the 10 Series wire drive units. Installation instruc-  
tions are included with the kits.  
6) Install the outgoing drive roll following the same  
procedure as steps 3 & 4.  
7) Center the middle guide between the two drive  
rolls and tighten in place.  
8) Back out the screws for the incoming and outgoing  
guide tubes.  
10 Series Wire Drives use 4-Roll drive roll kits with 4  
driven rolls, per Table C.1.  
9) Install the longer guide tube in the rear hole near  
the incoming drive roll. Slide the tube in until it  
almost touches the roll. Tighten in place.  
PROCEDURE TO INSTALL DRIVE  
ROLL AND WIRE GUIDES  
10) Install the remaining guide tube in the front hole.  
Be certain that the proper plastic insert is used.  
Fine wire chisel point tube must have largest  
radius next to drive roll. Tighten in place.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts such  
as output terminals or internal wiring.  
11) Re-latch both quick release levers.  
•
When inching with gun trigger, electrode and  
drive mechanism are “hot” to work and ground  
and could remain energized several seconds  
after the gun trigger is released.  
12) To start new electrode, straighten the first 6"  
(150mm) and cut off the first 1" (25 mm). Insert  
free end through the incoming tube. Press gun  
trigger and push wire into the drive roll.  
• Turn OFF input power at welding power  
source before installation or changing  
drive roll and/or guide tubes.  
TO SET DRIVE ROLL PRESSURE, see “Drive Roll  
Pressure Setting” in the OPERATION Section.  
• Welding power source must be connected  
to system ground per the National  
Electrical Code or any applicable local  
codes.  
10 Series Wire Drive Roll Kit Installation  
(KP1505 and KP1507)  
• Only qualified personnel should  
perform this installation.  
1) Turn OFF Welding Power Source.  
Observe all additional Safety Guidelines detailed  
throughout this manual.  
2) Pull open Pressure Door to expose rolls and wire  
guides.  
Synergic 7F Wire Drive 4-Roll Kits (KP655  
and KP656)  
3) Remove Outer Wire Guide by turning knurled  
thumb screws to unscrew from Feedplate.  
1) Turn OFF welding power source.  
4) Remove drive rolls, if any are installed, by pulling  
straight off shaft. Remove inner guide.  
2) Release both quick release levers by sliding the  
levers sideways into the open positions.  
5) Insert inner Wire Guide, groove side out, over the  
two locating pins in the feedplate.  
LN-10  
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A-7  
A-7  
INSTALLATION  
6) Install each drive roll by pushing over shaft until it  
butts up against locating shoulder on the drive roll  
shaft. (Do Not exceed maximum wire size rating of  
the wire drive).  
Gun Cable Connection with Standard  
Connection  
1. Check that the drive rolls and guide tubes are  
proper for the electrode size and type being used.  
If necessary, change them per “Wire Drive Roll  
Kits” in this section.  
7) Install Outer Wire Guide by sliding over locating  
pins and tightening in place.  
8) Engage upper drive rolls if they are in the “open”  
position and close Pressure Door.  
2. Lay the cable out straight. Insert the connector on  
the welding conductor cable into the brass conduc-  
tor block on the front of the wire drive head. Make  
sure it is all the way in and tighten the hand clamp.  
Keep this connection clean and bright. Connect  
the trigger control cable polarized plug into the  
mating 5 cavity receptacle on the front of the wire  
drive unit.  
TO SET DRIVE ROLL PRESSURE, see “Drive Roll  
Pressure Setting” in OPERATION Section.  
GUN AND CABLE ASSEMBLIES  
WITH STANDARD CONNECTION  
3. For GMA Gun Cables with separate gas fitting (10  
Series Wire Drive using K1500-1 Gun Adapter),  
connect the 3/16" I.D. gas hose from the wire drive  
unit to the gun cable barbed fitting.  
The 10 Series Wire Drive Heads each require a  
K1500 Gun Adapter installed See “Gun Adapters” in  
ACCESSORIES section. The K1500-2 Gun Adapter  
and Trigger Cable for Magnum 200-400 guns are fac-  
tory included with the LN-10.  
GUN AND CABLE ASSEMBLIES  
WITH FAST-MATE CONNECTION  
GMAW Guns  
(Requires K489-2 Fast Mate™ Adapter Kit used with  
the K1500-1 Gun Adapter)  
An expanding line of Magnum gun and cable assem-  
blies are available to allow welding with solid and  
cored electrodes using the GMAW process. See the  
appropriate Magnum literature for descriptions of the  
200 to 550 ampere air cooled gun and cables that are  
available. Gun cable lengths range from 10 ft. (3.0 m)  
to 25 ft. (7.6 m) and feed electrode sizes .025" (0.6  
mm) to 3/32" (2.4 mm). The entire line of Magnum  
Fast-Mate gun and cable assemblies can also be  
used by installing a K489-2 Fast-Mate adapter kit.  
See “Gun and Cable Assemblies with Fast-Mate  
Connection” in this section for details.  
GMAW Guns  
An expanding line of Magnum Fast-Mate™ air cooled  
and water cooled gun and cable assemblies are avail-  
able to allow welding with solid and cored electrodes  
using the GMAW process. See the appropriate  
Magnum literature for descriptions of the 200 to 400  
ampere air cooled gun and cables that are available  
as well as the Magnum “Super Cool” 450 ampere  
water cooled gun and cable. Gun cable lengths range  
from 10 ft. (3.0 m) to 25 ft. (7.6 m) and feed electrode  
sizes .025" (0.6 mm) to 5/64" (20 mm).  
Innershield Guns  
K126 and K115 gun and cable assemblies are avail-  
able to allow welding with Innershield electrodes. Gun  
cable lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m)  
The 350 ampere K126 will feed electrode sizes .062  
(1.6 mm) to 3/32" (2.4 mm). The 450 ampere K115  
will feed 5/64" (2.0 mm) to 3/32" (2.4 mm) electrode.  
An expanding line of Magnum X-Tractor gun and  
cable assemblies provides fume extraction capability  
for welding with solid and cored electrodes using the  
GMAW process. See the appropriate Magnum litera-  
ture for descriptions of the 250 to 400 ampere air  
cooled gun and cables that are available. Gun cable  
lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m) and  
feed electrode sizes .035" (0.9 mm) to 1/16" (1.6 mm).  
These guns require the use of either the K173-1 or  
K184* vacuum units.  
Three smoke extraction gun and cable assemblies are  
available, 250 ampere K309, 350 ampere K206 and  
the 500 ampere K289. All gun cable lengths are 15 ft.  
(4.5 m). These guns will feed electrode sizes .062"  
(1.6 mm) to 3/32" (2.4 mm) and require the use of the  
K184 vacuum unit for use with the LN-10.  
*Requires S14927-8 connector hose and an S20591  
hose adapter.  
LN-10  
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A-8  
A-8  
INSTALLATION  
Gun Cable Connection with Fast-Mate  
Connection  
GMAW Shielding Gas  
WARNING  
1. Check that the drive rolls, feeder guide tubes and  
gun connector guide tube are appropriate for the  
electrode size being used. If necessary, change  
them per “Wire Drive Roll Kits” in this section.  
CYLINDER may explode if damaged.  
• Keep cylinder upright and chained to  
support.  
• Keep cylinder away from areas where  
it may be damaged.  
• Never lift welder with cylinder attached.  
• Never allow welding electrode to touch cylinder.  
• Keep cylinder away from welding or other live elec-  
trical circuits.  
2. Connect gun to gun connector making sure all pins  
and gas tube line up with appropriate holes in con-  
nector. Tighten gun by turning large nut on gun  
cable clockwise.  
BUILDUP OF SHIELDING GAS may  
harm health or kill.  
• Shut off shielding gas supply when not  
in use.  
10 SERIES WIRE DRIVE WATER  
CONNECTIONS (FOR WATER  
COOLED GUNS)  
SEE AMERICAN NATIONAL STANDARD Z-49.1,  
“SAFETY IN WELDING AND CUTTING” PUBLISHED  
BY THE AMERICAN WELDING SOCIETY.  
10 Series Wire Drive: must have a K590-4  
Water Connection Kit installed for water cooled  
guns. (See ACCESSORIES).  
------------------------------------------------------------------------  
Using male quick-connect fittings, connect the water  
hoses to the coolant inlet and outlet on the back of the  
wire drive. Connect the other ends of these hoses to  
the appropriate ports on the water cooling units.  
Customer must provide a cylinder of shielding gas, a  
pressure regulator, a flow control valve, and a hose  
from the flow valve to the gas inlet fitting of the wire  
drive unit.  
In the event the water line fittings on your water  
cooled gun are incompatible with the female quick  
connects on the front of the wire drive, male quick-  
connects (L.E. Part No. S19663) are provided in the  
Kit for installation on 3/16" (5 mm) I.D. hose  
(Customer to provide appropriate clamps). The feed-  
er connectors self seal when disconnected.  
Connect a supply hose from the gas cylinder flow  
valve outlet to the 5/8-18 female inert gas fitting on the  
back panel of the wire drive or, if used, on the inlet of  
the Gas Guard regulator. (See Below).  
Gas Guard Regulator - The Gas Guard Regulator is  
an optional accessory (K659-1) on these models.  
Install the 5/8-18 male outlet of the regulator to the  
5/8-18 female gas inlet on the back panel of the wire  
drive. Secure fitting with flow adjuster key at top.  
Attach gas supply to 5/8-18 female inlet of regulator  
per instructions above.  
Synergic 7F Wire Drive (K679) :Must have a  
K682-2 Water Connection Kit installed. (See  
ACCESSORIES section of IM559).  
Using hose clamps provided with the K682-2 kit, con-  
nect appropriate water hoses to the coolant inlet and  
outlet fittings on the back of the K682-2 Kit. Connect  
the other ends of these hoses to the appropriate ports  
on the water cooling units.  
In the event the water line fittings on your water  
cooled gun are incompatible with the female quick  
connects on the front of the K682-2 Kit male quick-  
connects are provided with the kit for installation on  
3/16 (5 mm) I.D. hose (Customer to provide appropri-  
ate clamps). The feeder connectors self seal when  
disconnected.  
LN-10  
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A-9  
A-9  
INSTALLATION  
2) Connect the electrode lead to the power source  
output terminal of the desired polarity.  
ELECTRICAL INSTALLATION  
3) Connect the 9-socket plug of the control cable to  
the mating receptacle on the bottom of the LN-10  
control box.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts such  
as output terminals or internal wiring.  
4) Slip the current sensor cover off enough to expose  
the input connector stud. Connect the electrode  
cable from the power source to this stud with the  
nut provided, then reclose the current sensor  
cover.  
•
When inching with gun trigger, electrode and  
drive mechanism are “hot” to work and  
ground and could remain energized several  
seconds after the gun trigger is released.  
• Turn OFF input power at welding power  
source before installation or changing  
drive roll and/or guide tubes.  
Work Cable  
• Welding power source must be connected  
to system ground per the National  
Electrical Code or any applicable local  
codes.  
Connect a work lead of sufficient size and length (per  
the following table) between the proper output termi-  
nal on the power source and the work. Be sure the  
connection to the work makes tight metal-to-metal  
electrical contact.  
• Only qualified personnel should  
perform this installation.  
Current  
60% Duty  
Observe all additional Safety Guidelines detailed throughout this manual.  
Copper Work Cable Size, AWG  
Up to 100 ft Length (30m)  
Cycle  
Input Cable: LN-10 Control to Power  
Source  
400 Amps  
00 (67 mm2)  
500 Amps  
600 Amps  
000 (85 mm2)  
000 (85 mm2)  
Available Cable Assemblies:  
K1501 (Control Cable Only) Consists of a 9-conductor  
control cable with a 14-pin control cable plug, without  
electrode cable, and is available in lengths of 10 ft. (3  
m), 17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m), 50 ft. (15  
m) and 100 ft. (30 m).  
K1502 Consists of a 9-conductor control cable with a  
14-pin plug and a 3/0 (85 mm2 ) electrode cable with  
stud terminal. It is rated at 600 amps, 60% duty cycle  
and is available in lengths of 10 ft. (3 mm), 17 ft. (5  
m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15 m) and  
100 ft. (30 m) is also available with a 4/0 (107 mm2)  
electrode cable.  
K1503 Consists of a 9-conductor control cable with a  
14-pin plug and 2/0 (67 mm2) electrode cable with  
Twist-Mate™ connector. It is rated at 500 amps, 60%  
duty cycle and is available in lengths of 10 ft. (3 m), 17  
ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15 m)  
and 100 ft. (30 m) is also available with a 3/0 (85  
mm2)electrode cable.  
With input power disconnected from the power  
source, install the input cable per the following:  
1) Connect the end of the control cable with the 14-  
pin cable plug to the mating receptacle on the  
power source.  
LN-10  
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A-10  
A-10  
INSTALLATION  
K1561-1 Robotics Interface Module - The module  
plugs directly into the LN-10 control board and pro-  
vides an interface to a properly equipped Fanuc robot.  
When installed and properly configured, the K1561-1  
Robotics Interface Module allows complete control of  
the welding process from the robot controller.  
OPTIONAL FEATURES  
INSTALLATION  
K1501, K1502 and K1503 Input Cable Assemblies  
See “Electrical Installation” for instructions.  
Dual Procedure Switch Options  
The Lincoln Electric Company’s Automation Center  
should be contacted for questions regarding installa-  
tion or operation of the Robotics Interface Module.  
K683-1 Dual Procedure Switch (One per gun) -  
Requires K686-2 Adapter for LN-10. Kit includes gun  
switch, and mountings for Lincoln Innershield and  
Magnum guns, with 15 ft. (4.5 m) control cable and  
3-pin plug. K686-2 Adapter permits 3-pin plug and  
5-pin gun trigger plug to be connected to LN-10 5-pin  
Trigger/Dual Procedure receptacle.  
All other options, see ACCESSORIES section, are  
shipped with installation instructions.  
BOOM AND BENCH CONVERSIONS  
The modular design of these feeders allows them to  
be converted from bench to boom models or vise  
versa. Some additional parts are required to make this  
conversion.  
Connect the 5-pin plug of the K686-2 Adapter to the  
LN-10 Wire Feeder Trigger/Dual Procedure 5-socket  
receptacle.  
The 3-pin plug of the K683-1 Dual Procedure switch  
connects to the 3-socket receptacle of the Adapter,  
and the 5-pin plug of the welding un connects to the  
5-socket receptacle of the Adapter.  
Materials Required for bench to boom  
conversion:  
S13100-197 Plug and Lead assembly, allows a con-  
trol cable to connect from control box to the wire drive.  
K683-3 Dual Procedure Switch Kit includes gun  
switch, and mountings for Lincoln Innershield and  
Magnum guns, with 15 ft. (4.5m) control cable and 5-  
pin plug with two leads to connect to gun trigger.  
G2868 Mounting Bracket, allows reed switch to be  
relocated to control box.  
K1498-16 AND K1498-25 Control Box to Wire Drive,  
Control cable and power cable from control box to  
wire drive.  
Connect the 5-pin plug of the K683-3 Dual procedure  
Switch to the LN-10 Wire Feeder Trigger/Dual  
Procedure 5-socket receptacle.  
Materials Required for boom to bench  
conversion:  
L10286-1 Wire Reel Stand, for LN-10 or STT-10,  
The two lead plug cord extending out of the 5-pin  
plug of the Dual Procedure switch is to be connected  
to the two trigger leads of the welding gun per the  
instructions shipped with the kit.  
mount the reed switch onto the reel stand.  
S22777 Control Box Support Bracket, to mount the  
control box onto the wire drive.  
K1449-1 Dual Procedure Remote Control  
Provides remote rotating knob encoder control of Wire  
Feed Speed and Voltage, along with a dual procedure  
selector switch, when the remote control is connected  
and REMOTE is selected by the LN-10 Procedure  
key. The LN-10 A or B procedure light will also be on  
to indicate which procedure is selected by the remote  
control.  
S13100-198 Plug and Lead Assembly, electrical con-  
nection between control box and wire drive.  
The 4-pin plug of the remote control connects to the  
mating receptacle on the bottom of the LN-10 Control  
box.  
The K1450-”L” Extension cable is used to extend the  
16 ft (5m) cable attached to the remote control.  
Lengths “L” are available to match the Length of the  
control to boom mount wire drive cable being used.  
LN-10  
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SECTION B-1  
SECTION B-1  
OPERATION  
TABLE OF CONTENTS  
-OPERATION SECTION-  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
LN-10 Control Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Setup DIP Switch Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Setting the DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Head Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Welding Power Source Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Metric/English Wire Feed Speed Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-Step Trigger Mode Operation Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Security Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Robotics Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Maximum Limits Setting Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Minimum Limits Setting Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Keypad and Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Keypad and Display Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Power-Down Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Operation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Trigger Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Display Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Digital “Memory” Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Acceleration Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Security Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Maximum and Minimum Limits Setting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Dual Procedure Remote Control (K1449-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Reel Loading - Readi-Reels, Spools or Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
To Mount a 30 lb (14 kg) Readi-Reel Package  
B-2  
B-2  
B-2  
B-2  
B-2  
B-2  
B-3  
B-4  
B-4  
B-4  
B-5  
B-5  
B-5  
B-6  
B-6  
B-6  
B-6  
B-7  
B-7  
B-8  
B-8  
B-8  
B-9  
B-10  
B-10  
(Using the Molded Plastic K363-P Readi-Reel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
To Mount 10 to 44 lb (4.5 to 20 kg) Spools (12 in/300 mm Diameter) or  
14 lb (6 kg) Innershield Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
To Mount a 50 to 60 lb (22.7 to 27.2 kg) Coil:  
B-10  
B-10  
(Using K1504-1 Coil Reel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Procedure for Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gas Guard Regulator Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Reel Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Loss of Voltage Sense Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Grounding Lead Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Explanation of Prompting and Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
B-11  
B-11  
B-11  
B-12  
B-12  
B-12  
B-13  
B-13  
B-13  
B-13  
B-14  
LN-10  
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B-2  
B-2  
OPERATION  
Setting the DIP Switches  
SAFETY PRECAUTIONS  
The DIP switches are each labeled with an “ON”  
arrow showing the on direction for each of the 8 indi-  
vidual switches in each DIP switch (S1 and S2). The  
functions of these switches are also labeled and set  
as described below:  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts such  
as output terminals or internal wiring.  
• Unless using cold feed feature when inch-  
ing with gun trigger, electrode and drive mech-  
anism are “hot” to work and ground and could  
remain energized several seconds after the  
gun trigger is released.  
Pwr Sources  
Head  
M
1
4
2
S
3
R
4
+
5
-
S1  
S2  
ON  
S1  
ON  
S2  
1
2
3
4
5
6
7
8
6
7
8
• Turn OFF input power at welding power  
source before Control switch setup or  
changing drive roll and/or guide tubes.  
Wire Drive Head Selection  
• Welding power source must be connected  
to system ground per the National  
Electrical Code or any applicable local  
codes.  
The LN-10 control is set up for proper presettable wire  
feed speed by setting S1 DIP switches (5 to 8) as  
appropriate per the following examples for the head  
specification and 10 Series wire drive external gear  
selection being used:  
• Only qualified personnel should  
operate this Equipment.  
Observe all additional Safety Guidelines detailed  
throughout this manual.  
For K1563-1 or K1564-Series (LN-10 Boom) or  
K1559-1 (LN-10 Bench) with 35-500 IPM (0.89-12.7  
m/m) Low Speed Ratio set S1 DIP Switch as follows:  
Pwr Sources  
Head  
DUTY CYCLE  
The LN-10 models are rated at 60% duty cycle * for a  
maximum current of 600 amps.  
* Based on a 10 minute time period (6 minutes on, and 4 minutes off).  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
For K1563-1 or K1564-Series (LN-10 Boom) or  
K1559-1 (LN-10 Bench) with 50-750 IPM (1.25-19.0  
m/m) High Speed Ratio set S1 DIP Switch as fol-  
lows: (initial factory setting)  
LN-10 CONTROL DIP SWITCH  
SETUP  
Pwr Sources  
Head  
Initial set up of the LN-10 control for the system com-  
ponents being used and for general operator prefer-  
ences is done using a pair of 8-pole DIP switches  
located inside the LN-10 control box.  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Setup DIP Switch Access  
For K1563-2 (LN-10 Boom) or K1559-2 (LN-10  
Bench) with 55-825 IPM (1.40-21.0 m/m) Low  
Speed Ratio set S1 DIP Switch as follows:  
1) Shut off the input power to the LN-10 control by  
turning off the power at the welding power source  
it is connected to.  
Pwr Sources  
Head  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
2) Remove the two screws on the top of the LN-10  
control box door and swing the door down to  
open.  
For K1563-2 (LN-10 Boom) or K1559-2 (LN-10  
Bench) with 80-1250 IPM (2.00-31.8 m/m) High  
Speed Ratio set S1 DIP Switch as follows:  
3) Locate the two 8-pole DIP switches, near the top  
left corner of the LN-10 Control P.C. board,  
labeled S1 and S2.  
Pwr Sources  
Head  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
NOTE: Switch settings are only programmed during  
input power-up restoration.  
LN-10  
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B-3  
B-3  
OPERATION  
For K679-1 (Single Head Boom) with 50-770 IPM  
(1.27-19.5 m/m) Low Speed Ratio set S1 DIP Switch  
as follows:  
DC-250: *  
Pwr Sources  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Pwr Sources  
Head  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
DC-400:  
Pwr Sources  
For K679-2 (Single Head Boom) with 80-1200 IPM  
(2.00-30.5 m/m) High Speed Ratio set S1 DIP Switch  
as follows:  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Pwr Sources  
Head  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
DC-600: *  
DC-650 PRO:  
DC-1000: *  
Pwr Sources  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Welding Power Source Selection  
The LN-10 Control is set up for proper presettable  
weld voltage control by setting S1 DIP switches (1 to  
4) as appropriate per the following information for the  
welding power source being used:  
Pwr Sources  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
CV-250/CV 300-I:  
Pwr Sources  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Pwr Sources  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
CV-300/CV 400-I:  
Pwr Sources  
Pulse Power 500: *  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Pwr Sources  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
CV-400/CV 500-I:  
Pwr Sources  
V300 PRO:  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Pwr Sources  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
V350-PRO/CV-655: (initial factory setting)  
Pwr Sources  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
* Requires optional K1520-1 115V/42V Transformer  
Kit.  
LN-10  
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B-4  
B-4  
OPERATION  
S2 switch 2 ON = 4-Step without current interlock  
operation:  
Metric/English Wire Feed Speed Display Selection  
The LN-10 Control is set up for Wire Feed Speed dis-  
play in Metric units (m/min.) or English units (IPM) by  
setting S2 DIP Switch 1 (Labeled “M”):  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
S2 switch 1 OFF = IPM (as shipped)  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
1) Closing Trigger initiates gas flow.  
2) Opening Trigger initiates gas preflow timer fol-  
lowed by Run-in speed and strike voltage until arc  
strike initiates welding. (Trigger is released before  
arc is struck, but once established breaking arc  
stops the feeder operation).  
S2 switch 1 ON = m/min  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
3) Reclosing Trigger stops wire feed and initiates  
burnback time, then gas postflow time.  
4-Step Trigger Mode Operation Selection  
The LN-10 Control is set up for 4-Step Trigger mode  
operation with or without weld current interlock by set-  
ting S2 DIP switch 2 (Labeled “4”).  
4) Reopening Trigger stops gas flow if, or when, post-  
flow time is over.  
When 4-Step trigger mode is selected on the LN-10  
keypad (See Keypad and Display Operation in this  
section) S2 DIP switch setting determines the 4-step  
trigger operation:  
Security Mode Selection  
The LN-10 Control is set up for Security Mode (See  
“Security Mode” in this section) by setting S2 DIP  
Switch 3 (Labeled “S”):  
S2 switch 2 OFF = 4-Step with current interlock  
operation: (As shipped)  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
S2 switch 3 ON = Security mode ON  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
1) Closing Trigger initiates gas preflow time followed  
by Run-in speed and strike voltage until arc strike  
initiates welding.  
S2 switch 3 OFF = Security mode OFF (as shipped)  
2) Opening Trigger after welding arc is established  
continues welding with weld current interlock.  
(Breaking arc stops the feeder operation).  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
3) Reclosing Trigger continues welding but shuts off  
current interlock function.  
4) Reopening Trigger stops wire feed and initiates  
burnback time, then gas postflow time.  
LN-10  
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B-5  
B-5  
OPERATION  
Robotics Mode Selection  
Minimum Limits Setting Mode Selection  
The LN-10 control is set up for Robotics Mode by set-  
ting the S2 DIP Switch 4 (Labeled “R”). For Robotics  
Interface Mode to operate, a K1561-1 Robotics  
Interface Module must be installed.  
The LN-10 control is set up for allowing a minimum weld  
WFS and arc voltage setting for each procedure by set-  
ting S2 DIP Switch 6 (Labeled “-”).  
S2 switch 6 ON - Minimum Limits Setting mode ON  
S2 switch 4 ON = Robotics mode ON  
M
1
4
2
S
3
R
4
+
5
-
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
S2  
ON  
S2  
6
7
8
S2 switch 4 OFF = Robotics mode OFF (As shipped)  
When Minimum Limits Setting mode is selected, all keys  
except the procedure key are disabled. Welding is not  
allowed while in this mode. The mode is used for mini-  
mum limits setup only. See “Limits Setting Mode” in  
this section for the correct procedure for setting the WFS  
and voltage limits.  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
S2 switch 6 OFF = Minimum Limits Setting mode OFF  
(As shipped)  
Maximum Limits Setting Mode Selection  
The LN-10 control is set up for allowing a maximum  
weld WFS and arc voltage setting for each procedure  
by setting S2 DIP Switch 5 (Labeled “+”)  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
S2 switch 5 ON = Max. Limits Setting mode ON  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
When Maximum Limits Setting mode is selected, all keys  
except the procedure key are disabled. Welding is not  
allowed while in this mode. The mode is used for maxi-  
mum limits setup only. See “Limits Setting Mode” in  
this section for the correct procedure for setting the WFS  
and voltage limits.  
S2 switch 5 OFF = Maximum Limits Setting mode  
OFF (As shipped)  
M
1
4
2
S
3
R
4
+
5
-
S2  
ON  
S2  
6
7
8
LN-10  
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B-6  
B-6  
OPERATION  
Power-Down Save  
KEYPAD AND DISPLAY OPERATION  
R
LINCOLN  
Power to the LN-10 is supplied and controlled from  
the power source. The LN-10 automatically senses  
the loss of power when the power source is turned off.  
Dual procedure settings, including; trigger mode, cold  
feed speed, Run-in and weld speed and voltage,  
timers and acceleration are automatically saved for  
each feeder when power is removed. This feature  
does not require batteries and when power is restored  
it will automatically return all settings to the state they  
were in when power was removed. The operator may  
overwrite any or all of these settings following power  
up recall.  
COLD FEED COLD FEED  
V
GAS PURGE  
FORWARD  
REVERSE  
WFS  
REMOTE  
A
B
PROCEDURE  
VVOLTS  
COLD FEED  
TRIGGER  
2-STEP STD  
4-STEP LOCK  
SPOT  
1
PREFLOW  
RUN-IN  
VOLTS / WFS  
SPOT  
BURNBACK  
WIRE FEED SPEED  
2
POSTFLOW  
Operation Keys  
TIMER  
CONTROL  
Procedure Lights - Indicate which  
A REMOTE  
B procedure (A or B) is selected for the  
THE LINCOLN ELECTRIC COMPANY  
CLEVELAND, OHIO U.S.A.  
G3161  
selected feeder. The Procedure select  
key selects A or B, or if REMOTE Light  
is selected, the procedure selection  
light is controlled by connection of an  
optional Dual Procedure gun switch  
(K683-1, -3) or Dual Procedure  
Remote Control (K1449-1).  
PROCEDURE  
Keypad and Display Description  
Keypad - Seven key, membrane type with "snap" tac-  
tile feel and embossed domes. Long life design.  
Spatter resistant surface.  
Displays - Two digital LED displays with .56" (14.2  
mm) character height. Top (3-1/2 digit) displays  
Preset and Actual (while welding) arc voltage in volts  
with (+) or (-) polarity indicators, and also displays all  
timers in seconds. Bottom (4 digit) displays preset  
wire feed speed in IPM, or m/m, and acceleration  
selection.  
COLD FEED COLD FEED  
Cold Feed Keys - energize  
the wire feeder but not the  
power source or gas sole-  
noid valve. Cold Feed  
Forward speed is factory  
FORWARD  
REVERSE  
set at 200 IPM, It is adjustable with WFS encoder  
knob and is displayed on WFS display (with ”Cld”  
shown on the Voltage display) only while pressing  
Cold Feed Forward. The last speed set is stored in  
memory for the next cold feeding, unless it is changed  
in the Cold Feed trigger mode (See Trigger Mode  
Selection). Cold Feed Reverse retracts wire at a  
fixed 80 IPM speed which is not adjustable.  
Indicator Lights - Extra bright red LEDs for viewing  
at almost any angle. Always indicate the feeder and  
procedure selected, trigger mode being used and  
function or timer being displayed.  
Rotating Encoders - Knob controls increase or  
decrease settings of volts and wire feed speed. (ini-  
tially factory set to minimum) Alternately, the top  
encoder adjusts timer settings and bottom selects  
acceleration settings when selected for these parame-  
ters to be displayed.  
GAS PURGE  
Gas Purge key - energizes the gas  
solenoid valve but not the wire feeder or  
power source.  
LN-10  
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B-7  
B-7  
OPERATION  
Trigger Mode Selection  
Display Control Keys  
Trigger Mode Select key  
TRIGGER - enables operator to  
Timer Select key - enables operator to  
choose burnback, spot or gas timers, as  
indicated by the appropriate light.  
Pressing the key causes lights to  
TIMER  
COLD FEED  
2-STEP STD  
4-STEP LOCK  
choose mode of operation  
shown by the indicator  
lights. Pressing key caus-  
SPOT  
sequence (top to bottom, then all off) starting from the  
current indicated selection.  
es  
mode  
lights  
to  
sequence (top to bottom) starting from the current  
indicated selection.  
When a timer is selected the Voltage display shows  
the time setting in seconds, as indicated by “SEC” dis-  
played on the speed display. The times are set using  
the Voltage encoder knob.  
Top Light - Indicates gun trigger has been selected to  
perform the Cold Feed Forward function in exactly the  
same manner as Cold Feed Forward key (See  
Operation Keys - Cold Feed Keys) with the same  
memory stored adjustable speed setting, and “Cld”  
shown on the Voltage display.  
Top Light - indicates preflow time  
is being displayed, settable 0.0 to  
2.5 seconds (0.2 sec as shipped).  
This is the time the shielding gas  
1
PREFLOW  
SPOT  
Second Light - indicates 2-step (standard) trigger  
mode.  
BURNBACK flows before the wire feed and  
POSTFLOW power source are activated.  
2
1. Trigger closure energizes the solenoid valve,  
then the wire feeder and the power source  
after Preflow time.  
Second Light - indicates spot time is being displayed,  
settable 0.0 (as shipped) to 199.9 seconds.  
Third Light - indicates burnback time is being dis-  
played, settable 0.00 (as shipped) to 0.25 seconds.  
This is the time the arc power is delayed at the stop of  
the weld, and should be set to the lowest time  
required to prevent the wire sticking in the weld.  
2. Releasing the trigger turns off the wire feeder,  
then power source after burnback time and  
then the gas solenoid valve after Postflow time.  
Third Light - indicates 4-step (lock) trigger mode.  
This mode may be selected to include or exclude weld  
current interlock. (See “4-Step Trigger Mode  
Operation Selection” in this section for 4 step Trigger  
Mode operation)  
Bottom Light - indicates postflow time is being dis-  
played, settable 0.0 to 10.0 seconds (0.5 sec as  
shipped).  
This is the time the shielding gas flows after the wire  
feed and power source are deactivated.  
Bottom Light - indicates Spot Weld Mode, which will  
only light if a spot time is set (See “Display Control  
Keys” in this section). If set to 0.0 seconds, spot  
mode light selection will be skipped. Trigger closure  
energizes the gas solenoid valve, then wire feeder  
and the power source. The spot timer starts when  
current flows. The wire feeder and power source then  
solenoid valve are all turned off when the spot on  
timer times out even though the trigger is opened or is  
still closed. Preflow/Postflow and burnback timers are  
also functional in spot mode. (See “Display Control  
Keys” in this section).  
Pressing Timer Select Key again, or closing the gun  
trigger, shuts all timer lights off, indicating weld  
Voltage and Wire Feed Speed are again being dis-  
played, and set by the appropriate encoder knob.  
LN-10  
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B-8  
B-8  
OPERATION  
CONTROL  
Control Select key - enables operator to  
GAS PURGE  
Acceleration Selection  
choose Run-In procedure as indicated by the  
light turning on. When light is on, the settings  
of Run-In Wire Feed Speed and Voltage are  
To provide optimum starting of various  
processes and procedures, the wire feed  
acceleration of the LN-10 can be set to five  
levels; 1 thru 5, for each feeder and procedure.  
1 is the slowest acceleration and 5 is the  
fastest. (Factory set to 4.)  
CONTROL  
displayed. After Weld procedure is set, Run-in procedure should  
be set to optimize arc starting.  
Speed encoder knob can adjust run-in  
RUN-IN  
speed between min. rated speed and up to  
To change acceleration hold the Gas Purge Key closed, then  
press the Control key. The top (Voltage) display shows “Acc”  
indicating acceleration setting, 1 thru 5, is displayed on the bot-  
tom (Speed) display. Use the speed encoder knob to change  
setting from 1 thru 5.  
VOLTS / WFS the procedure Weld speed setting. Run-in  
speed setting can not exceed Weld speed  
setting. Run-in speed setting of 100 IPM or less is recommend-  
ed for optimum starting. Factory setting is near min. rated  
speed.  
To exit this function, and enter the acceleration setting into the  
procedure memory, press both keys again or close the trigger.  
If set below minimum rated speed “---” will show on the WFS  
display, indicating Run-in speed is set to match weld speed set-  
ting.  
Security Mode  
The Run-in (strike) voltage can be set above or below the Weld  
voltage setting up to a max of 60 V. If set below a min of 10 V,  
the Run-In (strike) voltage display shows “---”, indicating the  
Run-In Voltage is set to match the weld voltage setting. Also,  
the difference between Run-in voltage and Weld voltage set-  
tings is maintained automatically if the Weld voltage setting is  
changed, so the run-in voltage encoder knob does not need to  
be changed to follow the Weld voltage setting.  
Security mode is used to capture timer, acceleration, and control  
selections and settings, then to disable these selections until  
security mode is deactivated. Encoder knob setting changes of  
cold feed, weld speed and weld voltage are not disabled.  
Security mode is activated, or deactivated, by shutting off the  
input power to the LN-10 with all Timer and Control settings as  
desired for both procedures for both Feeders. Then setting S2  
DIP switch 3 inside the LN-10 Control Box ON or OFF and restor-  
ing input power (See “Setting DIP Switches” in this section).  
When trigger is closed (and preflow time is over) the wire feeds  
at Run-In speed and volts until the welding arc strikes, which  
causes the feed speed and volts to change to Weld settings.  
When activated, the Timer and Control selections no longer light,  
but function with the captured settings. All other keys and  
encoder knob controls function normally.  
If the arc does not strike within about 2 seconds, the Run-In  
speed automatically changes to Weld speed to permit “Hot”  
feeding at higher speed setting for loading wire.  
Pressing control key again, or closing the gun trigger, shuts off  
light indicating knob settings and displays are returned to Weld  
Voltage and Wire Feed Speed.  
Digital “Memory” Voltmeter  
When the welding gun trigger is activated, the top LN-10 display  
reads actual welding voltage from 0.0 to 60.0 VDC with auto-  
matic polarity indication for positive (+) or negative (-) electrode.  
If actual voltage drops below 8.0 volts for over 0.8 sec when the  
trigger is closed, Loss of Voltage Sense Shutdown will occur.  
See “Loss of Voltage Sense Shutdown” in this section.  
The last welding voltage monitored at the end of the weld is dis-  
played for 5 seconds after the weld has stopped, as indicated  
by a 5 second “blinking” display. This allows checking actual  
weld voltage after weld has stopped.  
Any keypad or trigger operation will interrupt the 5 second  
memory display.  
LN-10  
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B-9  
B-9  
OPERATION  
8. Open the control box door.  
Maximum and Minimum Limits Setting  
Modes  
9. Put DIP switch S2 switch 5 in the OFF position and  
DIP switch S2 switch 6 in the ON position.  
Limits setting modes are available for limiting the  
range for setting wire feed speed and voltage. The  
limits can be set independently for each procedure.  
The following steps should be followed for setting the  
maximum and minimum limits:  
10. Close the control box door.  
11. Turn on the power at the power source.  
12. Set the minimum WFS and voltage limits for pro-  
cedure A and procedure B using the two encoder  
knobs and the procedure key. The minimum WFS  
limit can be set from the minimum speed of the  
wire drive that is being used to the maximum limit  
that has been set for the selected procedure. The  
minimum voltage limit can be set over the range of  
10.0 to the maximum voltage limit that has been  
set for the selected procedure. The minimum lim-  
its can be turned off independently for each proce-  
dure by turning the encoder knobs counter clock-  
wise until the appropriate display (WFS or voltage  
reads “OFF” while the correct procedure light is  
lit. (The limits are set to “OFF” from the factory).  
1. Turn off the power at the power source.  
2. Remove the two screws at the top of the LN-10  
control box and open the control box door.  
3. Put DIP switch S2 switch 5 in the ON position.  
4. Close the control box door.  
5. Turn on the power at the power source.  
6. Set the maximum WFS and voltage limits for pro-  
cedure A and procedure B using the two encoder  
knobs and the procedure key. The maximum WFS  
limit can be set for the entire range of the wire  
drive that is being used. The maximum voltage  
limit can be set over the range of 10.0 to 60.0 volts.  
The maximum limits can be turned off indepen-  
dently for each procedure by turning the encoder  
knobs clockwise until the appropriate display (WFS  
or voltage) reads “OFF” while the correct proce-  
dure light is lit. (The limits are set to “OFF” from  
the factory.  
13. Turn off the power at the power source.  
14. Open the control box door.  
15. Put DIP switch S2 switch 6 in the OFF position.  
16. Close the control box door.  
17. Reinstall the two screws that had previously been  
removed in step 2.  
7. Turn off the power at the power source.  
LN-10  
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B-10  
B-10  
OPERATION  
DUAL PROCEDURE REMOTE  
CONTROL (K1449-1)  
WARNING  
Check to be sure the Retaining Spring has fully  
returned to the locking position and has SECURELY  
locked the Readi-Reel Cage in place. Retaining  
Spring must rest on the cage, not the welding elec-  
trode.  
When this option is connected to the LN-10 Control  
Box receptacle, and the Procedure Key selects  
“REMOTE” the front panel knob controls and proce-  
dure selection is transferred to the knob encoder con-  
trols and Procedure Selector Switch of the remote,  
which function in the exact same manner. Remote  
knob encoders set Weld voltage and wire feed speed,  
as well as Trigger Cold Feed Speed, but not Timers or  
Run-In.  
___________________________________________  
9) To remove Readi-Reel from Adapter, depress  
retaining spring tab with thumb while pulling the  
Readi-Reel cage from the molded adapter with  
both hands. Do not remove adapter from spindle.  
If using the optional K683-1, -3 Dual Procedure  
Switch, for a wire drive, to select A or B along with the  
(K1449-1) remote, both the front panel and remote  
Procedure selector and switch must be set to  
“REMOTE” and “Gun Switch” (center) positions.  
The LN-10 Procedure lights indicate whether A or B is  
remotely selected.  
WIRE REEL LOADING - READI-REELS,  
SPOOLS OR COILS  
To Mount a 30 Lb. (14 kg) Readi-Reel Package  
(Using the Molded Plastic K363-P Readi-Reel  
Adapter:)  
FIGURE B.1  
The Spindle should be located in the LOWER mounting hole.  
To Mount 10 to 44 Lb. (4.5-20 kg) Spools  
(12"/300 mm Diameter) or 14Lb.(6 Kg)  
Innershield Coils:  
1) Depress the Release Bar on the Retaining Collar  
and remove it from the spindle.  
2) Place the Adapter on the spindle.  
The Spindle should be located in the LOWER mounting hole.  
3) Re-install the Retaining Collar. Make sure that the  
Release Bar “pops up” and that the collar retainers  
fully engage the retaining groove on the spindle.  
(For 8" (200 mm) spools, a K468 spindle adapter must  
first be slipped onto spindle.)  
4) Rotate the spindle and adapter so the retaining  
spring is at the 12 o'clock position.  
(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil  
Adapter must be used).  
5) Position the Readi-Reel so that it will rotate in a  
direction when feeding so as to be de-reeled from  
bottom of the coil.  
1) Depress the Release Bar on the Retaining Collar  
and remove it from the spindle.  
2) Place the spool on the spindle making certain the  
spindle brake pin enters one of the holes in the  
back side of the spool. Be certain the wire comes  
off the reel in a direction so as to de-reel from the  
bottom of the coil.  
6) Set one of the Readi-Reel inside cage wires on the  
slot in the retaining spring tab.  
7) Lower the Readi-Reel to depress the retaining  
spring and align the other inside cage wires with  
the grooves in the molded adapter.  
3) Re-install the Retaining Collar. Make sure that the  
Release Bar “pops up” and that the collar retainers  
fully engage the retaining groove on the spindle.  
8) Slide cage all the way onto the adapter until the  
retaining spring "pops up" fully.  
LN-10  
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B-11  
B-11  
OPERATION  
To Mount a 50-60 Lb. (22.7-27.2 kg) Coil:  
(Using K1504-1 Coil Reel) (For 50-60 lb Readi-  
Reels a K438 Readi-Reel Adapter must be used).  
FEEDING ELECTRODE AND BRAKE  
ADJUSTMENT  
1) Turn the Reel or spool until the free end of the  
electrode is accessible.  
The Spindle must be located in the UPPER mounting hole.  
1) With the K1504-1 Coil Reel mounted on to the 2"  
(51 mm) spindle (or with reel laying flat on the  
floor) loosen the spinner nut and remove the reel  
cover. (See Figure B.2).  
2) While tightly holding the electrode, cut off the bent  
end and straighten the first 6" (150 mm). Cut off  
the first 1" (25 mm). (If the electrode is not proper-  
ly straightened, it may not feed or may jam causing  
a "birdnest".)  
2) Before cutting the tie wires, place the coil of elec-  
trode on the reel so it unwinds from the bottom as  
the reel rotates.  
3) Insert the free end through the incoming guide  
tube.  
3) Tighten the spinner nut against the reel cover as  
much as possible by hand using the reel cover  
spokes for leverage. DO NOT hammer on the  
spinner nut arms.  
4) Press the Cold Inch key or the Cold Feed Mode  
gun trigger and push the electrode into the drive  
roll.  
WARNING  
4) Cut and remove only the tie wire holding the free  
end of the coil. Hook the free end around the rim  
of the reel cover and secure it by wrapping it  
around. Cut and remove the remaining tie wires.  
When feeding with the gun trigger, unless “COLD  
FEED” trigger mode is selected, the electrode and  
drive mechanism are always “HOT” to work and  
ground and could remain “HOT” several seconds after  
the gun trigger is released.  
CAUTION  
___________________________________________  
Always be sure the free end of the coil is securely  
held while the tie wires are being cut and until the wire  
is feeding through the drive rolls. Failure to do this will  
result in “backlashing” of the coil, which may tangle  
the wire. A tangled coil will not feed so it must either  
be untangled or discarded.  
___________________________________________  
5) Be sure the coil reel is engaged with the spindle  
brake pin and the Release Bar on the Retaining  
Collar “pops up” and that the collar retainers fully  
5) Feed the electrode through the gun.  
6) Adjust the brake tension with the thumbscrew on  
the spindle hub, until the reel turns freely but with  
little or no overrun when wire feeding is stopped.  
Do not overtighten.  
engage the retaining groove on the spindle.  
SPINNER NUT  
COVER  
PLATE  
DRIVE ROLL PRESSURE SETTING  
The LN-10 pressure is factory pre-set to about posi-  
tion “2" as shown on the pressure indicator on the  
front of the feedplate door. This is an approximate  
setting.  
SLOTS  
CARDBOARD  
COIL LINER  
COIL  
The optimum drive roll pressure varies with type of  
wire, surface condition, lubrication, and hardness.  
Too much pressure could cause “birdnesting”, but too  
little pressure could cause wire feed slippage with  
load and/or acceleration. The optimum drive roll set-  
ting can be determined as follows:  
TIE WIRE  
SPRING  
LOADED ARM  
REEL  
FIGURE B.2  
LN-10  
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B-12  
B-12  
OPERATION  
1) Press end of gun against a solid object that is  
electrically isolated from the welder output and  
press the gun trigger for several seconds.  
4) Use Control Select and encoder knobs to set desired  
Weld feed speed and voltage then Run-in speed and  
voltage to optimize arc starting. (Set for each proce-  
dure if using front panel, remote control or optional  
dual procedure switch.) (Refer to “Operation  
Keys” and “Display Control Keys” in this section)  
2) If the wire "birdnests", jams, or breaks at the drive  
roll, the drive roll pressure is too great. Back the  
pressure setting out 1/2 turn, run new wire through  
gun, and repeat above steps.  
5) Adjust the wire feed acceleration if desired, for  
each feeder and procedure. (Refer to  
“Acceleration Selection” in this section)  
3) If the only result is drive roll slippage, disengage  
the gun, pull the gun cable forward about 6" (150  
mm). There should be a slight waviness in the  
exposed wire. If there is no waviness, the pres-  
sure is too low. Increase the pressure setting  
turn, reconnect the gun, tighten locking clamp and  
repeat the above steps.  
6) Use Timer Select and Voltage Encoder knob to set  
desired timers. (Refer to “Trigger Mode  
Selection” in this section)  
7) Feed the electrode through the gun and cable and  
then cut the electrode within approximately .38"  
(9.5 mm) of the end of the contact tip for solid wire  
and within approximately .75" (19mm) of the exten-  
sion guide for cored wire.  
PROCEDURE FOR SETTING ANGLE  
OF FEEDPLATE  
1) Loosen the clamping collar screw using a 3/16"  
Allen wrench. The clamping collar screw is  
accessed from the bottom of the feedplate. It is  
the screw which is perpendicular to the feeding  
direction.  
8) Connect work cable to metal to be welded. Work  
cable must make good electrical contact to the  
work. The work must also be grounded as stated in  
"Arc Welding Safety Precautions".  
WARNING  
2) Rotate feedplate to the desired angle and tighten  
clamping collar screw.  
• When using an Open Arc process, it is  
necessary to use correct eye, head, and  
body protection.  
GAS GUARD REGULATOR SETTING  
1) With the gas supply shut off, the Gas Guard regu-  
lator flow adjusting Key should be set to maximum  
(full clockwise) which is rated to be 60 SCFH (28  
l/min).  
____________________________________  
9) If used, be sure shielding gas valve is turned on.  
10) Position electrode over joint. End of electrode  
may be lightly touching the work.  
2) Adjust gas supply flow rate for a level higher than  
will be required, then adjust Gas Guard flow  
adjusting Key counterclockwise to the desired gas  
flow rate.  
11) Lower welding helmet, close gun trigger, and start  
welding. Hold the gun so the contact tip to work  
distance gives the correct electrical stickout as  
required for the procedure being used.  
MAKING A WELD  
12) To stop welding, release the gun trigger and then  
pull the gun away from the work after the arc goes  
out and Postflow time, if used, is over.  
1) Use only a Lincoln Electric recommended constant  
voltage DC power source compatible with the LN-  
10 Wire Feeder.  
13) If necessary to optimize arc starting, readjust wire  
speed acceleration, (Refer to “Acceleration  
Selection” in this section) and/or Run-In speed,  
(Refer to “Display Control Keys” in this section).  
2) Properly connect the electrode and work leads for  
the correct electrode polarity.  
3) Use the Mode Selection key to set desired trigger  
mode for each procedure. (Refer to “Trigger  
Mode Selection” in this section)  
LN-10  
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B-13  
B-13  
WIRE FEED OVERLOAD PROTECTION  
OPERATION  
WIRE REEL CHANGING  
At the end of a coil, remove the last of the old elec-  
trode coil from the conductor cable by either pulling it  
out at the nozzle end of the gun or by using the follow-  
ing procedure:  
The LN-10 has solid-state overload protection of the  
wire drive motor. If the wire drive motor becomes  
overloaded for an extended period of time, the protec-  
tion circuitry turns off the power source, wire feed and  
gas solenoid, and then displays “H30” on the WFS  
display (with blank Voltage display). This indicates  
the wire drive motor is overloaded and will remain  
shut down for about 30 seconds before the unit will  
automatically reset. The “H30” display decrements  
every second until it reaches “H00”. At that time, the  
unit resets automatically and the previous displays will  
return indicating the unit is ready to operate again.  
Overloads can result from improper tip size, liner,  
drive rolls, or guide tubes, obstructions or bends in the  
gun cable, feeding wire that is larger than the rated  
capacity of the feeder or any other factors that would  
impede normal wire feeding. (See “Avoiding Wire  
Feeding Problems” in the MAINTENANCE section).  
1) Cut the end of the electrode off at the gun end. Do  
not break it off by hand because this puts a slight  
bend in the wire making it difficult to pull it back  
through the nozzle.  
2) Disconnect the gun cable from the gun connector  
on the LN-10 wire drive unit and lay the gun and  
cable out straight.  
3) Using pliers to grip the wire, pull it out of the cable  
from the connector end.  
4) After the electrode has been removed, reconnect  
the gun cable to the drive. Load a new reel of elec-  
trode per the instructions in “Wire Reel Loading”  
in this section.  
GROUNDING LEAD PROTECTOR  
The frame of the LN-10 Control is grounded to the  
frame of the power source by a lead in the control  
cable. An overload protector prevents welding current  
from damaging this lead if the electrode circuit touch-  
es the wire feeder frame while the electrode is electri-  
cally hot.  
LOSS OF VOLTAGE SENSE SHUTDOWN  
If the actual displayed voltage, when the trigger is  
closed, drops below 8.0 volts for over 0.8 second it is  
assumed the voltage feed back sensing circuit to the  
LN-10 is opened or faulty, so Loss of Voltage Sense  
Shutdown occurs until the trigger is released.  
If such a grounding lead fault occurs, the WFS display  
will show “GLP,” (with blank Voltage display) and the  
trigger circuit will be disabled. To reset the circuit,  
release the trigger, make sure that the electrode is not  
touching the wire feeder frame, and then either press  
any key on the keypad or close the trigger. When the  
GLP circuit is reset, the “GLP” display is removed and  
the wire feeder is returned to normal operating mode.  
This shutdown stops the motor, shuts off the gas flow  
and disables the power source output to prevent the  
LN-10 voltage control from driving the power source  
output too high due to loss of proper feedback sensing  
via #21 (WORK) and #67 (ELECTRODE) sensing  
leads.  
DH-10  
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B-14  
B-14  
OPERATION  
EXPLANATION OF PROMPTING  
AND ERROR MESSAGES  
Display  
Prompt or Error  
Er  
EEPROM error. Usually occurs at power-up.  
Indicates one or more of the recalled settings  
is out of acceptable limits. Press any key to  
return to normal operation. Be sure to check  
all voltage, wire feed speed, acceleration and  
timer settings before you proceed.  
Acc  
Displayed on Voltage display, indicates WFS  
display is showing acceleration setting, “1" to  
“5" (See “Acceleration Selection” in this  
section).  
OFF  
Displayed on WFS and voltage displays; indi-  
cates limits for WFS or voltage are off for the  
displayed procedure. (See “Maximum and  
Minimum Limits Setting Modes” in this  
section).  
SEC  
GLP  
Displayed on WFS display, indicates Voltage  
display is showing a Timer setting in sec-  
onds. (See “Display Control Keys” in this  
section)  
Displayed on WFS display, indicates that the  
Grounding Lead Protector circuit was activat-  
ed due to excessive current flow into the  
wire feeder frame. When the GLP circuit is  
activated the wire feeder is disabled (the trig-  
ger output to the power source is opened up,  
the motor is stopped, and the gas solenoid is  
turned off). To resume normal operation,  
release the trigger, make sure that the elec-  
trode is not touching the wire feeder frame,  
and then either press a key on the keypad or  
close the trigger. (See “Grounding Lead  
Protector” in this section)  
Cld  
Displayed on Voltage display when Cold  
Feed Forward or Cold Feed Reverse Key is  
pressed, or Cold Feed Trigger mode is  
selected. Indicates wire is fed “cold” (no  
weld voltage) at the speed indicated on the  
WFS display. (See “Operation Keys” and  
“Trigger Mode Selection” in this section).  
---  
Displayed on Voltage or WFS displays with  
RUN-IN selected, indicates setting will match  
those set for Weld Voltage and Wire Feed  
Speed (See “Display Control Keys” in this  
section).  
HXX  
Displayed on WFS display, indicates wire  
feed overload. XX indicates time remaining  
in seconds before unit resets automatically.  
(See “Wire Feed Overload Protection” in  
this section and “Avoiding Wire Feeding  
Problems” in the MAINTENANCE section).  
DH-10  
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SECTION C-1  
SECTION C-1  
ACCESSORIES  
TABLE OF CONTENTS  
-ACCESSORIES SECTION-  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
LN-10 Wire Feeder Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Drive Roll and Guide Tube Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Spindle Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun Adapters (For 10 Series Wire Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
C-2  
C-2  
C-3  
C-4  
C-4  
C-5  
C-5  
Miscellaneous Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5 & C-6  
LN-10  
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C-2  
C-2  
ACCESSORIES  
GENERAL  
The following is a list of all the accessories that can be  
used with the LN-10 Wire Feeder. A description of  
each item is given later in the section.  
TABLE C.1 — LN-10 WIRE FEEDER ACCESSORIES.  
KP1505 Series  
KP1507 Series  
K1501  
DRIVE ROLL AND WIRE GUIDE KITS  
DRIVE ROLL AND WIRE GUIDE KITS  
INPUT CABLE ASSEMBLY (CONTROL CABLE ONLY)  
INPUT CABLE ASSEMBLY  
K1502  
K1503  
INPUT CABLE ASSEMBLY  
K1520-1  
K590-4  
K659-1  
K1449-1  
K1450-”L”  
K683-1  
K683-3  
K162H  
K1504-1  
K435  
115V/42V TRANSFORMER KIT  
WATER CONNECTION KIT  
GAS GUARD REGULATOR  
DUAL PROCEDURE REMOTE CONTROL  
EXTENSION CABLE (“L” REPRESENTS 12, 16, OR 25 FT. (3.6, 4.9, OR 7.6M))  
DUAL PROCEDURE SWITCH  
DUAL PROCEDURE SWITCH  
SPINDLE ADAPTER  
COIL ADAPTER  
COIL ADAPTER  
K468  
COIL ADAPTER  
K363P  
K438  
READI-REEL ADAPTER  
READI-REEL ADAPTER  
K1500-1  
K1500-2  
K1500-3  
K126  
K115  
K470  
K471  
K497  
K541  
K598  
GUN ADAPTER  
GUN ADAPTER  
GUN ADAPTER  
INNERSHIELD GUN AND CABLE ASSEMBLY  
INNERSHIELD GUN AND CABLE ASSEMBLY  
MAGNUM 300 GMAW GUN AND CABLE ASSEMBLY  
MAGNUM 400 GMAW GUN AND CABLE ASSEMBLY  
MAGNUM 200 GMAW GUN AND CABLE ASSEMBLY  
MAGNUM 400 SHORT NECK GMAW GUN AND CABLE ASSEMBLY  
MAGNUM 550 GMAW GUN AND CABLE ASSEMBLY  
MAGNUM “SUPER COOL” FM WATER COOLED  
GMAW GUN AND CABLE ASSEMBLY  
MAGNUM 200 FM GMAW GUN AND CABLE ASSEMBLY  
MAGNUM 250L FM GMAW GUN AND CABLE ASSEMBLY  
MAGNUM 300 FM GMAW GUN AND CABLE ASSEMBLY  
MAGNUM 400 FM GMAW GUN AND CABLE ASSEMBLY  
REMOTE SWITCH INTERFACE MODULE  
ROBOTICS INTERFACE MODULE  
SWIVEL MOUNT  
K684  
K498  
K534  
K478  
K479  
K1558-1  
K1561-1  
K1557-1  
K1556-1  
K1555-1  
LIGHT DUTY CASTER KIT  
INSULATED LIFT HOOK  
LN-10  
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C-3  
C-3  
ACCESSORIES  
TABLE C.2 – DRIVE ROLL AND GUIDE TUBE KITS  
Wire Size  
4-Roll  
4-Roll  
10-Series Drives  
(4-Driven)  
Synergic 7F Drives  
(2-Driven)  
Solid Steel Electrode  
0.025”  
(0.6 mm)  
(0.8 mm)  
(0.9 mm)  
(1.0 mm)  
(1.2 mm)  
(1.4 mm)  
(1.6 mm)  
(2.0 mm)  
(2.4 mm)  
KP1505 - 030S  
KP1505 - 030S  
KP1505 - 035S  
KP1505 - 045S  
KP1505 - 045S  
KP1505 - 052S  
KP1505 - 1/16S  
KP1505-5/64  
KP655 - 025S  
KP655 - 030S  
KP655 - 035S  
KP655 - 035S  
KP655 - 052S  
KP655 - 052S  
KP655 - 1/16  
KP655 - 3/32  
---------------  
0.030”  
0.035”  
0.040”  
0.045”  
0.052”  
1/16”  
5/64”  
3/32”  
KP1505-3/32  
Cored Electrode  
0.030  
(0.8 mm)  
(0.9 mm)  
(1.0 mm)  
(1.2 mm)  
(1.4 mm)  
(1.6 mm)  
(1.7 - 1.8 mm)  
(2.0 mm)  
(2.4 mm)  
KP1505 - 035C  
KP1505 - 035C  
KP1505 - 045C  
KP1505 - 045C  
KP1505 - 052C  
KP1505 - 1/16C  
KP1505 - 068  
KP1505 - 5/64  
KP1505 - 3/32  
KP1505 - 7/64H  
KP1505 - 7/64  
KP1505 - 120  
---------------  
0.035”  
0.040”  
0.045”  
0.052”  
1/16”  
KP655 - 035C  
KP655 - 035C  
KP655 - 052C  
KP655 - 052C  
KP655 - 1/16  
KP655 - 3/32  
KP655 - 3/32  
---------------  
0.068” - 0.072”  
5/64”  
3/32”  
7/64” Lincore Hard Facing (2.8mm)  
---------------  
7/64”  
.120”  
(2.8mm)  
(3.0mm)  
---------------  
---------------  
Aluminum Electrode  
0.035”  
0.040”  
3/64”  
(0.9 mm)  
(1.0 mm)  
(1.2 mm)  
(1.6 mm)  
KP1507 - 035A  
KP1507 - 040A  
KP1507 - 3/64A  
KP1507 - 1/16A  
KP656 - 035A  
---------------  
KP656 - 3/64A  
KP656 - 1/16A  
1/16”  
Aluminum Electrode  
(For use with Binzel Guns Only)  
0.040”  
(1.0 mm)  
(1.2 mm)  
(1.6 mm)  
---------------  
---------------  
---------------  
KP647 - 040A  
KP647 - 3/64A  
KP647 - 1/16A  
3/64”  
1/16”  
LN-10  
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C-4  
C-4  
ACCESSORIES  
K1450-”L” - Extension cables are available in  
lengths “L” of 12, 16 or 25 ft. (3.6, 4.9 or 7.6) to match  
the control to Feeder cable length used.  
INPUT CABLE ASSEMBLIES:  
K1501 (Control Cable Only) Consists of a 9-conduc-  
tor control cable with a 14-pin control cable plug,  
without electrode cable, and is available in lengths of  
10 ft. (3 m), 17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m),  
50 ft. (15 m) and 100 ft. (30 m).  
K683-1 DUAL PROCEDURE SWITCH  
Requires K686-2 Adapter for LN-10. Kit includes gun  
switch, and mountings for Lincoln Innershield and  
Magnum guns, with 15 ft. (4.5 m) control cable and 3-  
pin plug. K686-2 Adapter permits 3-pin plug and 5-pin  
gun trigger plug to be connected to LN-10 5-pin  
Trigger/Dual Procedure receptacle.  
K1502 Consists of a 9-conductor control cable with a  
14-pin plug and a 3/0 (85 mm2 ) electrode cable with  
stud terminal. It is rated at 600 amps, 60% duty  
cycle and is available in lengths of 10 ft. (3 mm), 17  
ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15 m)  
and 100 ft. (30 m) is also available with a 4/0 (107  
mm2) electrode cable.  
K683-3 DUAL PROCEDURE SWITCH  
Kit includes gun switch, and mountings for Lincoln  
Innershield and Magnum guns, with 15 ft. (4.5m) con-  
trol cable and 5-pin plug with two leads to connect to  
gun trigger.  
K1503 Consists of a 9-conductor control cable with a  
14-pin plug and 2/0 (67 mm2) electrode cable with  
Twist-Mate™ connector. It is rated at 500 amps,  
60% duty cycle and is available in lengths of 10 ft. (3  
m), 17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft.  
(15 m) and 100 ft. (30 m) is also available with a 3/0  
(85 mm2)electrode cable.  
SPINDLE ADAPTERS:  
K162H (Not required for LN-10 Bench Models)  
Spindle for boom mounting Readi-Reels and 2" (51  
mm) I.D. spools with 60 lb. (27.2 kg) capacity. User  
mounted to appropriately prepared boom framework.  
Includes an easily adjustable friction brake for con-  
trol of overrun.  
K1520-1 115V/42V TRANSFORMER  
KIT Required to use LN-10 with Lincoln Power  
Sources without 42VAC auxiliary and a 14-pin con-  
nector receptacle. These power sources include the  
DC-250, DC-600, DC-1000 and Pulse Power 500.  
Also can be used with older DC-400 models.  
When a 2" (51 mm) spindle is used with Readi-Reels  
or coils not on 12" (305 mm) O.D. spools, an adapter  
is required:  
Coil Adapter:  
K590-4 WATER CONNECTION KIT  
Includes water cooled gun tube fittings and self-seal-  
ing outlet and inlet quick-connectors for mounting into  
the DH wire drive connection box.  
K1504-1 Permits 50 lb to 60 lb (22.7-27.2 Kg.)  
Coils to be mounted on 2” (51 mm) O.D. spindles.  
K435 Permits 14 lb. (6 kg) Innershield coils to be  
mounted on 2" (51 mm) O.D. spindles.  
K659-1 GAS GUARD REGULATOR  
Adjustable flow regulator with removable adjustor key  
for CO2 and Argon blend gases. Mounts onto wire  
drive gas inlet, and reduces gas waste and arc start  
"blow" by reducing surge caused by excess pressure  
in supply hose.  
K468 Permits 8" (203 mm) O.D. spools to be  
mounted on 2" (51 mm) O.D. spindles.  
Readi-Reel Adapters:  
K1449-1 DUAL PROCEDURE  
REMOTE CONTROL Includes a remote con-  
K363P Adapts Lincoln Readi-Reel coils of elec-  
trode 30 lb. (14 kg) and 22 lb. (10 kg) to a 2" (51  
mm) spindle. Durable molded plastic one piece con-  
struction. Designed for easy loading; adapter  
remains on spindle for quick changeover.  
trol box with a 16 ft. (5 m) length control cable with 4-  
pin plug for the mating receptacle on the bottom of the  
LN-10 control box. The remote control box contains a  
procedure selector switch and 2 rotating knob  
encoders, one controls arc voltage and the other con-  
trols wire feed speed, which function the same as  
comparable controls on the LN-10 front panel, when  
the remote is connected and selected by the LN-10  
Procedure Key.  
K438 Adapts Lincoln Readi-Reel coils of electrode  
50-60 lb. (22.7-27.2 kg) to a 2" (51 mm) spindle.  
LN-10  
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C-5  
C-5  
ACCESSORIES  
GUN ADAPTERS (FOR 10 SERIES  
WIRE DRIVE) Adapts 10 Series heads for  
The following Lincoln gun and cable assemblies are  
equipped with a Fast-Mate™ connector. They can be  
used with 10 Series wire feed models by installing a  
K489-2 Fast-Mate™ adapter kit and a K1500-1  
Lincoln Gun adapter.  
desired gun connection:  
K1500-1 for standard Lincoln Innershield gun con-  
nection, or with Fast-Made™ guns with K489-2 Fast-  
Mate Adapter Kit. Also for Magnum 200/300/400 with  
K466-1 connection kit, or Magnum 550 with K613-1.  
K684 Magnum "Super Cool" FM water cooled  
GMAW gun and cable assemblies are rated 450  
amps, 100% duty cycle (CO2). (Consult sales specifi-  
cations for appropriate models)  
K1500-2 for Magnum 200/300/400 gun with K466-  
10 connection kit. (Also Tweco 4). Factory provided  
with the LN-10.  
K498 Magnum 200 FM GMAW gun and cable  
assemblies are rated for 200 amps 60% duty cycle.  
(Consult sales specifications for appropriate models)  
K1500-3 for Magnum 550 gun with K613-7 connec-  
tion. (Also Tweco 5).  
K534 Magnum 250L FM GMAW gun and cable  
assemblies are rated for 250 amps, 30% duty cycle.  
(Consult sales specifications for appropriate models)  
GUN AND CABLE ASSEMBLIES  
The following Lincoln gun and cable assemblies are  
compatible with 10 Series Wire Feed heads with  
appropriate K1500 Gun Adapter:  
K478 Magnum 300 FM GMAW gun and cable  
assemblies are rated for 300 amps, 60% duty cycle.  
(Consult sales specifications for appropriate models)  
K126 (Requires K1500-1) Innershield gun and cable  
assemblies are rated at 350 amps, 60% duty cycle.  
(Consult sales specifications for appropriate models)  
K479 Magnum 400 FM GMAW gun and cable  
assemblies are rated for 400 amps, 60% duty cycle.  
(Consult sales specifications for appropriate models)  
K115 (Requires K1500-1) Innershield gun and cable  
assemblies are rated at 450 amps, 60% duty cycle.  
(Consult sales specifications for appropriate models)  
K1558-1 REMOTE SWITCH INTERFACE  
MODULE  
K470 (With K466-9 requires K1500-2) Magnum 300  
GMAW gun and cable assemblies are rated 300  
amps, 60% duty cycle. (Consult sales specifications  
for appropriate models)  
The Module provides for user interface connection of  
an external switch (flow switch, etc.) which must be  
closed to enable the feeder welding operation. Also,  
the Module provides for interface connection of exter-  
nal equipment (fume extractor, etc.) to the Module’s  
isolated relay contacts which actuate when the feeder  
welding gas solenoid is activated (representing weld-  
ing operation in process).  
K471 (With K466-9 requires K1500-2) Magnum 400  
GMAW gun and cable assemblies are rated 400  
amps, 60% duty cycle. (Consult sales specifications  
for appropriate models)  
K1561-1 ROBOTICS INTERFACE  
MODULE  
The module plugs directly into the LN-10 control board  
and provides an interface to a properly equipped  
Fanuc robot. When installed and properly configured,  
the K1561-1 Robotics Interface Module allows com-  
plete control of the welding process from the robot  
controller.  
K497 (With K466-9 requires K1500-2) Magnum 200  
GMAW gun and cable assemblies are rated 200  
amps, 60% duty cycle. (Consult sales specifications  
for appropriate models)  
K541 (With K466-9 requires K1500-2) Magnum 400  
Short Neck GMAW gun and cable assemblies are  
rated 400 amps, 60% duty cycle. (Consult sales  
specifications for appropriate models)  
The Lincoln Electric Company’s Automation Center  
should be contacted for questions regarding installa-  
tion or operation of the Robotics Interface Module.  
K598 (With K613-7 requires K1500-3) Magnum 550  
GMAW gun and cable assemblies are rated 550  
amps, 60% duty cycle. (Consult sales specifications  
for appropriate models)  
LN-10  
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C-6  
C-6  
ACCESSORIES  
K1557-1 SWIVEL MOUNT  
The K1557-1 Swivel mount attaches to the power  
source. This kit includes a feeder adapter plate that  
allows the feeder to rotate on top of the power source.  
The feeder can be easily separated from the swivel  
mount at any time. This option is compatible with the  
K1556-1 Light Duty Caster Kit.  
K1556-1 LIGHT DUTY CASTER KIT  
This option provides 4 casters and all required hard-  
ware to mount it to the Power Feed 10. This option is  
compatible with the K1557-1 Swivel Mount.  
K1555-1 INSULATED LIFT HOOK  
For applications where an insulated lift hook is  
required. This kit provides an easily installed, heavy  
duty insulated lift eye that mounts to the wire reel  
stand mast. See the instructions provided with the kit  
for installation.  
LN-10  
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SECTION D-1  
SECTION D-1  
MAINTENANCE  
TABLE OF CONTENTS  
-MAINTENANCE SECTION-  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Drive Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Reel Mounting - Readi-Reels and 10 to 30 lb (4.5 to 14 kg) Spools . . . . . . . . . . . . . . . . . . . .  
Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Motor and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun and Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Procedure for Removing Feedplate from Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
D-2  
D-2  
D-2  
D-2  
D-2  
D-2  
D-2  
D-2  
D-2  
D-3  
LN-10  
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D-2  
D-2  
MAINTENANCE  
Avoiding Wire Feeding Problems  
MAINTENANCE  
Wire feeding problems can be avoided by observing  
the following gun handling and feeder set up proce-  
dures:  
Safety Precautions  
WARNING  
a) Do not kink or pull cable around sharp corners.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts such  
as output terminals or internal wiring.  
b) Keep the electrode cable as straight as possible  
when welding or loading electrode through cable.  
•
When inching with gun trigger, electrode and  
drive mechanism are “hot” to work and  
ground and could remain energized several  
seconds after the gun trigger is released.  
c) Do not allow dolly wheels or trucks to run over  
cables.  
• Turn OFF input power at welding power  
source before installation or changing  
drive roll and/or guide tubes.  
d) Keep cable clean by following maintenance  
instructions.  
• Welding power source must be connected  
to system ground per the National  
Electrical Code or any applicable local  
codes.  
e) Use only clean, rust-free electrode. The Lincoln  
electrodes have proper surface lubrication.  
• Only qualified personnel should  
perform this installation.  
f) Replace contact tip when the arc starts to become  
unstable or the contact tip end is fused or  
deformed.  
Observe all additional Safety Guidelines detailed  
throughout this manual.  
g) Do not use excessive wire spindle brake settings.  
h) Use proper drive rolls, guide tubes and drive roll  
pressure settings.  
Routine Maintenance  
Drive Rolls and Guide Tubes  
Periodic Maintenance  
After feeding every coil of wire, inspect the drive roll  
section. Clean it as necessary. Do not use a solvent  
for cleaning the idle roll because it may wash the  
lubricant out of the bearing. The driver roll and guide  
tubes are stamped with the wire sizes they will feed.  
If a wire size other than that stamped on the roll(s) is  
to be used, the roll(s) and guide tubes must be  
changed.  
Wire Drive Motor and Gearbox  
Every year inspect the gearbox and coat the gear  
teeth with a moly-disulfide filled grease. Do not use  
graphite grease.  
Every six months check the motor brushes. Replace  
them if they are less than 1/4” long.  
The drive rolls for .035” (0.9mm) through .052”  
(1.3mm) cored electrode and 1/16” (1.6mm) through  
3/32” (2.4mm) electrode have a double set of teeth so  
they can be reversed for additional life. Drive rolls for  
.023" (0.6 mm) through .052" (1.3 mm) solid elec-  
trodes and aluminum sizes have no teeth, but use two  
grooves so they also can be reversed for additional  
life.  
Gun and Cable Maintenance  
See appropriate Operator’s Manual.  
Procedure for Removing Feedplate from  
Wire Feeder  
1) Loosen the clamping collar screw using a 3/16"  
Allen wrench. The clamping collar screw is  
accessed from the bottom of the feedplate. It is  
the screw which is perpendicular to the feeding  
direction.  
See “Procedure to Install Drive Roll and Guide Tubes”  
in the INSTALLATION section for roll changing  
instructions.  
2) Loosen the retaining screw, which is also  
accessed from bottom of feeder, using a 3/16"  
Allen wrench. Continue to loosen the screw until  
the feedplate can be easily pulled off of the wire  
feeder.  
Wire Reel Mounting - Readi-Reels and  
10 through 30lb (4.5-14kg) Spools  
No routine maintenance required. Do not lubricate 2”  
(51mm) spindle.  
LN-10  
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D-3  
D-3  
MAINTENANCE  
FIGURE D.1 - MAJOR COMPONENT LOCATIONS  
1. Control Box Assembly  
2. Door & Feedplate Assembly  
3. Motor & Gear Box Assembly  
4. Wire Drive Assembly  
5. Spindle Assembly  
6. Reel Stand & Base Assembly  
7. Current Sensing Reed Switch (Energizer Assembly)  
7
6
Bench Model Only  
5
4
Bench Model  
Shown  
3
1
2
Bench Model  
Shown  
LN-10  
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SECTION E-1  
SECTION E-1  
THEORY OF OPERATION  
TABLE OF CONTENTS  
-THEORY OF OPERATION SECTION-  
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E  
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Receptacle, Control Board and Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Feed Head and Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Protection and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Grounding Lead Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Loss of Voltage Sense Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
E-2  
E-3  
E-4  
E-5  
E-5  
E-5  
E-5  
LN-10  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.1 — LN-10 GENERAL DESCRIPTION.  
SOLENOID  
TO GUN TRIGGER  
AND  
DUAL PROCEDURE  
WIRE DRIVE  
WIRE  
DRIVE  
MOTOR  
RECEPTACLE  
OPTIONAL  
REMOTE  
CONTROL  
KIT  
OPTIONAL  
ROBOTIC  
INTERFACE  
MODULE  
TACH FEEDBACK  
CURRENT SENSING  
REED SWITCH  
INPUT  
CABLE  
CONTROL BOARD  
RECEPTACLE  
42VAC  
GROUND  
LEAD  
PROTECTOR  
VOLTS  
WFS  
DISPLAY  
BOARD  
ENCODER  
ENCODER  
KEYPAD  
GENERAL DESCRIPTION  
The LN-10 is a single head, 42 VAC input, 4-roll wire  
feeder. A single control with dual procedure presetta-  
bility of wire feed speed (inches per minute or meters  
per minute) and arc voltage is used in conjunction  
with a Lincoln constant voltage (CV) welding power  
source.  
The LN-10 wire feeders have controls providing key-  
pad or remote selectability of either of two proce-  
dures. Also offered are four independently selectable  
gun trigger modes for each procedure; cold feed, 2-  
step and 4-step trigger and spot weld. The unit incor-  
porates 4 selectable, presettable timers for each pro-  
cedure. Preflow, postflow, burnback and spot weld  
can all be preset.  
Arc starting can be optimized for each procedure with  
5 selectable wire feed acceleration rates. A gas  
purge key is provided, as well as cold feed forward  
and reverse keys with independently adjustable for-  
ward feed speed settings.  
LN-10  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.2 — LN-10 INPUT RECEPTACLE, CONTROL BOARD AND OPERATOR CONTROLS.  
SOLENOID  
TO GUN TRIGGER  
AND  
DUAL PROCEDURE  
WIRE DRIVE  
WIRE  
DRIVE  
RECEPTACLE  
MOTOR  
OPTIONAL  
REMOTE  
CONTROL  
KIT  
OPTIONAL  
ROBOTIC  
INTERFACE  
MODULE  
TACH FEEDBACK  
CURRENT SENSING  
REED SWITCH  
INPUT  
CABLE  
CONTROL BOARD  
RECEPTACLE  
42VAC  
GROUND  
LEAD  
PROTECTOR  
VOLTS  
WFS  
DISPLAY  
BOARD  
ENCODER  
ENCODER  
KEYPAD  
The control board receives commands from the user  
operated controls such as the volts encoder, the wire  
feed speed (WFS) encoder and the keypad. It also  
receives feedback information from the wire feed head  
as to the wire feed speed and the arc voltage. The  
control board compares the feedback information with  
the user command signals and generates the appro-  
priate signals to control wire feed speed, arc voltage  
and gas flow.  
INPUT RECEPTACLE, CONTROL  
BOARD AND OPERATOR  
CONTROLS  
The 42 VAC input voltage is applied to the LN-10  
through a 9-pin amphenol type receptacle. The  
remote control and trigger leads are also accessed  
through this 9-pin receptacle. The 42 VAC is rectified  
by a full wave bridge and sent to the control board  
where it is filtered. This filtered DC voltage is applied  
to a switching power supply. The switching power  
supply manufactures +12VDC and -12VDC regulated  
supplies for the control board circuitry. A +5VDC reg-  
ulated supply is also developed for the control board  
circuitry.  
The current sensing switch and ground lead protector  
are connected to the control board via plug J1. The  
current sensing reed switch closes when welding cur-  
rent is established. This closure signals the control  
board to change from the run-in welding parameters  
to the preset welding wire feed speed and arc voltage.  
If the ground lead protector is activated, the trigger cir-  
cuit will be disabled and the WFS display will show  
“GLP”.  
LN-10  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.3 — LN-10 WIRE FEED HEAD AND RECEPTACLE.  
SOLENOID  
TO GUN TRIGGER  
AND  
DUAL PROCEDURE  
WIRE DRIVE  
WIRE  
DRIVE  
MOTOR  
RECEPTACLE  
OPTIONAL  
REMOTE  
CONTROL  
KIT  
OPTIONAL  
ROBOTIC  
INTERFACE  
MODULE  
TACH FEEDBACK  
CURRENT SENSING  
REED SWITCH  
INPUT  
CABLE  
CONTROL BOARD  
RECEPTACLE  
42VAC  
GROUND  
LEAD  
PROTECTOR  
VOLTS  
WFS  
DISPLAY  
BOARD  
ENCODER  
ENCODER  
KEYPAD  
WIRE FEED HEAD AND  
RECEPTACLE  
The leads to the drive motor, gas solenoid, and the  
tach (hall effect device) are brought into the control  
box via the wire drive receptacle. This 14-pin recepta-  
cle also houses the gun trigger leads, the electrode  
voltage sense lead and the leads for the optional dual  
procedure switch. When the gun trigger is activated  
the control board energizes the gas solenoid, then the  
wire drive motor and welding power source. The con-  
trol board receives tach feedback information and  
adjusts the motor armature voltage to match the pre-  
set wire feed speed.  
LN-10  
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E-5  
E-5  
THEORY OF OPERATION  
PROTECTION AND SHUTDOWN  
WIRE FEED OVERLOAD  
PROTECTION  
LOSS OF VOLTAGE SENSE  
SHUTDOWN  
The LN-10 has solid-state overload protection of the  
wire drive motor. If the wire drive motor becomes  
overloaded for an extended period of time, the protec-  
tion circuitry turns off the power source, wire feed and  
gas solenoid, and then displays “H30” on the WFS  
display (with blank voltage display). This indicates the  
wire drive motor is overloaded and will remain shut  
down for about 30 seconds before the unit will auto-  
matically reset. The “H30” display decrements every  
seconds until it reaches “HOO”. At that time, the unit  
resets automatically and the previous displays will  
return indicating the unit is ready to operate again.  
Overloads can result from improper tip size, liner,  
drive rolls, guide tubes, obstructions or bends in the  
gun cable, feeding wire that is larger than the rated  
capacity of the feeder or any other factors that would  
impede normal wire feeding. (See “Avoiding Wire  
Feeding Problems” in the MAINTENANCE section).  
If the actual displayed voltage when the trigger is  
closed, drops below 8.0 volts for over 0.8 second it is  
assumed the voltage feed back sensing circuit to the  
LN-10 is opened or faulty. Loss of Voltage Sense  
Shutdown occurs until the trigger is released.  
This shutdown stops the motor, shuts off the gas flow  
and disables the power source output to prevent the  
LN-10 voltage control from driving the power source  
output too high due to loss of proper feedback sensing  
via #21 (WORK) and #67 (ELECTRODE) sensing  
leads.  
GROUNDING LEAD PROTECTOR  
The frame of the LN-10 control is grounded to the  
frame of the power source by a lead in the control  
cable. An overload protector prevents welding current  
from damaging this lead if the electrode circuit touch-  
es the wire feeder frame while the electrode is electri-  
cally hot.  
If such a grounding lead fault occurs, the WFS display  
will show “GLP”, (with blank voltage display) and the  
trigger circuit will be disabled. To reset the circuit  
release the trigger, make sure that the electrode is not  
touching the wire feeder frame, and then either press  
any key on the keypad or close the trigger. When the  
GLP circuit is reset, the “GLP” display is removed and  
the wire feeder is returned to normal operating mode.  
LN-10  
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E-6  
E-6  
NOTES  
LN-10  
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F-1  
F-1  
TROUBLESHOOTING AND REPAIR  
TABLE OF CONTENTS  
-TROUBLESHOOTING AND REPAIR SECTION-  
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F  
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Tach Adjustment and Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Keypad Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Encoder PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gas Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Display PC Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gas Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Encoder PC Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Motor and Gear Box Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Current Sensing Reed Switch Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
F-2  
F-3  
F-5  
F-17  
F-17  
F-19  
F-23  
F-27  
F-29  
F-31  
F-31  
F-33  
F-35  
F-37  
F-41  
F-43  
LN-10  
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F-2  
F-2  
TROUBLESHOOTING AND REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained  
Personnel. Unauthorized repairs performed on this equipment may result in danger to  
the technician and machine operator and will invalidate your factory warranty. For your  
safety and to avoid electrical shock, please observe all safety notes and precautions  
detailed 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 3. RECOMMENDED COURSE OF  
ACTION.  
The last column labeled “RECOMMENDED  
COURSE OF ACTION” lists the most likely  
components that may have failed in your  
machine. It also specifies the appropriate  
test procedure to verify that the subject  
component is either good or bad. If there  
are a number of possible components,  
check the components in the order listed to  
eliminate one possibility at a time until you  
locate the cause of your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM  
(SYMPTOMS)”. This column describes  
possible symptoms that the machine may  
exhibit. Find the listing that best describes  
the symptom that the machine is exhibiting.  
Symptoms are grouped into the following  
categories: function problems, feeding prob-  
lems, and welding problems.  
All of the referenced test procedures  
referred to in the Troubleshooting Guide are  
described in detail at the end of this chap-  
ter. Refer to the Troubleshooting and Repair  
Table of Contents to locate each specific  
Test Procedure. All of the specified test  
points, components, terminal strips, etc. can  
be found on the referenced electrical wiring  
diagrams and schematics. Refer to the  
Electrical Diagrams Section Table of  
Contents to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS.  
The second column labeled “POSSIBLE  
AREAS OF MISADJUSTMENT(S)” lists the  
obvious external possibilities that may con-  
tribute to the machine symptom. Perform  
these tests/checks in the order listed. In  
general, these tests can be conducted with-  
out removing the case wrap-around cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the  
tests/repairs safely, contact the Lincoln Electric Service Department for technical  
troubleshooting assistance before you proceed. Call 1-800-833-9353.  
---------------------------------------------------------------------------------------------------------  
LN-10  
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F-3  
F-3  
TROUBLESHOOTING AND REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
- Remove the PC board from the static-shielding bag  
and place it directly into the equipment. Don’t set the  
PC board on or near paper, plastic or cloth which  
could have a static charge. If the PC board can’t be  
installed immediately, put it back in the static-shield-  
ing bag.  
WARNING  
ELECTRIC SHOCK  
can kill.  
•
Have an electrician install and  
service this equipment. Turn the  
input power OFF at the fuse box  
before working on equipment. Do  
not touch electrically hot parts.  
- If the PC board uses protective shorting jumpers,  
don’t remove them until installation is complete.  
- If you return a PC board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow  
proper failure analysis.  
CAUTION  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
4. Test the machine to determine if the failure  
symptom has been corrected by the  
replacement PC board.  
NOTE: It is desirable to have a spare (known good)  
PC board available for PC board troubleshooting.  
1. Determine to the best of your technical ability  
that the PC board is the most likely component  
causing the failure symptom.  
NOTE: Allow the machine to heat up so that all  
electrical components can reach their operating  
temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and  
substitute it with the original PC board to  
recreate the original problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static  
electrical damage and electrical shock. Read  
the warning inside the static resistant bag and  
perform the following procedures:  
a. If the original problem does not reappear by  
substituting the original board, then the PC  
board was not the problem. Continue to look  
for bad connections in the control wiring  
harness, junction blocks, and terminal strips.  
PC board can be damaged by static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the PC  
board was the problem. Reinstall the  
replacement PC board and test the machine.  
- Remove your body’s static  
charge before opening the static-  
shielding bag. Wear an anti-static  
wrist strap. For safety, use a 1  
Meg ohm resistive cord connected  
6. Always indicate that this procedure was  
followed when warranty reports are to be  
submitted.  
to  
a
grounded part of the  
equipment frame.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
- If you don’t have a wrist strap,  
touch an un-painted, grounded,  
part of the equipment frame. Keep  
touching the frame to prevent  
static build-up. Be sure not to  
touch any electrically live parts at  
the same time.  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” will help avoid  
denial of legitimate PC board warranty claims.  
Workstations  
- Tools which come in contact with the PC board must  
be either conductive, anti-static or static-dissipative.  
LN-10  
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F-4  
F-4  
NOTES  
LN-10  
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F-5  
F-5  
TROUBLESHOOTING AND REPAIR  
TROUBLESHOOTING GUIDE  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The drive motor does not turn 1. If an error message “HXX” 1. For feeders using the Remote  
when the gun trigger is activated.  
The displays are lit and the correct  
input voltage (42 VAC) is applied  
to the LN-10.  
appears on the wire feed dis-  
play, the unit may be over-  
loaded. The “XX” indicates the  
time remaining in seconds  
before the unit automatically  
resets.  
Switch Interface Module, make  
sure there is continuity (zero  
ohms) in the circuit connecting  
the two terminals marked 1A on  
the remote switch interface P.C.  
board.  
2. Make certain the dip switches 2. Make sure the gun trigger circuit  
are set correctly for the power  
source being used. See  
Welding Power Source  
Selection.  
is working properly. See the  
Wiring Diagram.  
3. Perform the Wire Drive Motor  
Test.  
3. A jumper plug or K1558-1  
Remote Switch Interface  
Module must be properly  
installed into connector J5 on  
the control board.  
4. The control board may be faulty.  
The drive motor does not turn,  
although the arc voltage is present  
and the gas solenoid works when  
the gun trigger is activated.  
1. Perform the Wire Drive Motor  
1. Check the connections between  
the drive motor and the control  
board. See the Wiring Diagram.  
Test.  
2. The control board may be faulty.  
There is NO control of wire feed  
speed. The motor turns, the gas  
solenoid operates and arc voltage  
is present. The WFS can be pre-  
set.  
1. Perform the Tach Adjustment  
1. Check the tach leads between  
the tach (hall effect device) and  
the control board. See the  
Wiring Diagram.  
and Feedback Test.  
2. Perform the Wire Drive Motor  
Test  
3. The control board may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-6  
F-6  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS (Continued)  
The wire feeds and the gas sole- 1. Make certain the electrode and 1. Check the continuity (zero  
noid operates but no arc voltage is  
present.  
work cables are connected  
correctly.  
ohms) of leads #2 and #4  
between the input cable recep-  
tacle and plug J8 on the control  
board. See the Wiring Diagram.  
2. Make certain the control cable  
between the LN-10 and the  
power source is in good working 2. The control board may be  
condition.  
faulty.  
3. Make certain the power source  
is operating properly and capa-  
ble of producing welding voltage  
and current.  
4. Make certain the welding gun  
and cable are in good operating  
condition.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-7  
F-7  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS (Continued)  
The wire feed speed does not 1. The “run-in” and “weld” wire 1. Check the current sensing reed  
change when welding current is  
established.  
feed speeds may be set at the  
same value.  
switch for proper operation.  
A. While not welding the volt-  
age at pins 3J1 to 4J1  
should be approximately 12  
VDC. The reed switch  
should be open. If the 12  
VDC is missing either the  
reed switch is stuck closed  
or the control board is defec-  
tive.  
2. Check the current sensing reed  
switch leads and connectors for  
loose or faulty corrections. See  
the Wiring Diagram.  
B. While welding current is  
flowing the voltage at pins  
3J1 to 4J1 should be  
approximately 0 VDC. The  
reed switch should be  
closed. If the voltage is not  
at or near 0 VDC, the reed  
switch is faulty.  
2. The control board may be  
faulty.  
The voltmeter does not function 1. Make sure the dip switch set- 1. The control board may be  
properly. The welding may vary  
from normal performance. The wire  
feeds properly.  
tings on the control board are  
correct for the power source  
being used. See Welding 2. The display board may be  
faulty.  
Power Source Selection.  
defective.  
2. Make sure the voltage sense  
leads are connected.  
A. Lead #67 has continuity  
(zero ohms) to the electrode.  
B. Lead #21 has continuity  
(zero ohms) to the work  
piece.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
F-8  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS (Continued)  
The “Cold Feed Forward” and/or 1. Check the connectors and wires 1. Perform the Keypad Resis-  
the “Cold Feed Reverse” buttons  
do not function properly. The motor  
operates properly in other modes.  
between the display board and  
the control board for loose or  
faulty connections. (J11 and J3) 2. The display board may be  
faulty.  
tance Test.  
2. Check the connector J10  
between the keypad and the 3. The control board may be  
display board for loose  
connections.  
faulty.  
The “Gas Purge” button does not 1. Check the connectors and wires 1. Perform the Keypad Resis-  
activate the gas solenoid. The gas  
solenoid operates properly in other  
modes.  
between the display board and  
the control board for loose or  
faulty connections. (J11 and J3) 2. The display board may be  
faulty.  
tance Test.  
2. Check the connector J10  
between the keypad and the 3. The control board may be  
display board for loose  
connections.  
faulty.  
The “Procedure” button does not 1. Check the connectors and wires 1. Perform the Keypad Resis-  
function properly.  
between the display board and  
the control board for loose or  
tance Test.  
faulty connections. (J11 and J3) 2. The display board may be  
faulty.  
2. Check the connector J10  
between the keypad and the 3. The control board may be  
display board for loose  
connections.  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
F-9  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS (Continued)  
The “Timer” or "Control” button 1. Make certain the DIP switches 1. Perform the Keypad Resis-  
does not function correctly.  
on the control board are not set  
for the security mode. DIP  
tance Test.  
switch S2 position 3 must be in 2. The display board may be  
the OFF position. See Security  
faulty.  
Mode Selection.  
3. The control board may be  
faulty.  
2. Check the connectors and wires  
between the display board and  
the control board for loose or  
faulty connections. (J11 and J3)  
3. Check the connector J10  
between the keypad and the  
display board for loose  
connections.  
Pressing the trigger key has no 1. Make certain the DIP switches on 1. Perform the Keypad Resis-  
effect while not welding.  
the control board are not set for  
the security mode. DIP switch S2  
position 3 must be in the OFF  
tance Test.  
position. See Security Mode 2. The display board may be  
Selection. faulty.  
2. Check the connectors and wires 3. The control board may be  
between the display board and  
the control board for loose or  
faulty connections. (J11 and J3)  
faulty.  
3. Check the connector J10  
between the Keypad and the dis-  
play board for loose connections.  
1. The unit maybe in a mode that  
utilizes only one display. To  
check if this is the problem,  
make sure that both knobs  
change the display when both  
displays are showing a number.  
One of the encoder control knobs  
functions but the other one does  
not.  
1. Perform the Encoder Board  
Test.  
2. The control board may be  
faulty.  
2. Check the wiring and plug con-  
nections between the encoder  
boards and the control board.  
(Plug J2) See the Wiring  
Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-10  
F-10  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS (Continued)  
Neither encoder control knob 1. Check the wiring and plug con- 1. Perform the Encoder Board  
functions.  
nections between the encoder  
boards and the control board.  
Test.  
(Plug J2) See the Wiring 2. The control board may be  
Diagram. faulty.  
The LN-10 is dead. The displays 1. Make sure the LN-10 is con- 1. The input rectifier bridge may  
and LEDs on the keypad are off.  
The green and red LEDs on the  
control board are not lit.  
nected properly to the power  
source.  
be faulty. Check for 42 VAC at  
the red leads. Also check for at  
least 42 VDC at leads #542(+)  
to #500(-). See the Wiring  
Diagram.  
2. Make sure 42 VAC is being  
applied to the LN-10 at the input  
receptacle terminals A and B.  
2. The control board may be  
faulty.  
The displays and LEDs on the key- 1. Check the wires and connectors 1. Check leads #512 (1J3) to #500  
pad are off. The green and red  
LEDs on the control board are both  
blinking normally at about one sec-  
ond intervals.  
(J11 and J3) between the dis-  
play board and the control  
board for loose or faulty connec-  
tions.  
(3J3) for the presence of  
12.8 VDC. If the 12.8 VDC is  
not present the control board  
may be faulty.  
2. If the 12.8 VDC is present the  
display board may be faulty.  
The displays and LEDs on the key- 1. Make sure the LN-10 is con- 1. The control board may be  
pad are off. The green and/or red  
LEDs on the control board are  
blinking at a very fast or erratic  
rate.  
nected properly to the power  
source.  
defective.  
2. Make sure 42 VAC is being  
applied to the LN-10 at the input  
receptacle terminals A and B.  
The wire feed is consistent and 1. Make certain the DIP switch S1 1. The control board may be  
adjustable, but operates at the  
wrong speed.  
is correctly set for the wire drive  
and gear ratio. See Wire Drive  
Head Selection.  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-11  
F-11  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS (Continued)  
The wire feeds for a few seconds 1. Make sure the electrode and 1. Make sure the #21 lead has  
and stops. The voltage display  
reads less than 8 VDC while the  
wire is feeding.  
work cables are connected  
securely and properly.  
continuity (zero ohms) to the  
workpiece and #67 lead has  
continuity (zero ohms) to the  
electrode wire. See the Wiring  
Diagram.  
2. Make sure the #21 lead is con-  
nected correctly at the power  
source.  
2. The control board may be  
faulty.  
3. Make sure the power source is  
operating correctly and capable  
of putting out more than 8 VDC.  
The dual procedure switch is not 1. Make sure the dual procedure 1. Check the resistance between  
functioning at the gun.  
switch is installed and connect-  
ed properly.  
pins E & M of the 14 pin  
Amphenol connector on the  
wire drive while the dual proce-  
dure switch is opened and  
closed. The resistance must  
change from an open to almost  
no resistance. If the resistance  
doesn’t change when the switch  
is opened and closed, check  
leads #519 and #520 for a bro-  
ken solder connection or wire.  
See the Wiring Diagram.  
2. The “Remote LED” on the  
keypad must be lit and the  
toggle switch on the remote  
control (if present) must be in  
the gun position.  
2. Check the resistance between  
leads #519 and #520 of the plug  
that goes into connector J7 on  
the control P.C. board. As the  
dual procedure switch is  
opened and closed, the resis-  
tance between leads #519 and  
#520 must change. If the resis-  
tance doesn’t change, Check  
for a broken connection or wire  
in the #519 and #520 leads.  
See the Wiring Diagram.  
3. The control board may be  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-12  
F-12  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS (Continued)  
The knobs do not control the com- 1. Limits may be set for wire feed 1. Perform the Encoder Board  
plete range of wire feed speed or  
voltage.  
speed or voltage. See maxi-  
mum and minimum limit set-  
ting modes.  
Test.  
2. The control board may be  
faulty.  
2. DIP switch S1 may be incorrect-  
ly set for the wire drive or gear  
ratio. See Wire Drive Head  
Selection.  
3. Make sure that the DIP switch  
settings match the power  
source being used.  
See  
Welding Power Source  
Selection.  
An “Er” message is displayed when 1. This indicates an EEPROM 1. The control board may be  
the LN-10 is powered up.  
error has been detected. Check  
all the settings to make sure  
they are within the acceptable  
ranges. If the “Er” message is  
still displayed remove the input  
power. While pressing the Timer  
and Control keys, turn on the  
input power. The message “Ln”  
should be displayed. Leave on  
for 5 seconds. Remove the  
input power. Note: All the set-  
tings will be removed.  
faulty.  
A “GLP” message is displayed.  
1. The Ground Lead Protector cir- 1. The GLP reed switch may be  
cuit has activated due to exces-  
sive current flow in the wire  
feeder frame. This can be  
caused be the electrode coming  
in contact with the wire feeder  
frame or poor connections in the  
work cable circuit. The wire  
faulty. This switch is normally  
open and should only close  
when current is flowing through  
the green lead and wire feeder  
frame. It may be stuck closed.  
See the Wiring Diagram.  
feeder will be disabled. Remedy 2. The control board may be  
the “grounding” problem and  
resume normal operations by  
releasing the gun trigger and  
then closing the gun trigger.  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-13  
F-13  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS (Continued)  
When the gun trigger is activated 1. Make sure the gas supply is 1. Perform the Gas Solenoid  
the wire feeds and arc voltage is  
present but gas does not flow.  
adequate and connected cor-  
rectly to the LN-10.  
Test.  
2. The control board may be  
faulty.  
The preset arc voltage does not 1. Make sure the power source is 1. The control board may be  
match the actual voltage. set for remote voltage control. faulty.  
2. Make sure the DIP switches on 2. The control cable between the  
the LN-10 control board are set  
correctly for the power source  
being used.  
power source and the LN-10  
may be defective.  
The preset WFS does not match 1. Check the wiring and connec- 1. Perform the Tach Adjustment  
the actual WFS.  
tions between the tachometer  
and the control board. See the  
Wiring Diagram.  
and Feedback Test.  
2. The control board may be  
faulty.  
2. Make sure the DIP switches on  
the LN-10 control board are set  
correctly.  
The K1449-1 remote control is not 1. Make certain the K1449-1 is con- 1. Check for continuity between  
functioning when the Procedure  
LED is in the REMOTE position.  
nected properly to the LN-10.  
the pins of the Amphenol con-  
nector on the left side of the  
bottom of the control box and  
the plug that goes into Molex  
connector J4 on the control P.C.  
2. The K1449-1 remote control may  
be faulty.  
board.  
See The Wiring  
Diagram.  
2. The control board may be  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-14  
F-14  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FEEDING PROBLEMS  
The wire is feeding rough or not 1. Check for mechanical restric- 1. If the drive rolls are turning  
feeding, but the drive rolls are  
turning.  
tions in the wire feed path.  
erratically perform the Wire  
Drive Motor Test and Tach  
Adjustment and Feedback  
Test.  
2. Make sure the gun liner is cor-  
rect for the electrode wire being  
used.  
3. Check the contact tip.  
4. Make sure the drive rolls are  
installed correctly.  
5. Make sure the DIP switches on  
the control board are set  
correctly. See Wire Drive Head  
Selection.  
The contact tip seizes in the gun 1. The tip may be overheated 1. Apply a light coating of high  
liner.  
because of prolonged or  
excessive high current and/or  
duty cycle.  
temperature anti-seize lubri-  
cant-graphite grease to the tip’s  
threads.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-15  
F-15  
TROUBLESHOOTING AND REPAIR  
Observe all Safety Guidelines detailed throughout this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
The welding arc is variable or 1. The electrode or work cables 1. If the drive rolls are turning  
“hunting”.  
may have faulty connections.  
erratically perform the Wire  
Drive Motor Test and Tach  
Adjustment and Feedback  
Test.  
2. Make sure the welding proce-  
dures are correct for the  
process being used.  
3. Make sure the DIP switches on  
the control board are set  
correctly.  
4. The gas shielding may not be  
sufficient or contaminated.  
5. The power source may be  
faulty.  
Poor arc striking with sticking or 1. Make sure the welding proce- 1. If the drive rolls are turning  
“blast-offs”. The bead may be nar-  
row, ropey and have porosity.  
dures are correct for the  
process being used.  
erratically perform the Wire  
Drive Motor Test and Tach  
Adjustment and Feedback  
Test.  
2. The gas shielding may not be  
sufficient or contaminated.  
2. Make certain weld procedures  
and parameters are correct for  
the process being performed.  
3. Make sure the set screw in the  
connector block is in place and  
tightened against the liner  
bushing.  
4. Weld procedures and/or para-  
meters incorrect for process  
being performed.  
5. The power source may be  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
LN-10  
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F-16  
F-16  
NOTES  
LN-10  
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F-17  
F-17  
TROUBLESHOOTING AND REPAIR  
TEST PROCEDURES  
WIRE DRIVE MOTOR TEST  
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 or machine operator and will invalidate your factory warranty. For  
your safety and to avoid electrical shock, please observe all safety notes and pre-  
cautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This test will help determine if the wire drive motor is receiving the correct voltage and is  
capable of running properly.  
MATERIALS NEEDED  
5/16 in. Nut Driver  
Volt-Ohmmeter  
LN-10  
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F-18  
F-18  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR TEST (continued)  
FIGURE F.1 — WIRE DRIVE MOTOR TEST.  
(+)WHITE  
LEAD  
(-)BLACK  
LEAD  
TEST PROCEDURE  
5. If the correct voltages are NOT present  
at the armature motor leads, check the  
associated leads and plugs for loose or  
faulty connections. See the Wiring  
Diagram. If the leads and connections  
are OK, the control board may be  
faulty.  
1. Remove input power to the LN-10 unit.  
2. Using the 5/16 in. nut driver, remove  
the wire drive cover.  
3. Locate the motor armature leads for the  
motor to be tested (one black (-) lead  
and one white (+) lead). Do not discon-  
nect the leads. See Figure F.1.  
6. If the correct voltages are present at  
the motor armature leads and the motor  
does not run and vary speed with  
changes in armature voltage, the motor  
or gear box may be faulty. See Wire  
Drive Motor and Gear Box Removal  
and Replacement.  
4. Apply the correct input power (42 VAC)  
to the LN-10. Activate the gun trigger.  
With the motor running, check the  
armature voltage at the black lead #541  
(-) and white lead #539(+). The normal  
voltage range is approximately 1 to 25  
VDC depending on motor speed. When  
the armature voltage is increased the  
motor speed should also increase.  
7. Install the wire drive cover.  
LN-10  
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F-19  
F-19  
TROUBLESHOOTING AND REPAIR  
TACH ADJUSTMENT AND FEEDBACK TEST  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in dan-  
ger to the technician or machine operator and will invalidate your factory warranty.  
For your safety and to avoid electrical shock, please observe all safety notes and  
precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This test will determine if the hall effect module (tach) is functioning correctly.  
MATERIALS NEEDED  
5/16 in. Nut Driver  
Volt-Ohmmeter  
9/16 in. Wrench  
LN-10  
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F-20  
F-20  
TROUBLESHOOTING AND REPAIR  
TACH ADJUSTMENT AND FEEDBACK TEST (continued)  
FIGURE F.2 — TACH FEEDBACK TEST.  
#500  
BLACK  
#555  
BLUE  
FIGURE F.2A—MODULE LOCK NUT  
#512  
RED  
Lock Nut  
TEST PROCEDURE  
6. Activate the gun trigger. Make sure the  
motor is running. Check for the pres-  
ence of approximately 5.0 VDC from  
blue lead #555 (+) to black lead #500  
(-). The 5.0 VDC represents the correct  
feedback voltage from the hall effect  
device to the control board.  
1. Remove input power to the LN-10 unit.  
2. Using the 5/16 in. nut driver, remove  
the wire drive cover.  
3. Locate the three hall effect leads (blue,  
red and black). See Figure F.2.  
7. If the above voltage reading is not cor-  
rect, the hall effect device may need to  
be adjusted or replaced. See Tach  
Adjustment Procedure.  
4. Apply the correct input power (42 VAC)  
to the LN-10.  
5. Check for approximately 12 VDC from  
red lead #512 (+) to black lead #500 (-).  
If the 12 VDC is NOT present or low,  
the control board or associated leads or  
plugs may be faulty. See the Wiring  
Diagram.  
LN-10  
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F-21  
F-21  
TROUBLESHOOTING AND REPAIR  
TACH ADJUSTMENT AND FEEDBACK TEST (continued)  
TACH ADJUSTMENT  
PROCEDURE  
3. Using the 9/16 in. wrench loosen the  
locking nut.  
Proper positioning of the module is critical  
to the proper operation the LN-10 wire feed-  
er. If the device is not screwed in far  
enough the motor speed could be unstable  
or run at full speed with no control. If  
screwed in too far it will rub a moving part  
inside the gearbox.  
4. Gently screw the hall effect module into  
the mounting plate until it just touches  
and stops against the rotating part  
inside the gearbox. See Figure F.2A.  
5. Back the module out 1/2 turn. Using the  
9/16 in. wrench and carefully snug the  
lock nut without rotating the module  
position. See Figure F.2A.  
1. Remove input power to the LN-10 wire  
feeder.  
6. Install the wire drive cover.  
2. Make sure the module is securely  
attached to the gearbox.  
LN-10  
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F-22  
F-22  
NOTES  
LN-10  
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F-23  
F-23  
TROUBLESHOOTING AND REPAIR  
KEYPAD RESISTANCE TEST  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in dan-  
ger to the technician or machine operator and will invalidate your factory warranty.  
For your safety and to avoid electrical shock, please observe all safety notes and  
precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This test will determine if any key is not functioning properly.  
MATERIALS NEEDED  
5/16 in. Nut driver  
Analog Volt-Ohmmeter  
Small Screwdriver  
LN-10  
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F-24  
F-24  
TROUBLESHOOTING AND REPAIR  
KEYPAD RESISTANCE TEST (continued)  
FIGURE F.3 — KEYPAD RESISTANCE TEST.  
DISPLAY  
BOARD  
J11  
9
3
5
1
7
J10  
2
4
6
8
6. Check the keypad resistances referenc-  
TEST PROCEDURE  
ing Figure F.3 and Table F.1.  
1. Remove input power to the LN-10 unit.  
7. The resistances are checked at plug  
J10 on the keypad. See Figure F.3.  
2. Using the 5/16 in. nut driver, remove  
the two screws from the top of the con-  
trol panel. See Figure F.3.  
8. If any of the resistances are not correct,  
the keypad may be faulty.  
3. Carefully lower the control panel.  
9. When test is complete, carefully install  
the display board and connect plugs  
J10 and J11.  
4. Remove plug J11 from the display  
board.  
10. Reassemble the front panel.  
5. Perform the Display Board Removal  
Procedure.  
LN-10  
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F-25  
F-25  
TROUBLESHOOTING AND REPAIR  
KEYPAD RESISTANCE TEST (continued)  
NOTE: There should not be continuity  
between pins until a key is pressed on the  
keypad.  
TABLE F.1 — KEYPAD RESISTANCE TEST.  
MAXIMUM  
TEST POINTS  
ALLOWABLE RESISTANCE  
(TYPICAL RESISTANCE)  
FROM PIN  
TO PIN  
2J10  
3J10  
4J10  
6J10  
7J10  
8J10  
9J10  
KEY PRESSED  
CONTROL  
TIMER  
1J10  
1J10  
1J10  
1J10  
1J10  
1J10  
1J10  
100 OHMS (50 OHMS TYPICAL)  
100 OHMS (50 OHMS TYPICAL)  
100 OHMS (50 OHMS TYPICAL)  
100 OHMS (50 OHMS TYPICAL)  
100 OHMS (50 OHMS TYPICAL)  
100 OHMS (50 OHMS TYPICAL)  
100 OHMS (50 OHMS TYPICAL)  
TRIGGER  
PROCEDURE  
COLD FEED FORWARD  
COLD FEED REVERSE  
GAS PURGE  
LN-10  
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F-26  
F-26  
NOTES  
LN-10  
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F-27  
F-27  
TROUBLESHOOTING AND REPAIR  
ENCODER PC BOARD TEST  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in dan-  
ger to the technician or machine operator and will invalidate your factory warranty.  
For your safety and to avoid electrical shock, please observe all safety notes and  
precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This test will help determine if the encoder PC boards are functioning properly.  
MATERIALS NEEDED  
5/16 in. Nut Driver  
Volt-Ohmmeter (analog recommended)  
LN-10  
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F-28  
F-28  
TROUBLESHOOTING AND REPAIR  
ENCODER PC BOARD TEST (continued)  
FIGURE F.4 — ENCODER PC BOARD TEST.  
#500  
#526  
J2  
#516  
#527  
#517  
#505  
ENCODER  
PC BOARDS  
7. While slowly rotating the Volts control  
check for a “pulsing” 0 to 5 VDC signal  
from 8J2 (lead #516) to 6J2 (lead  
#517). If the 5 VDC supply IS present  
at the encoder board and the pulsing  
signal is NOT, the Volts encoder board  
may be faulty. Also check the lead and  
plug connections between the encoder  
board and the control board. See the  
Wiring Diagram.  
TEST PROCEDURE  
1. Remove input power to the LN-10 unit.  
2. Using the 5/16 in. nut driver, remove  
the two screws from the top of the con-  
trol panel.  
3. Carefully lower the control panel.  
4. Locate plug J2 on the control board.  
See Figure F.4. Do not remove the plug  
from the control board.  
8. While slowly rotating the WFS control  
check for a “pulsing” 0 to 5 VDC signal  
from 3J2 (lead #526) to 7J2 (lead  
#527). If the 5 VDC supply IS present  
at the encoder board and the pulsing  
signal is NOT, the WFS encoder board  
may be faulty. Also check the lead and  
plug connections between the encoder  
board and the control board. See the  
Wiring Diagram.  
5. Apply the correct input power (42 VAC)  
to the LN-10 unit.  
6. Carefully check for the presence of 5  
VDC from 5J2 (lead #505) to 4J2 (lead  
#500). This is the supply voltage from  
the control board to both encoder  
boards. (Volts and WFS). If this voltage  
is missing or low the control board may  
be defective. Also make certain the 5  
VDC supply is being applied to the  
encoder boards via leads #505 and  
#500. See the Wiring Diagram.  
NOTE: “Pulsing” means that as the control  
is rotated the signal will fluctuate from 0 to 5  
VDC.  
9. Remove input power to the LN-10 unit.  
10. Reassemble the control panel.  
LN-10  
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F-29  
F-29  
TROUBLESHOOTING AND REPAIR  
GAS SOLENOID TEST  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in danger  
to the technician or machine operator and will invalidate your factory warranty. For  
your safety and to avoid electrical shock, please observe all safety notes and pre-  
cautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This procedure will help determine if the gas solenoid is receiving the correct voltage and  
if the solenoid is functional.  
MATERIALS NEEDED  
5/16 in. Nut Driver  
Volt-Ohmmeter  
12 VDC @ 1 amp power source  
LN-10  
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F-30  
F-30  
TROUBLESHOOTING AND REPAIR  
GAS SOLENOID TEST (continued)  
FIGURE F.5 — GAS SOLENOID TEST.  
GAS SOLENOID  
LEAD  
GAS  
SOLENOID  
NOTE: WIRE FEEDER SHOWN  
WITH DRIVE MOTOR ASSEMBLY  
REMOVED FOR CLARITY  
6. If the 10 VDC is missing or low, check  
TEST PROCEDURE  
the leads and connections between the  
solenoid and the control board. See the  
Wiring Diagram. If the leads and con-  
nections are OK the control board may  
be faulty.  
1. Remove input power to the LN-10 unit.  
2. Using the 5/16 in. nut driver, remove  
the wire drive cover.  
7. If the 10 VDC is present at the solenoid  
leads and the solenoid does not  
activate the solenoid may be faulty.  
Normal solenoid coil resistance is  
approximately 22 ohms.  
3. Locate the gas solenoid and lead con-  
nection. See Figure F.5. Do not discon-  
nect the leads.  
4. Apply the correct input power (42 VAC)  
to the LN-10 unit.  
8. The solenoid can be further checked by  
disconnecting the solenoid leads from  
the LN-10 wiring harness and applying  
an external 12 VDC supply to the leads.  
If the solenoid does not activate the  
solenoid is faulty.  
5. While pressing the gas purge button or  
activating the gun trigger, check for  
approximately 10 VDC at the solenoid  
leads. If the 10 VDC is present the gas  
solenoid should activate.  
9. Reconnect all disconnected leads.  
10. Install the wire drive cover.  
LN-10  
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F-31  
F-31  
TROUBLESHOOTING AND REPAIR  
COMPONENT REPLACEMENT PROCEDURES  
DISPLAY PC BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in danger  
to the technician or machine operator and will invalidate your factory warranty. For  
your safety and to avoid electrical shock, please observe all safety notes and pre-  
cautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
This will aid the technician in the removal and replacement of the display PC board.  
MATERIALS NEEDED  
5/16 in. Nut Driver  
Small Screwdriver  
LN-10  
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F-32  
F-32  
TROUBLESHOOTING AND REPAIR  
DISPLAY PC BOARD REMOVAL AND REPLACEMENT (continued)  
FIGURE F.6 — DISPLAY PC BOARD REMOVAL AND REPLACEMENT.  
DISPLAY  
PC BOARD  
J11  
J10  
MOUNTING  
PIN  
REMOVAL PROCEDURE  
REPLACEMENT PROCEDURE  
1. Remove input power to the LN-10 unit.  
1. Install plug J10 into the new display  
board.  
2. Using the 5/16 in. nut driver, remove  
the two screws from the top of the con-  
trol panel.  
2. Mount the display board onto the six  
mounting pins.  
3. Lower the control panel.  
3. Install plug J11 into the new display  
board.  
4. Locate and remove plug J11 from the  
display board. Observe static electricity  
precautions. See Figure F.6.  
4. Reinstall the control panel.  
5. Carefully pry the display board from the  
six mounting pins. Note that the keypad  
is still attached to the display board via  
plug J10.  
6. Carefully remove plug J10 from the dis-  
play board.  
LN-10  
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F-33  
F-33  
TROUBLESHOOTING AND REPAIR  
GAS SOLENOID REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained per-  
sonnel. Unauthorized repairs performed on this equipment may result in danger to  
the technician or machine operator and will invalidate your factory warranty. For  
your safety and to avoid electrical shock, please observe all safety notes and pre-  
cautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of either of the gas  
solenoids.  
MATERIALS NEEDED  
5/16 in. Nut Driver  
5/16 in. Wrench  
Pliers  
Phillips Head Screwdriver  
LN-10  
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F-34  
F-34  
TROUBLESHOOTING AND REPAIR  
GAS SOLENOID REMOVAL AND REPLACEMENT (continued)  
FIGURE F.7 — GAS SOLENOID REMOVAL AND REPLACEMENT.  
SOLENOID  
CLAMP  
MOUNT  
LINCOLN  
ELECTRIC  
GAS  
HOSE  
NOTE: WIRE FEEDER SHOWN WITH  
DRIVE MOTOR ASSEMBLY  
REMOVED FOR CLARITY  
PROCEDURE  
8. Using the Phillips head screwdriver  
remove the two screws holding the  
solenoid to the bracket. Remove the  
solenoid.  
1. Remove input power to the LN-10 unit.  
2. Using the 5/16 in. nut driver, remove  
the wire drive cover.  
9. Mount the new solenoid onto the  
bracket using the two Phillips head  
screws.  
3. Locate the gas solenoid assembly and  
remove the input gas lines using pliers.  
See Figure F.7.  
10. Install the solenoid assembly into the  
LN-10.  
4. Label and remove the two leads con-  
nected to the solenoid.  
11. Connect the gas hose.  
5. Remove the rubber hose and clamp  
from the gas solenoid. Be careful not to  
damage the rubber hose.  
12. Connect the two wires previously  
removed. Be sure the leads are  
connected to their original positions.  
6. Using the 5/16 in. wrench remove the  
two screws that mount the solenoid  
assembly to the rear panel of the wire  
feeder.  
13. Install the wire drive cover and connect  
the input gas line.  
7. Remove the solenoid assembly from  
the LN-10 unit.  
LN-10  
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F-35  
F-35  
TROUBLESHOOTING AND REPAIR  
ENCODER PC BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained per-  
sonnel. Unauthorized repairs performed on this equipment may result in danger to  
the technician or machine operator and will invalidate your factory warranty. For  
your safety and to avoid electrical shock, please observe all safety notes and pre-  
cautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of either the WFS  
or Volts control encoder boards.  
MATERIALS NEEDED  
5/16 in. Nut Driver  
5/64 in. Allen Wrench  
1/2 in. Wrench  
LN-10  
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F-36  
F-36  
TROUBLESHOOTING AND REPAIR  
ENCODER PC BOARD REMOVAL AND REPLACEMENT (continued)  
FIGURE F.8 — ENCODER PC BOARD REMOVAL AND REPLACEMENT.  
ENCODER  
PC BOARD  
WASHER  
NUT  
FELT WASHER  
KNOB  
SPACER  
ALLEN  
SCREW  
PROCEDURE  
7. Remove harness plug J17 from the  
encoder PC board.  
1. Remove input power to the LN-10 unit.  
2. Using the 5/16 in. nut driver remove the  
two screws from the top of the control  
panel.  
8. Install harness plug J17 into the new  
encoder PC board.  
9. Assemble the PC board into the front  
panel and secure with the washer and  
nut previously removed.  
3. Lower the control panel.  
4. Using the 5/64 in. Allen wrench remove  
the control knob, spacer and felt  
washer from the encoder board that is  
to be removed. See Figure F.8.  
10. Assemble the felt washer, spacer and  
control knob onto the shaft and secure  
with the 5/64 in. Allen wrench.  
5. Using the 1/2 in. wrench remove the  
nut and washer from the control shaft.  
11. Replace the control panel.  
6. Carefully remove the PC board from  
the front panel.  
LN-10  
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F-37  
F-37  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in danger  
to the technician or machine operator and will invalidate your factory warranty. For  
your safety and to avoid electrical shock, please observe all safety notes and pre-  
cautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
The procedure will aid the technician in the removal and replacement of either the motor  
or gear box.  
MATERIALS NEEDED  
Pliers  
5/16 in. Nut Driver  
3/16 in. Allen Wrench  
7/16 in. Socket Wrench and Extension  
3/4 in. Wrench  
5/16 in. Wrench  
Flat Head Screwdriver  
LN-10  
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F-38  
F-38  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT (continued)  
FIGURE F.9 — WIRE FEED ASSEMBLY REMOVAL.  
MOTOR  
ARMATURE  
LEADS  
TACH  
LEADS  
CAP SCREW  
LOCK WASHER  
3/4 in. NUT  
FLATWASHER  
#67  
LINCOLN  
ELECTRIC  
GAS HOSE  
FITTING  
PROCEDURE  
7. Disconnect the motor armature leads.  
8. Remove any necessary cable ties.  
1. Remove input power to the LN-10 unit.  
2. Remove the electrode wire from the  
wire drive.  
9. Using the 3/4 in. wrench remove the  
electrode cable from the wire feed  
assembly.  
3. Using the 5/16 in. nut driver remove the  
wire drive cover.  
10. Using the 7/16 in. socket wrench and  
extension remove four mounting  
screws, lock washers and flat washers.  
The motor, gear box and feed head  
assembly are now free from the LN-10  
unit.  
4. Disconnect the #67 lead at the quick  
connect. See Figure F.9.  
5. Disconnect the gas hose from the brass  
gun connector.  
6. Disconnect the tach (hall effect device)  
leads.  
11. Remove the wire feed assembly.  
LN-10  
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F-39  
F-39  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT (continued)  
FIGURE F.10 — DRIVE MOTOR AND WIRE DRIVE ASSEMBLY REMOVAL.  
DRIVE  
MOTOR  
GEAR BOX  
INSPECTION COVER  
CONDUCTOR  
BLOCK  
GEAR BOX  
#67  
LEAD  
WIRE  
DRIVE  
ASSEMBLY  
ALLEN  
SCREWS  
TO REMOVE THE DRIVE  
MOTOR FROM THE GEAR BOX:  
TO REMOVE THE WIRE DRIVE  
ASSEMBLY FROM THE GEAR  
BOX:  
12. Using the flat head screwdriver and  
7/16 in. wrench remove the gear box  
inspection cover nearest to the drive  
motor. See Figure F.10.  
16. Using the 3/16 in. Allen wrench loosen  
the two Allen screws located at the bot-  
tom of the wire drive unit.  
13. Using the 5/16 in. wrench remove the  
motor mounting screws located inside  
the gear box.  
17. Remove lead #67 from the conductor  
block.  
18. Carefully slide and remove the wire  
drive assembly from the gear box  
assembly.  
14. Using the flat head screwdriver remove  
the two screws mounting the “top” of  
the motor to the gear box.  
15. Carefully remove the drive motor from  
the gear box assembly. Note motor  
lead placement for reassembly.  
LN-10  
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F-40  
F-40  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT (continued)  
REPLACEMENT PROCEDURES  
7. Install the gear box inspection cover and  
secure it with the slot head screws and  
nut previously removed.  
1. Carefully slide the wire drive assembly  
and gear box together.  
2. Tighten the two Allen type screws at  
the bottom of the wire drive unit using  
the 3/16 in. Allen wrench.  
8. Place the entire assembly into the  
LN-10 unit. Align the mounting holes  
with wire feeder base.  
3. Attach lead #67 to the conductor block.  
9. Secure the assembly to the wire feeder  
base using the four screws, lock wash-  
ers and flat washers previously  
removed.  
4. Carefully slide the drive motor into the  
gear box assembly. Be sure to position  
the motor leads so that they can be  
properly connected. See Figure F.10.  
10. Connect the gas hose to the brass gun  
conductor block.  
5. Install the flat head screws that mount  
the “top” of the drive motor to the gear  
box.  
11. Connect the motor armature leads.  
12. Connect the tach (hall effect device)  
leads.  
6. Install the mounting screws located  
inside the gear box using the 5/16 in.  
wrench.  
13. Connect lead #67 quick connects  
together.  
14. Connect the electrode cable to the to  
the wire feed assembly.  
15. Replace any cut or removed cable ties.  
16. Install the wire drive cover.  
LN-10  
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F-41  
F-41  
TROUBLESHOOTING AND REPAIR  
CURRENT SENSING REED SWITCH REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in danger  
to the technician or machine operator and will invalidate your factory warranty. For  
your safety and to avoid electrical shock, please observe all safety notes and pre-  
cautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
The procedure will aid the technician in the removal and replacement of the current sens-  
ing reed switch.  
MATERIALS NEEDED  
3/4 in. Wrench  
Slot Head Screwdriver  
LN-10  
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F-42  
F-42  
TROUBLESHOOTING AND REPAIR  
CURRENT SENSING REED SWITCH REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.11 — CURRENT SENSING REED SWITCH /PLUG LOCATION.  
Current Sensing  
Reed Switch  
Plug  
Locking Screw  
Reed Switch  
Cover  
3\4" Nuts  
driver, loosen the locking screw and remove the  
reed switch from the energizer. Note lead routing for  
PROCEDURE  
reassembly. See Figure F.11.  
1. Remove input power to the LN-10 unit.  
5. Replace Reed Switch into the copper energizer and  
tighten locking screw. Mount the assembly to the  
machine using 3/4” nuts.  
2. Remove the reed switch plug from the front of the  
machine. See Figure F.11.  
3. Remove the Reed Switch Cover. See Figure F.11.  
6. Plug in Reed Switch lead to front of machine.  
7. Slide Reed Switch cover back on the LN-10.  
4. Using a 3/4” socket, remove the two nuts from the  
copper energizer. Remove Reed Switch and cop-  
per energizer assembly. Using a slot head screw-  
LN-10  
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F-43  
F-43  
TROUBLESHOOTING AND REPAIR  
RETEST AFTER REPAIR  
If a failed test indicates that any mechanical  
Check the Feeder selection and Procedure  
part which could affect the machine's elec-  
trical characteristics must be replaced, or if  
any electrical components are repaired or  
replaced, the machine must be retested and  
meet the following standards.  
keys for proper operation.  
1. Press the Trigger key. The LEDs  
should toggle through the various trig-  
ger selections as the key is pressed  
and released.  
Apply the correct input power (42 VAC) to  
the LN-10 unit. The following checks should  
be performed.  
2. Press the Timer key. The LEDs should  
toggle through the various modes as  
the key is pressed and released.  
1. Press the Purge key. The gas solenoid  
should activate, then deactivate when  
the key is released.  
3. Press the Control key. The “Run-In  
Volts/WFS” LED should light up. Press  
the Control key again. The LED should  
turn off.  
2. Press the Cold Feed Forward key.  
Check that the direction of rotation of  
the drive roll is correct to feed wire out  
of the front of the machine. Check that  
the drive roll shaft stops abruptly when  
the key is released.  
The Volts and WFS controls must function  
and change the appropriate display.  
CHECK WIRE FEED SPEED  
RANGE  
3. Press the Cold Feed Reverse key.  
Check that the direction of rotation of  
the drive roll is correct to retract the  
electrode wire back into the machine.  
Check that the drive roll shaft stops  
abruptly when the key is released.  
LN-10 with low speed gear installed:  
35-500 IPM  
LN-10 with high speed gear installed:  
50-750 IPM  
LN-10  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
ELECTRICAL DIAGRAMS SECTION  
Electrical Diagrams Section...........................................................................................Section G  
Wiring Diagram (Control) .............................................................................................................G-2  
Wiring Diagram (Wire Drive)........................................................................................................G-3  
Control Board Schematic (Sheet 1) .............................................................................................G-4  
Control Board Schematic (Sheet 2) .............................................................................................G-5  
Control Board Layout...................................................................................................................G-6  
Display Board Schematic.............................................................................................................G-7  
Display Board Layout...................................................................................................................G-8  
Encoder Board Schematic ...........................................................................................................G-9  
Encoder Board Layout ...............................................................................................................G-10  
LN-10  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - LN-10 (CONTROL)  
ELECTRICAL SYM  
BOLS PER E1537.  
CAVITY NUM  
PIN NUMBERING SEQUENCE  
BERING SEQ  
UENCE  
*
**  
(COMPONENT SIDE OF P.C. BOARD)  
(COMPONENT SIDE OF P.C. BOARD)  
1 2  
1
1
1
3
5
5
J10  
1
8
J17  
J3  
J8  
J1  
J4  
J11  
J6  
1
PIN 1  
10  
4
6
6
1
3 4  
6
6
10  
CONNECTOR CAVITY  
1
4
8
7
***  
NUMBERING SEQUENCE  
J2  
J5  
J7  
(NON LEAD SIDE OF CONNECTOR)  
J19***  
14  
12  
5
8
7
1
2
U
2
1
CASE  
P10  
P11  
GROUNDING  
STUD  
LEAD COLOR CODING  
B - BLACK  
GROUNDING  
P19  
P17  
J19  
LEAD  
1 2  
3
4
5
6
7
8
PROTECTOR  
PIN 1  
PIN 1  
R - RED  
2
1
U
J11  
W - WHITE  
P19***  
U - BLUE  
DISPLAY  
P.C. BOARD  
C
9
500 H G F D E  
A
7
B
W
1 2  
3
4
5
6
8
J10  
ARC  
CURRENT  
SENSOR  
CONTROL P.C BOARD  
KEYPAD  
500  
C
W
1
2
500  
505  
B
C
A
N.B.  
J6  
N.A., N.B.  
J8  
6
3
4
5
6
7
8
J2  
J7  
J3  
5
J4  
J5  
B
A
J1  
J17**  
VOLTS  
517  
516  
E
F
121314  
9 1011  
12  
9 1011  
1 2  
3
4
1 2  
4
3
4
5
6
7
8
1 2  
3
4
6
1 2  
3
4
1 2  
3
4
5
6
7
8
1 2  
3
4
5
6
7
8
9 10  
1 2  
3
4
5
6
7
8
1 2  
3
4
5
7
8
9 10  
505  
500  
D
E
D
1
2
1 2  
3
3
4
5
6
7
8
J18  
J17**  
WFS  
BRIDGE  
542  
F
527  
526  
H
+
G
H
G
R
AC AC  
-
R
500  
R.F. TOROID  
ASSEMBLY  
OPTIONAL REMOTE  
CONTROL KIT  
A
J
I
B
A
E
D
C
L
G
J13  
M
N
K
H
F
B
C
D
J15  
J12  
WIRE DRIVE  
INPUT CABLE  
RECEPTACLE  
RECEPTACLE  
A
C
D
B
CABLE TO  
WIRE DRIVE  
A
TO MOTOR  
TO MOTOR  
TO MOTOR TACHOMETER  
TO MOTOR TACHOMETER  
TO MOTOR TACHOMETER  
539  
541  
U
R
B
B
F
G
H
K
L
FOR CONNECTION  
TO ROBOTICS  
INTERFACE  
SHIELDED  
CABLE  
HARNESS  
A
NOTES:  
N.A. THE JUMPER PLUG (SHOWN), THE OPTIONAL REMOTE  
SWITCH INTERFACE MODULE (NOT SHOWN), OR THE  
OPTIONAL ROBOTIC INTERFACE MODULE (NOT SHOWN)  
MUST BE INSTALLED INTO CONNECTOR J5 ON THE  
CONTROL P.C. BOARD FOR THE LN-10 TO OPERATE.  
TO BRASS BLOCK VOLTAGE SENSE  
TO SOLENOID  
TO SOLENOID  
N
C
D
E
M
I
67  
512  
522  
519  
520  
W
SHIELDED  
CABLE  
TO DUAL PROCEDURE SWITCH  
TO DUAL PROCEDURE SWITCH  
TO TRIGGER  
N.B. THE OPTIONAL ROBOTIC INTERFACE MODULE MOUNTS  
IN CONNECTORS J5 AND J6.  
B
CONTROL  
CABLE  
TO TRIGGER  
W
J
4-24-98  
L10218-1  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
LN-10  
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G-3  
G-3  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - LN-10 (WIRE DRIVE)  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(NON LEAD SIDE OF CONNECTOR)  
ELECTRICAL SYMBOLS PER E1537.  
J1  
J2  
J3  
1
1 2  
1
7
2 1  
7
P1  
P2  
P3  
J4  
P4  
8
8
14  
14  
3
4
3 4  
ELECTRODE  
CABLE  
522  
FROM  
CURRENT  
SENSOR  
GAS  
512  
P.M.  
TACH.  
B
3
U
2
R
1
J3  
B
1
W
2
J1  
P1  
CHOKE PLUG ASSEMBLY  
GEARBOX  
J2  
2
1
2
2
1
1
3
3
P2  
N.A.  
541  
539  
P3  
GUN  
N.A. CHOKE PLUG ASSEMBLY NOT  
INCLUDED ON EARLIER WIRE  
DRIVES.  
TRIGGER AND  
DUAL PROCEDURE  
SWITCH  
P4  
11  
1
12  
2
6
8
10  
K
13  
5
4
3
E
7
9
14  
C
J4  
J5  
RECEPTACLE  
L
H
I
M
A
F
G
N
J
D
B
J6  
B
C
D
A
E
WIRE DRIVE RECEPTACLE  
3-5-99F  
M18036  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
LN-10  
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G-4  
G-4  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CONTROL PC BOARD #1  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
LN-10  
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G-5  
G-5  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CONTROL PC BOARD #2  
- 2 6 6 1 3  
G
512  
541  
BLACK  
J7  
11  
R189  
512  
5.62K  
512  
M
D46  
R187  
5.11K  
11  
J7  
MOTOR REVERSING  
CIRCUITRY  
6
3
505  
C73  
0.1  
RED  
505  
13  
50V  
3.32K  
R169  
X10  
J7  
J7  
539  
10  
J7  
TACH  
9
R170  
332  
4.75K  
R149  
WHITE  
BLUE  
512  
MOTOR  
1
512  
1
C72  
C64  
0.1  
C62  
330p  
50V  
BLACK  
4
5
.0047  
50V  
D45  
X16  
TACH  
50V  
2
500  
500  
512  
12  
13  
542  
4.75K  
R112  
500  
505  
11  
X4  
R148  
6.19K  
D39  
D24  
R173  
2.21K  
1N4936  
1N4936  
FWD  
REV  
Q10  
33A  
Q11  
33A  
C61  
D
D
S
9
6
7
3
4
5
1
6
7
3
4
5
1
9
C71  
330p  
50V  
Vdd  
Vb  
Vb  
HO  
Vcc  
nc  
Vdd  
SD  
nc  
100  
200V  
200V  
0.1  
G
G
12  
11  
C42  
0.1  
LIN  
X27  
HO  
X26  
R151  
R111  
50V  
500  
S
10  
14  
8
8
C65  
0.1  
C63  
0.1  
C43  
0.1  
C46  
HIN  
nc  
Vcc  
100  
50V  
R154  
15.0  
0.1  
505  
14  
13  
10  
12  
nc  
Vs  
nc  
15.0  
50V  
50V  
50V  
50V  
C
E
C
E
REV  
FWD  
500  
nc  
Vs  
Vss  
HIN  
LIN  
4.75K  
R155  
R152  
11  
13  
SD  
Vss  
LO  
LO  
G
G
2
2
COM  
COM  
D40  
D23  
D20  
4A  
200V  
C66  
IR2110  
C40  
1.0  
IR2110  
Q13  
Q12  
40A  
1N4936  
1N4936  
.33  
C68  
1.0  
40A  
200V  
35V  
500  
R157  
150  
600V  
600V  
C41  
0.1  
35V  
R110  
150  
C67  
0.1  
D22  
50V  
D42  
4A  
3W  
3W  
0.05  
475  
1N4936  
50V  
0.05  
200V  
500  
4.75K  
R106  
PWM  
C45  
330p  
50V  
500  
10  
9
X4  
8
6
1
500  
512  
3
X4  
R107  
6.19K  
PROC  
B
A
100  
2
DIR  
505  
+5REF  
R119  
C44  
330p  
50V  
R171  
2.21K  
R186  
2.21K  
5
4
475  
D21  
1N4936  
X4  
R121  
PROC  
13.7K  
D49  
R92  
505  
6
7
4
5
J7  
+5REF  
DUAL PROCEDURE  
519  
3.32K  
8
9
X16  
DP  
500  
1
2
13  
5
X5  
X5  
R103  
100  
X5  
14  
14  
X6  
12  
D31  
R126  
10K  
D19  
C48  
330p  
50V  
R120  
C31  
AVE  
13.7K  
10  
J7  
520  
6
5
6
C53  
0.1  
13  
12  
R90  
C69  
0.1  
7
1
1.00K  
11  
R130  
4.75K  
X6  
50V  
X5  
7
50V  
500  
D29  
R118  
10K  
C49  
0.1  
C51  
500  
C54  
D28  
1.0  
50V  
35V  
C50  
1.0  
542  
1
542  
35V  
C52  
330p  
50V  
500  
D30  
J8  
512  
505  
VL  
500  
R114  
2.21K  
C60  
.022  
200V  
488  
-12.8 VDC  
512  
D27  
512  
TRIGGER  
J7  
J7  
4.75K  
J5  
J5  
WHITE  
8
R116  
1
8
9
2
R143  
3.32K  
X16  
TRIG  
14  
SWITCHING  
POWER SUPPLY  
10  
9
T1  
A
B
T1  
C59  
1.8  
20V  
2
C58  
SOLENOID  
D25  
GAS SOLENOID  
D36  
1N4936  
C47  
512  
J7  
J7  
D35  
4
SOLENOID  
DRIVER  
2
500  
WHITE  
1N4936  
10  
R134  
D26  
1N4936  
FAULT  
J5  
GAS  
SOLENOID  
1.00K  
500  
D34  
3
4
500  
5
4
+12.8 VDC  
522  
Q5  
7
2
512  
505  
X10  
600mA  
40V  
D
+5 VDC  
D48  
J5  
Q4  
1N4936  
15A  
60V  
D
R141  
100  
Q14  
TO  
G
S
26.7  
J5  
J5  
J5  
J5  
J5  
J5  
J5  
J5  
J5  
J5  
18A  
G
X29  
7
8
4
5
6
2
3
Q7  
VCC  
OUT  
VFB  
INTERFACE  
P.C. BOARD  
OR  
5
R182  
200V  
CR1-  
600mA  
40V  
IN  
S
OUT  
DZ8  
2
VREF  
RT/CT  
GND  
16V  
1W  
J6  
J6  
J6  
J6  
J6  
J6  
J6  
J6  
J6  
J6  
COMP 1  
500  
C78  
1
6
GND  
1
1200  
100V  
D47  
4A  
200V  
3
C57  
18  
CS  
TO  
X28  
505  
ROBOTIC  
INTERFACE  
P.C. BOARD  
2
3
4
5
6
7
8
9
7
GASR  
C77  
15V  
500  
C79  
20  
2700p  
50V  
512  
C56  
1200  
100V  
C80  
DZ9  
16V  
1W  
50V  
8
TRIGR  
CFFR  
CFRR  
BBR  
5600  
35V  
9
332  
PDOWN  
C75  
6
T1  
C81  
0.1  
R175  
2700p  
50V  
C
TO  
10  
11  
12  
13  
14  
7
6
CURRENT  
505  
50V  
D51  
7
ARC  
C76  
2700p  
50V  
ROBOTIC  
INTERFACE  
P.C. BOARD  
1
X10  
CURRENT  
WHITE  
3
CURRENT  
SENSE  
R99  
J1  
J1  
2.21K  
C33  
4.7  
D50  
VOLTS  
35V  
500A  
WFS  
WHITE  
4
ANALOG  
500  
500A  
COMMAND  
R232  
2.21K  
(
PINS  
2
7
&
9
)
VOLTS  
500  
J8  
500  
J7  
4
10  
505  
512  
512  
505  
512  
GENERAL INFORMATION  
ELECTRICAL SYMBOLS PER E1537  
LAST NO. USED  
R-250  
C-101  
D-53  
9
8
D53  
D52  
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
UNLESS OTHERWISE SPECIFIED)  
GROUND  
FAULT  
14  
10  
LABELS  
=
Ohms  
(
1/4W UNLESS OTHERWISE SPECIFIED)  
(UNLESS OTHERWISE SPECIFIED)  
4
3
14  
X10  
GLP  
BLUE  
1
3
3
X16  
13  
=
1A, 400V  
SUPPLY VOLTAGE NET  
R233  
J1  
J1  
11  
X4  
2.21K  
C36  
0.1  
C37  
C34  
C38  
0.1  
C32  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
X6  
X5  
PROTECT  
SHEET 2 OF 2  
X10  
X16  
0.1  
0.1  
0.1  
C100  
4.7  
74HC132  
50V  
50V  
50V  
50V  
50V  
LM224  
LM2901  
12  
500  
BLUE  
2
LM2901  
LM2901  
12  
35V  
FRAME CONNECTION  
11  
7
R234  
2.21K  
EARTH GROUND CONNECTION  
12  
FILENAME: G3166_2CA  
NOTES  
:
EQUIP.  
TYPE  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
Ch’ge.Sht.No.  
500  
LN-10  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLES SIZES PER E-2056  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY  
A
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
XA  
ON  
2
PLACE DECIMALS IS  
+
.O2  
CONTROL P.C. BOARD SCHEMATIC  
SHT.  
SUBJECT  
500  
500  
ON  
3
PLACE DECIMALS IS  
+
.OO2  
488  
4-24-98  
3-5-99F  
NONE  
10/2496  
SCALE  
DATE  
ON ALL ANGLES IS  
+
.5 OF  
A
DEGREE  
MATERIAL TOLERANCE ("t") TO AGREE  
WITH PUBLISHED STANDARDS  
G
LM/RP  
CHK.  
SUP’S’D’G.  
3166-2  
DR.  
NO.  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
LN-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY-CONTROL  
3 1 G 6 8 - 2  
ITEM  
REQ’D. PART NO.  
DESCRIPTION  
ITEM  
REQ’D.  
PART NO.  
DESCRIPTION  
R 3 8 , R 1 7 4  
2
S 1 9 4 0 0 - 1 3 0 1  
S 1 9 4 0 0 - 2 2 1 1  
1 . 3 K 1 / 4 W  
C 1 , C 2 , C 3 , C 4 , C 5 , C 6 , C 7 , C 1 8  
1 4  
S 1 6 6 6 8 - 5  
. 0 2 2 / 5 0  
. 1 / 5 0  
R 4 0 , R 9 9 , R 1 1 4 , R 1 7 1 , R 1 7 3  
1 0  
2 . 2 1 K 1 / 4 W  
C 2 6 , C 3 0 , C 3 1 , C 4 7 , C 5 1 , C 5 8  
R 1 8 6 , R 1 8 8 , R 2 3 2 , R 2 3 3 , R 2 3 4  
C 8 , C 9 , C 1 0 , C 1 1 , C 1 2 , C 1 3 , C 1 4  
3 5  
S 1 6 6 6 8 - 1 1  
R 4 2  
1
2
1
2
7
T
1 0 8 1 2 - 6 8  
1 K 1 / 2 W T R I M M E R  
5 . 0 M E G R E S I S TO R  
2 2 1 1 / 4 W  
C 1 5 , C 1 6 , C 2 1 , C 2 3 , C 2 4 , C 2 5  
R 4 4 , R 4 6  
T 1 4 2 3 0 - 2 3  
C 2 8 , C 3 2 , C 3 4 , C 3 6 , C 3 7 , C 3 8  
R 5 0  
S 1 9 4 0 0 - 2 2 1 0  
S 1 9 4 0 0 - 3 0 1 0  
S 1 9 4 0 0 - 2 6 R 7  
C 4 1 , C 4 2 , C 4 3 , C 4 6 , C 4 9 , C 5 3  
R 5 9 , R 8 2  
3 0 1 1 / 4 W  
C 6 3 , C 6 4 , C 6 5 , C 6 7 , C 6 9 , C 7 1  
R 6 0 , R 6 2 , R 6 6 , R 6 7 , R 6 9 , R 7 0  
2 6 . 7 1 / 4 W  
C 7 3 , C 8 1 , C 8 2 , C 1 0 1  
R 1 8 2  
C 1 9 , C 3 3 , C 1 0 0  
3
2
5
6
2
1
1
1
1
1
3
1
1
3 1  
S 1 3 4 9 0 - 2 5  
S 1 6 6 6 8 - 1  
4 . 7 / 3 5  
R 6 3 , R 8 8  
2
S 1 9 4 0 0 - 1 2 1 1  
S 1 9 4 0 0 - 6 1 9 0  
S 1 9 4 0 0 - 2 4 3 1  
S 1 9 4 0 0 - 3 9 R 2  
S 1 9 4 0 0 - 7 5 R 0  
S 1 9 4 0 0 - 1 0 0 0  
1 . 2 1 K 1 / 4 W  
6 1 9 1 / 4 W  
2 . 4 3 K 1 / 4 W  
3 9 . 2 1 / 4 W  
7 5 1 / 4 W  
C 2 0 , C 2 2  
2 2 p F / 1 0 0  
1 . 0 / 3 5  
R 6 4 , R 8 5  
2
C 2 7 , C 4 0 , C 5 0 , C 5 4 , C 6 8  
S 1 3 4 9 0 - 4 2  
S 1 6 6 6 8 - 8  
R 6 5 , R 8 4  
2
C 4 4 , C 4 5 , C 4 8 , C 5 2 , C 6 1 , C 6 2  
3 3 0 p F / 1 0 0  
1 2 0 0 / 1 0 0  
1 8 / 1 5  
R 7 7 , R 7 8  
2
C 5 6 , C 7 8  
S 1 3 4 9 0 - 1 3 8  
S 1 3 4 9 0 - 3 9  
S 1 3 4 9 0 - 1 9  
S 1 3 4 9 0 - 4  
R 7 9 , R 8 0  
2
C 5 7  
R 1 0 3 , R 1 0 4 , R 1 1 1 , R 1 1 9 , R 1 4 1  
2 4  
1 0 0 1 / 4 W  
C 5 9  
1 . 8 / 2 0  
R 1 5 0 , R 1 5 1 , R 2 0 0 , R 2 0 1 , R 2 0 2  
C 6 0  
. 0 2 2 / 2 0 0  
. 3 3 / 2 0 0  
4 7 0 0 p F / 5 0  
2 7 0 0 p F / 5 0  
2 0 / 5 0  
R 2 0 3 , R 2 0 4 , R 2 0 5 , R 2 0 6 , R 2 0 7  
C 6 6  
S 1 3 4 9 0 - 9 4  
S 1 6 6 6 8 - 1 0  
S 1 6 6 6 8 - 4  
R 2 1 6 , R 2 1 7 , R 2 1 8 , R 2 1 9 , R 2 2 0  
C 7 2  
R 2 2 1 , R 2 2 2 , R 2 2 3 , R 2 5 0  
C 7 5 , C 7 6 , C 7 7  
R 1 0 7 , R 1 4 8 , R 1 7 8  
3
2
2
4
1
1
2
2
1
2
2
2
1
1
1
1
1
2
1
1
1
1
1
2
3
1
2
1
1
1
1
1
1
2
1
1
2
1
S 1 9 4 0 0 - 6 1 9 1  
S 1 9 4 0 0 - 5 6 2 1  
S 1 9 4 0 0 - 3 7 4 1  
S 1 9 4 0 0 - 1 3 7 2  
S 1 9 4 0 0 - 6 8 1 1  
S 1 9 4 0 0 - 7 5 0 0  
S 1 9 4 0 0 - 1 5 0 1  
S 1 9 4 0 0 - 3 3 2 2  
T 1 4 6 4 8 - 9  
6 . 1 9 K 1 / 4 W  
5 . 6 2 K 1 / 4 W  
3 . 7 4 K 1 / 4 W  
1 3 . 7 K 1 / 4 W  
6 . 8 1 K 1 / 4 W  
7 5 0 1 / 4 W  
C 7 9  
S 1 3 4 9 0 - 7 3  
S 1 3 4 9 0 - 1 0 7  
T 1 2 1 9 9 - 1  
R 1 1 3 , R 1 8 9  
C 8 0  
5 6 0 0 / 3 5 V  
1 N 4 0 0 4  
R 1 1 7 , R 1 2 3  
D 1 , D 2 , D 3 , D 4 , D 5 , D 6 , D 7 , D 8 , D 9  
D 1 0 , D 1 1 , D 1 2 , D 1 3 , D 1 4 , D 1 5  
D 1 6 , D 1 9 , D 2 5 , D 2 7 , D 2 8 , D 2 9  
D 3 0 , D 3 1 , D 3 4 , D 4 5 , D 4 6 , D 4 9  
D 5 0 , D 5 1 , D 5 2 , D 5 3  
D 2 0 , D 4 2 , D 4 7  
R 1 2 0 , R 1 2 1 , R 1 6 7 , R 1 7 7  
.04  
9.00  
R 1 2 2  
R 1 2 8  
8.82  
R 1 3 7 , R 1 7 6  
R 1 3 9 , R 1 4 0  
R 1 4 6  
1 . 5 K 1 / 4 W  
3 3 . 2 K 1 / 4 W  
2 . 5 K 5 W  
3
T 1 2 7 0 5 - 4 7  
T 1 2 7 0 5 - 3 4  
4 A / 2 0 0 V  
1 N 4 9 3 6  
D 2 1 , D 2 2 , D 2 3 , D 2 4 , D 2 6 , D 3 5  
D 3 6 , D 3 8 , D 3 9 , D 4 0 , D 4 1 , D 4 8  
D Z 1 , D Z 2  
1 2  
R 1 5 2 , R 1 5 4  
R 1 5 6 , R 1 5 8  
R 1 7 0 , R 1 7 5  
R 1 7 2  
S 1 9 4 0 0 - 1 5 R 0  
T 1 2 3 0 0 - 8 6  
S 1 9 4 0 0 - 3 3 2 0  
S 1 9 4 0 0 - 4 4 2 2  
S 1 9 4 0 0 - 1 0 0 3  
T 1 2 3 0 0 - 8 0  
S 1 9 4 0 0 - 1 5 0 3  
S 1 9 4 0 0 - 5 1 1 1  
S 1 9 8 6 9 - 8  
1 5 1 / 4 W  
R 3 3  
R 9  
. 0 5 / 3 W  
2
4
2
2
1
1
1
1
1
1
3
1
1
8
T 1 2 7 0 2 - 4 0  
T 1 2 7 0 2 - 3 8  
T 1 2 7 0 2 - 1 1  
S 1 8 2 4 8 - 4  
S 1 8 2 4 8 - 8  
S 1 8 2 4 8 - 6  
S 2 1 1 3 4 - 1 4  
S 2 1 1 3 4 - 1 0  
S 1 8 2 4 8 - 1 2  
S 1 8 2 4 8 - 1 0  
T 1 2 2 1 8 - 7  
T 1 3 6 5 7 - 2  
T 1 3 6 5 7 - 3  
S 1 5 0 0 0 - 2 5  
1 N 4 7 3 5  
1 N 4 7 5 1  
R 6  
R 1 0  
3 3 2 1 / 4 W  
D Z 3 , D Z 4 , D Z 5 , D Z 6  
D Z 8 , D Z 9  
D 3 5  
D Z 9  
R 1 7 9  
4 4 . 2 K 1 / 4 W  
1 0 0 K 1 / 4 W  
1 N 4 7 4 5 A  
H E A D E R  
H E A D E R  
H E A D E R  
R 1 7 9  
J 1 , J 4  
R 1 8 0  
5
WAT T 0 . 5 O H M R E S I S TO R  
J 2  
R 1 8 1  
1 5 0 K 1 / 4 W  
J 3  
R 1 8 7  
5 . 1 1 K 1 / 4 W  
J 5  
M O L E X C O N N E C TO R  
M O L E X C O N N E C TO R  
H E A D E R  
S 1 , S 2  
T 1  
S P S T S L I D E S W I T C H PA C K A G E  
T R A N S F O R M E R  
D 3 4  
C 7 5  
J 6  
R 1 5 6  
R 1 1 9  
R 1 5 8  
C 5 7  
R 1 5 4  
S 2 0 3 7 5 - 1  
J 7  
R 1 5 1  
D 4 2  
D 2 3  
R 1 1 0  
T P 1  
T 1 3 6 4 0 - 1 6  
S 2 4 0 1 0 - 3  
8 0 J  
J 8  
H E A D E R  
R 1 5 2  
C 6 4  
D 2 0  
D 2 1  
R 1 7 5  
R 1 7 4  
C 7 2  
X 1  
I . C . , C M O S , M C U ( S S )  
I . C . , C M O S , M C U ( S S )  
1 4 P I N I . C . ( S S )  
C 7 7  
R 1 8 1  
R 1 7 6  
R 1 7 8  
L 1 , L 2 , L 3  
3 3 0 u H  
C 6 8  
R 1 5 0  
D 3 9  
R 1 4 9  
C 6 1  
R 1 4 8  
R 1 4 7  
C 6 2  
C 4 1  
D 3  
C 7  
D 1  
X 2  
S 2 4 0 1 1 - 5  
L E D 1  
R E D L E D  
R 1 0 9  
C 2 5  
R 1 0 7  
X 3  
S 1 7 9 0 0 - 8  
L E D 2  
G R E E N L E D  
O P TO C O U P L E R  
5.48  
C 4 4  
R 2 0  
D 4 0  
C 4 5  
D 3 0  
R 2 5  
R 2 4  
R 1 8  
X 4 , X 1 8  
X 5 , X 1 0 , X 1 6  
X 6  
S 1 7 9 0 0 - 2 4  
S 1 5 1 2 8 - 1 1  
S 1 5 1 2 8 - 4  
I C , 7 4 H C 1 3 2 , C M O S , G AT E , N A N D, 2 - I N , S T ( S S )  
1 4 P I N Q UA D C O M PA R ATO R  
I C , L M 2 2 4 , O P - A M P  
O C I 1 , O C I 2 , O C I 3 , O C I 4 , O C I 5  
O C I 6 , O C I 7 , O C I 8  
O C I 9 , O C I 1 0  
R 1 5 7  
R 1 0 6  
D 4 1  
R 1 5 3  
R 1 1 8  
D 2 2  
C 6 7  
D 6  
R 1 0 8  
R 1 1 2  
R 1 2 4  
C 3 4  
4.97  
R 2 3  
2
3
1
1
2
2
1
8
1
8
S 1 5 0 0 0 - 2 0  
T 1 2 7 0 4 - 6 8  
T 1 2 7 0 4 - 5 4  
T 1 2 7 0 4 - 6 9  
S 2 0 1 0 6 - 1  
P H OTO F E T  
D 2  
C 6  
D 2 4  
C 3 6  
D Z 8  
X 8 , X 9  
X 1 1  
S 1 7 9 0 0 - 5  
I C , 7 4 H C 3 7 3 , C M O S , L AT C H , 3 - S TAT E , O C T ( S S )  
I C , C M O S , X C V R , E I A 4 8 5 ( S S )  
A M P L I F I E R  
C 4 2  
Q 1 , Q 3 , Q 5  
2 N 4 4 0 1  
R 1 5 5  
R 2 5 0  
S 2 0 3 5 3 - 4  
Q 4  
N - C H A N N E L F E T ( S S )  
2 N 4 4 0 3  
R 1 5 9  
R 1 7  
R 2 2  
C 5 2  
C 4 9  
R 1 2 2  
R 1 0 5  
R 1 2 8  
C 4 8  
C 2 7  
D 2 9  
R 1 2 0  
X 1 2  
S 1 5 1 2 8 - 2 0  
S 1 5 1 2 8 - 1 0  
M 1 5 1 0 2 - 3  
Q 7  
C 1  
D 2 8  
R 1 2 6  
C 5 4  
R 1 2 3  
R 1 2 9  
X 2 1  
I C , 4 3 1 , VO LTA G E R E F.  
I C , S 8 0 5 4 H N , C M O S , U N D E RVOT- S E N S I N G ( S S )  
I . C . , E E P R O M , ( S S )  
Q 1 0 , Q 1 1  
H E X F E T W / H . S . A S B LY ( S S )  
T R A N S I S TO R , I G + D, T 2 4 7 , 6 0 0 V  
H . S . A S B LY ( S S )  
2 6 7 1 / 4 W  
C 3 1  
D 2 7  
D 2 5  
X 2 2  
Q 1 2 , Q 1 3  
S 2 0 1 0 6 - 3  
D 4  
R 1 7 2  
R 1 9  
X 2 4  
M 1 5 1 0 4 - 8  
Q 1 4  
S 1 8 3 9 5 - 5  
R 1 2 5  
D 3 1  
R 1 2 1  
C 8 2  
R 7 3  
R 1 4 4  
R 1 6 7  
R 1 2 7  
R 1 1 7  
D 1 9  
D 4 9  
C 9  
X 2 5  
M 1 5 1 0 5 - 7  
I C , C M O S , M P U, A / D, 1 0 - B I T ( S S )  
H V G AT E D R I V E ( S S )  
R 1 , R 2 , R 3 , R 4 , R 5 , R 8 , R 4 7 , R 4 8  
R 6  
S 1 9 4 0 0 - 2 6 7 0  
S 1 9 4 0 0 - 4 7 5 2  
S 1 9 4 0 0 - 1 0 0 1  
C 3 7  
C 5 3  
R 4 2  
R 1 1 3  
R 5 3  
R 2 2 4  
C 1 9  
R 4 4  
R 1 3 0  
C 5 1  
R 1 8 9  
R 1 8 7  
R 1 6 0  
X 2 6 , X 2 7  
X 2 8  
S 1 5 0 1 8 - 1 6  
M 1 5 4 5 8 - 4  
4 7 . 5 K 1 / 4 W  
R 2 2 3  
R 2 2 5  
R 2 2 2  
R 2 2 6  
R 2 2 1  
R 2 2 7  
R 2 2 0  
R 3 7  
R 3 8  
R 5 7  
3.13  
8
P I N I C  
R 4 3  
C 2 2  
R 7 , R 3 9 , R 7 5 , R 7 6 , R 9 0 , R 1 2 9  
R 1 3 4 , R 1 3 8  
1 K 1 / 4 W  
R 5 5  
R 2 3 6  
R 1 0 2  
X 2 9  
S 1 8 3 9 5 - 3  
H E AT S I N K A S B LY  
C 3 8  
R 1 8 6  
C 3 0  
R 9 3  
R 4 1  
R 2 4 4  
C 1 0  
C 1 2  
X 3 0 , X 3 1  
Y 1  
S 1 7 9 0 0 - 2 6  
S 1 6 6 6 5 - 5  
I C , 7 4 H C 1 5 1 , C M O S , M U X , DATA , 8 - I N P U T ( S S )  
8 . 0 M H Z  
D Z 2  
R 9 , R 1 0  
2
9
S 1 9 4 0 0 - 1 0 0 4  
S 1 9 4 0 0 - 1 5 0 0  
1 M 1 / 4 W  
1 5 0 1 / 4 W  
R 5 6  
R 5 1  
R 1 1  
X 2 2  
D Z 1  
D 1 2  
R 2 2 8  
R 2 1 9  
R 2 1 8  
R 2 1 7  
R 2 1 6  
R 1 1 , R 5 1 , R 5 6 , R 6 8 , R 8 1 , R 8 3  
R 8 6 , R 1 1 0 , R 1 5 7  
R 1 2 , R 1 3 , R 1 4 , R 1 5 , R 1 2 4  
R 1 6 , R 1 9 , R 2 1 , R 4 9 , R 5 4 , R 5 8  
R 6 1 , R 7 3 , R 7 4 , R 8 7 , R 9 8 , R 1 0 2  
R 1 0 6 , R 1 1 2 , R 1 1 5 , R 1 3 0 , R 1 4 3  
R 1 4 9 , R 1 5 5 , R 1 6 2 , R 2 3 6 , R 2 4 4  
R 1 7 , R 4 5 , R 9 2 , R 9 6 , R 1 1 6 , R 1 6 0  
R 1 6 9  
C 3 2  
R 2 2 9  
D 9  
R 2 3 0  
R 2 3 1  
D 1 4  
D 1 0  
D 1 3  
R 2 7  
R 2 9  
R 2 6  
R 3 2  
R 2 8  
5
S 1 9 4 0 0 - 2 6 7 1  
S 1 9 4 0 0 - 4 7 5 1  
2 . 6 7 K 1 / 4 W  
4 . 7 5 K  
C 2 0  
R 5 0  
R 1 6  
R 2 0 8  
R 2 0 7  
R 2 0 9  
R 2 0 6  
R 2 1 0  
R 2 0 5  
R 2 0 4  
R 2 1 1  
2 2  
R 5 4  
R 5 2  
D 1 1  
R 9 6  
D 7  
R 2 4 3  
R 7  
R 4 9  
D 8  
R 2 4 7  
R 4 5  
R 1 0 0  
D 5 1  
R 2 3 5  
D 5 3  
R 1 2  
C 2  
R 1 5  
C 3  
R 1 3  
C 5  
C 4  
R 1 4  
R 9 9  
R 2 3 3  
R 7 5  
R 2 4 8  
R 2 4 6  
7
S 1 9 4 0 0 - 3 3 2 1  
3 . 3 2 K 1 / 4 W  
R 2 1 2  
R 2 1 3  
R 2 1 4  
R 2 1 5  
R 2 0 3  
R 2 0 2  
R 2 0 1  
R 2 0 0  
R 8 7  
R 8 6  
R 6 8  
R 6 1  
R 7 2  
D 5 0  
D 5 2  
C 3 3  
C 1 0 0  
R 1 8 , R 2 0 , R 2 4 , R 2 5  
R 2 2 , R 2 3 , R 1 0 5 , R 1 2 5 , R 1 4 2  
R 2 6 , R 2 7 , R 2 8 , R 2 9 , R 1 0 8 , R 1 0 9  
R 1 4 7 , R 1 5 3  
4
5
8
S 1 9 4 0 0 - 3 9 2 2  
S 1 9 4 0 0 - 2 2 1 2  
S 1 9 4 0 0 - 4 7 5 0  
3 9 . 2 K 1 / 4 W  
2 2 . 1 K 1 / 4 W  
4 7 5 1 / 4 W  
R 8 4  
R 6 5  
R 7 8  
R 7 7  
R 8 0  
R 7 9  
R 8 3  
R 8 1  
R 8 2  
R 5 9  
R 8 5  
R 6 4  
R 8 8  
R 6 3  
R 2 3 2  
R 2 3 4  
.18  
0
R 3 0 , R 5 5 , R 9 3 , R 1 2 7 , R 1 5 9 , R 1 6 1  
R 3 1 , R 3 2 , R 3 7 , R 4 1 , R 4 3 , R 5 2  
R 5 3 , R 7 1 , R 7 2 , R 1 0 0 , R 1 1 8 , R 1 2 6  
R 1 4 4 , R 2 0 8 , R 2 0 9 , R 2 1 0 , R 2 1 1  
R 2 1 2 , R 2 1 3 , R 2 1 4 , R 2 1 5 , R 2 2 4  
R 2 2 5 , R 2 2 6 , R 2 2 7 , R 2 2 8 , R 2 2 9  
R 2 3 0 , R 2 3 1 , R 2 3 5 , R 2 4 3 , R 2 4 5  
R 2 4 6 , R 2 4 7 , R 2 4 8 , R 2 4 9  
R 3 3 , R 5 7  
6
S 1 9 4 0 0 - 3 9 2 1  
S 1 9 4 0 0 - 1 0 0 2  
3 . 9 2 K 1 / 4 W  
1 0 K 1 / 4 W  
3 6  
0
.18  
5.17  
5.85  
9.82  
04  
10.00  
2
1
S 1 9 4 0 0 - 6 8 1 0  
T 1 4 6 4 8 - 2 3  
6 8 1 1 / 4 W  
2 0 5 W  
R 3 4  
CAPACITORS = MFD/VOLTS  
RESISTORS = OHMS, 1/4 WATT UNLESS OTHERWISE SPECIFIED.  
INDUCTANCE = HENRYS  
Ch’ge. Sht. No.  
EQUIP.  
LN-10  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
3-5-99F  
4-20-2000A  
TYPE  
CONTROL P.C. BOARD ASEMBLY  
SUBJECT  
SCALE FULL  
SHT.  
G3168-1  
LJB  
12-8-98  
REF.  
3168-2  
DR  
DATE  
CHK  
SUP’S’D’G  
NO.  
G
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
LN-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
SCHEMATIC - DISPLAY PC BOARD  
5V_A  
2
8
4
7
3
8
3
8
3
8
16  
15  
3
7
6
5
4
2
a
BANK4  
BANK3  
Vdd  
1
2
4
5
6
7
9
10  
1
2
4
5
6
7
9
10  
X5  
1
1
2
4
5
6
7
9
10  
C
B
b
c
3
5
6
9
13  
9
DP  
A
BANK2  
BANK1  
BANK5  
DATA IN  
CLOCK  
/ENABLE  
d
TO KEYPAD  
DISP3  
e
h
DISP2  
DISP4  
17  
12  
11  
19  
14  
D
DISP1  
Vss  
20  
1
g
10  
18  
f
J10  
A
B
C
D
E
COLD FEED FORWARD  
8
DATA OUT  
MC14489  
Rx  
7
8
9
5
6
4
3
R9  
475  
J10  
J10  
J10  
J10  
J10  
J10  
COLD FEED REVERSE  
GAS PURGE  
R10  
475  
16  
11  
12  
13  
14  
3
A
Vcc  
CLK1  
SS/PL  
QH  
R11  
2
B
500  
475  
1
C
X3  
FEEDER/SCHEDULE SELECT  
DUAL PROCEDURE  
TRIGGER MODE SELECT  
TIMER SELECT  
9
D
R12  
475  
7
E
/QH  
CLK2  
SA  
4
15  
10  
6
F
5
R13  
475  
G
3
8
3
8
3
8
3
8
16  
7
6
5
4
2
a
BANK4  
BANK3  
Vdd  
8
1
2
4
5
6
7
9
10  
1
1
H
X6  
GND  
1
15  
3
2
4
5
6
7
9
2
4
5
6
7
9
74HC165  
b
c
2
4
5
6
7
9
F
R14  
475  
13  
9
BANK2  
BANK1  
BANK5  
DATA IN  
CLOCK  
/ENABLE  
d
DISP7  
G
H
e
h
DISP5  
DISP6  
DISP8  
R15  
475  
17  
12  
11  
19  
14  
10  
10  
10  
Vss  
J10  
J10  
CONTROL SELECT  
20  
1
g
2
1
R26  
475  
10  
18  
f
8
500  
DATA OUT  
MC14489  
Rx  
COM.  
500  
TO CONTROL P.C. BOARD  
J11  
554  
551  
MISO  
3
R20  
475  
500  
J11  
LATCH  
13  
12  
1
2
4
5
R17  
475  
X4  
X4  
1
C5  
.0047  
50V  
2
9
7
6
5
4
2
a
BANK1  
BANK2  
Vdd  
X7  
LED1  
LED5  
LED8  
13  
3
J11  
500  
b
c
d
e
f
552  
SCK  
11  
10  
5
6
R18  
X4  
X4  
475  
15  
16  
17  
12  
10  
11  
BANK3  
BANK4  
BANK5  
DATA IN  
/ENABLE  
CLOCK  
1
C6  
.0047  
50V  
1
2
14  
Vss  
g
LED2  
LED3  
LED4  
LED6  
LED7  
LED9  
LED10  
LED11  
500  
20  
19  
8
J11  
h
553  
MOSI  
6
18  
R19  
475  
DATA OUT  
MC14489  
Rx  
1
C7  
.0047  
50V  
2
500  
5V_A  
500  
500  
5V_A  
D2  
R32  
100  
16  
3
3
Vdd  
X5  
Vdd  
X7  
J11  
J11  
R33  
100  
512A  
500  
9
7
a
X1  
BANK1  
7
8
X8  
IN  
OUT  
C1  
C3  
0.1  
C10  
0.1  
X3  
LED12  
LED16  
LED18  
LED22  
LED23  
13  
3
6
5
4
2
BANK2  
Vdd  
b
R34  
100  
0.1  
50V  
50V  
50V  
MC14489  
MC14489  
74HC165  
8
c
GND  
C11  
15  
16  
17  
12  
10  
11  
BANK3  
BANK4  
BANK5  
DATA IN  
/ENABLE  
CLOCK  
d
R35  
100  
4.7  
Vss  
Vss  
14  
14  
35V  
e
f
1
14  
Vss  
LED13  
LED14  
LED15  
LED17  
LED19  
LED20  
LED21  
5V_B  
20  
19  
8
500  
g
500  
R36  
100  
h
5V_B  
18  
DATA OUT  
MC14489  
Rx  
R37  
100  
D1  
R38  
100  
14  
3
3
Vdd  
Vdd  
X8  
9
3
8
4
R39  
100  
X4  
X4  
X2  
IN  
OUT  
X6  
C2  
C4  
C9  
X4  
HEXINV  
0.1  
0.1  
0.1  
GND  
50V  
50V  
50V  
MC14489  
MC14489  
500  
C8  
4.7  
Vss  
Vss  
7
14  
14  
35V  
500  
500  
500  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
LN-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY-DISPLAY  
C 3  
C 4  
R 3 0  
C 1 0  
R 3 1  
R 3 2  
R 3 3  
R 3 4  
R 3 5  
C 1 1  
C 1  
R 3 9  
R 3 8  
R 3 7  
R 3 6  
C 8  
R 1 8  
R 1 7  
C 9  
C 2  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
LN-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-9  
G-9  
ELECTRICAL DIAGRAMS  
SCHEMATIC - ENCODER PC BOARD  
2 2 0 6 6  
S
+5VDC  
J17  
J17  
7
2
C1  
C2  
0.1  
1.8  
D1  
D2  
50V  
20V  
1
+
X
J17  
J17  
4
2
3
475  
5
6
R2  
TO CONTROL BOARD  
A1  
475  
Y
-
R1  
OPTICAL ROTARY ENCODER  
D3  
D4  
J17  
J17  
1
8
J17  
J17  
3
4
NOTES :  
FILE: S22066_1BA  
LABELS  
GENERAL INFORMATION  
N.A.  
SINCE COMPONENTS OR CIRCUITRY ON  
A PRINTED  
ELECTRICAL SYMBOLS PER E1537  
FRAME CONNECTION  
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING  
SUPPLY  
VOLTAGE NET  
MFD  
CAPACITORS =  
(
.022/50V  
1/4W UNLESS OTHERWISE SPECIFIED)  
(UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
THE INTERCHANGEABILITY  
THIS DIAGRAM MAY NOT  
OF A COMPLETE  
BOARD.  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
RESISTORS = Ohms (  
DIODES = 1A, 400V  
SHOW THE EXACT COMPONENTS  
EARTH GROUND CONNECTION  
OR CIRCUITRY OF  
CONTROLS HAVING A COMMON CODE NUMBER.  
EQUIP.  
TYPE  
Ch’ge.Sht.No.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLES SIZES PER E-2056  
SYNERGIC 7F  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
4-7-95  
ON 2 PLACE DECIMALS IS + .O2  
ENCODER P.C. BD. SCHEMATIC  
SUBJECT  
ON 3 PLACE DECIMALS IS + .OO2  
NONE  
ON ALL ANGLES IS + .5 OF A DEGREE  
MATERIAL TOLERANCE ("t") TO AGREE  
WITH PUBLISHED STANDARDS  
SCALE  
SHT. S 22066  
B.S.  
11-8-94  
JRF  
DR.  
DATE  
CHK.  
SUP’S’D’G.  
NO.  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
LN-10  
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G-10  
G-10  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY-ENCODER  
M
1 7 7 9 7 - 1  
ITEM  
REQ’D PART NO  
DESCRIPTION  
C1  
C2  
1
1
S16668-11  
S13490-19  
.1/50  
1.8/20  
D1,D2,D3,D4  
J17  
4
1
2
T12705-23  
S19365-8  
1N5818  
RIGHT ANGLE HEADER  
475 1/4W  
R1,R2  
S19400-4750  
.04  
CAPACITORS = MFD/VOLTS  
RESISTORS = OHMS  
1.85  
ENCODER  
D1  
C2  
D2  
D4  
C1  
J17  
A1  
R2  
R1  
D3  
M17797-1  
0
.04  
2.30  
0
Ch’ge. Sht. No.  
EQUIP.  
SYNERGIC 7F  
ENCODER P.C. BOARD ASSEMBLY  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
TYPE  
4-7-95  
10-23-98F  
SUBJECT  
FULL  
SCALE  
SHT.  
NO.  
F.V.  
11-21-94  
B.S.  
REF.  
17797-1  
DR  
DATE  
CHK  
SUP’S’D’G  
M
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
LN-10  
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SVM ERROR REPORTING FORM  
We need to know if there are errors in our manuals. We also value any suggestions as to  
additional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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