Lincoln Electric Welding System SVM143 A User Manual

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SVM143-A  
DH-10 Heads & Controls  
March, 1999  
Boom Mount or Bench Models  
For use with: DH-10 Control - Boom Mount Code 10357  
DH-10 Drive - Boom Mount Codes 10358 (Std.), 10359 (Hi/Std.)  
DH-10 Boom Package Codes 10380, 10495, 10496 (Std.), and 10517, 10518, 10519 (Hi/Std.)  
Standard - Single Head Drive Codes 10190, 10191  
DH-10 Feeder Double Head - Bench Model Codes 10360 (Std.), 10361 (Hi/Std.)  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However, your  
overall safety can be increased by  
proper installation ... and thought-  
ful operation on your part. DO  
NOT INSTALL, OPERATE OR  
REPAIR THIS EQUIPMENT  
WITHOUT READING THIS  
MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
OPERATOR’S MANUAL  
World's Leader in Welding and Cutting Products  
Premier Manufacturer of Industrial Motors  
• 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  
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.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
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.  
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.  
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.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
Mar. ‘93  
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v
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
Page  
i-iv  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A  
Technical Specifications — DH-10 Complete Units or Controls & Heads  
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . .  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installation of the DH-10 Boom Mount Wire Feeder Components . . . . .  
Wire Drive Speed Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Feed Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Procedure to Install Drive Roll and Wire Guides . . . . . . . . . . . . . . . . . .  
Gun and Cable Assemblies with Standard Connection . . . . . . . . . . . . .  
Gun and Cable Assemblies with Fast-Mate Connection . . . . . . . . . . . .  
DH Double Head Drives Water Connections  
A-2  
A-3  
A-3  
A-4  
A-4  
A-5  
A-6  
A-6  
A-7  
A-8  
(For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Optional Features Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
A-8  
A-9  
A-10  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
DH-10 Control Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Keypad and Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Dual Procedure Remote Control (K1449-1) . . . . . . . . . . . . . . . . . . . . . .  
Wire Reel Loading - Readi-Reel, Spools or Coils . . . . . . . . . . . . . . . . .  
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-2  
B-2  
B-2  
B-5  
B-8  
B-8  
B-10  
B-10  
B-10  
B-10  
B-10  
B-11  
B-11  
B-11  
B-12  
B-12  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Reel Mounting - Readi-Reels and  
10 to 30 lb (4.5 to 14 kg) Spools . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Procedure for Removing Feedplate from Wire Feeder . . . . . . . . . . . . .  
D-2  
D-2  
D-2  
D-2  
D-3  
D-3  
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E  
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Receptacle, Control Board, and Operator Controls . . . . . . . . . . .  
Wire Feed Heads and Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
E-2  
E-3  
E-4  
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F  
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . .  
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .  
F-2  
F-3  
F-5  
F-17  
F-31  
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G  
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
DH-10  
P-288  
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SECTION A-1  
SECTION A-1  
INSTALLATION  
TABLE OF CONTENTS  
-INSTALLATION SECTION-  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A  
Technical Specifications — DH-10 Complete Units or Controls & Heads . . . . . . . . . . . . . . . . . . . .  
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Available Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installation of the DH-10 Boom Mount Wire Feeder Components . . . . . . . . . . . . . . . . . . . . . . . . . .  
Mounting the DH Double Header Wire Drive Unit (K1497-1 or -2) . . . . . . . . . . . . . . . . . . . . . . .  
Mounting Single Head Wire Drive Unit (K679-1 or -2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Mounting the DH-10 Control Box (K1496-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Connecting Wire Drive Unit to Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Speed Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Control Speed Range Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Double Header (DH) Wire Drive Ratio Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Feed Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Procedure to Install Drive Roll and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Single Drive 4-Roll Kits (KP655 and KP656) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
DH 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
DH Double Head Drives Water Connections (For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . .  
DH Double Head Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Single Head Drives (K679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
GMAW Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Cable: DH-10 Control to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Optional Features Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
A-2  
A-3  
A-3  
A-3  
A-4  
A-4  
A-4  
A-4  
A-4  
A-5  
A-5  
A-5  
A-5  
A-5  
A-6  
A-6  
A-7  
A-7  
A-7  
A-7  
A-7  
A-8  
A-8  
A-8  
A-8  
A-8  
A-8  
A-8  
A-9  
A-9  
A-9  
A-10  
DH-10  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS – DH-10 Complete Units or Controls & Heads  
The K1499-1 or -2 DH-10 consists of a control and a double head 10 series wire drive assembly pre-  
mounted on a platform with two 2 in. O.D. spindle mountings. Specifications for the units follow:  
CONTROLS SECTION OF COMPLETE UNITS  
SPEC.# TYPE  
INPUT POWER  
PHYSICAL SIZE•  
TEMPERATURE RATING  
Dimensions  
Height  
K1499-1 Double Head 40 - 42 Vac + 10% 20.50 in.  
Control  
Width  
19.75 in.  
Depth  
31.50 in.  
Weight  
84.5 lbs  
Operating  
Storage  
Bench Model 4.0 Amps 50/60 Hz (520.7 mm) (501.7 mm) (800.1 mm) (38.3 kg)  
+40°C to  
-20°C  
+40°C to  
-40°C  
K1499-2 Double Head  
Control Bench Model  
• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual.  
WIRE DRIVE SPECIFICATIONS FOR COMPLETE UNITS•  
SPEC.# TYPE  
LOW SPEED RATIO  
HIGH SPEED RATIO  
Wire Size  
Solid  
Wire Size  
Speed  
Cored  
Speed  
Solid  
Cored  
K1499-1 DH-10  
Double Head  
35 - 500 IPM  
(0.89 - 12.7 m/m) (0.6 - 2.4 mm)  
.025 - 3/32 in.  
.030 - .120 in.  
(0.8 - 3.0 mm)  
50 - 750 IPM  
(1.25 - 19.0 m/m)  
.025 - 1/16 in.  
(0.6 - 1.6 mm)  
.030 - 5/64 in.  
(0.8 - 2.0 mm)  
K1499-2 DH-10  
Left Head  
35 - 500 IPM  
(0.89 - 12.7 m/m) (0.6 - 2.4 mm)  
.025 - 3/32 in.  
.030 - .120 in.  
(0.8 - 3.0 mm)  
50 - 750 IPM  
(1.25 - 19.0 m/m)  
.025 - 1/16 in.  
(0.6 - 1.6 mm)  
.030 - 5/64 in.  
(0.8 - 2.0 mm)  
DH-10  
Right Head  
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)  
• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual.  
The various components of the DH-10 system are available separately or in kits for mounting on boom  
assemblies. The description of the various components follow:  
CONTROLS (BOOM MOUNT)  
SPEC.# TYPE  
INPUT POWER  
PHYSICAL SIZE•  
TEMPERATURE RATING  
Dimensions  
Height  
40 - 42 Vac + 10% 14.80 in.  
4.0 Amps 50/60 Hz (375.9 mm) ( 360.7mm) (106.7 mm) (8.2 kg)  
Width  
14.20 in.  
Depth  
4.20 in.  
Weight  
18.0 lbs  
Operating  
+40°C to  
-20°C  
Storage  
+40°C to  
-40°C  
K1496-1DH-10  
Control  
Controls  
• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual.  
Included with all K1521-[ ] DH-10 Standard and Zipline Boom Packages  
The K1496-1 DH-10 control can be used with any of the following Wire Drive Heads  
WIRE DRIVE HEADS (BOOM MOUNT)•  
SPEC.# TYPE  
LOW SPEED RATIO  
HIGH SPEED RATIO  
Wire Size  
Solid  
Wire Size  
Solid  
Speed  
Cored  
Speed  
Cored  
K1497-1  
¤
DH-10  
35 - 500 IPM  
.025 - 3/32 in.  
.030 - .120 in.  
(0.8 - 3.0 mm)  
50 - 750 IPM  
(1.25 - 19.0 m/m)  
.025 - 1/16 in.  
(0.6 - 1.6 mm)  
.030 - 5/64 in.  
(0.8 - 2.0 mm)  
Double Head (0.89 - 12.7 m/m) (0.6 - 2.4 mm)  
K1497-2DH-10  
Left Head  
35 - 500 IPM  
(0.89 - 12.7 m/m) (0.6 - 2.4 mm)  
.025 - 3/32 in.  
.030 - .120 in.  
(0.8 - 3.0 mm)  
50 - 750 IPM  
(1.25 - 19.0 m/m)  
.025 - 1/16 in.  
(0.6 - 1.6 mm)  
.030 - 5/64 in.  
(0.8 - 2.0 mm)  
DH-10  
Right Head  
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)  
K1563-1 LN-10  
35 - 500 IPM  
.025 - 3/32 in.  
.030 - .120 in.  
(0.8 - 3.0 mm)  
50 - 750 IPM  
(1.25 - 19.0 m/m)  
.025 - 1/16 in.  
(0.6 - 1.6 mm)  
.030 - 5/64 in.  
(0.8 - 2.0 mm)  
Single Head (0.89 - 12.7 m/m) (0.6 - 2.4 mm)  
K1563-2 LN-10  
55 - 825 IPM  
.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)  
Single Head (1.40 - 21.0 m/m) (0.6 - 1.6 mm)  
K679-1*  
Std Drive  
Synergic 7F 50 - 770 IPM  
Single Head* (1.27 - 19.5 m/m) (0.6 - 1.6 mm)  
.025 - 1/16 in.  
.035 - 5/64 in.  
(0.9 - 2.0 mm)  
---  
---  
---  
K679-2*  
Hi.-Sp. Drive Single Head*  
Synergic 7F  
---  
---  
---  
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)  
• Excluding Wire Reel - More detailed dimensions and weight information can be found in Section F of this manual.  
¤ Included in K1521-1,-2,-3 DH-10 Boom Packages.  
Included in K1521-4,-5,-6 DH-10 Boom Packages.  
*Single head drives use 4-roll drives with 2 driven rolls (Drive roll kits not common with -10 Series drives)  
DH-10  
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A-3  
A-3  
INSTALLATION  
a 3/0 weld cable. Available in lengths  
“L” of 16, 20, or 25 ft (4.9, 6.1, or  
7.6 m) for recommended boom  
lengths of 8-9 ft, 10-12 ft, or 16-18 ft  
(2.4-2.7 m, 3.0-3.7 m, or 4.9-5.5 m)  
respectively.  
GENERAL DESCRIPTION  
The DH-10 is a modular line of 42 VAC input dual  
head 4-roll wire feeders. A single control with dual  
procedure presettability of wire feed speed (in IPM or  
M/min) and arc voltage for each head is used with a  
single DC welding power source.  
K681-“L”  
Same as above but does not include  
weld cable available in lengths “L” of  
12, 16, or 25 ft (3.6, 4.9, or 7.6 m).  
The DH-10 models have controls providing keypad or  
remote selectability of wire drive head, and either of  
two procedures preset independently for each head.  
The DH-10 boom packages are available in standard  
packages as follows:  
The units offer 4 independently selectable gun trigger  
modes for each head procedure; cold feed, 2 step and  
4-step trigger and spot weld mode.  
K1521-1 includes:  
• DH-10 Control (Same as K1496-1)  
• DH-10 Std. Wire Drive Head (Same as K1497-1)  
• 16 ft (4.9 m) Control Cable (Same as K681-16)  
• 16 ft (4.9 m) Control and Weld Cable (Same as  
K1498-16)  
Also, 4 selectable, presettable timers for each head  
procedure; preflow, postflow, burnback and spot weld  
time.  
Arc starting can be optimized for each head procedure  
with 5 selectable wire feed acceleration rates, and  
independent control of slower run-in procedure.  
K1521-2 includes:  
• DH-10 Control (Same as K1496-1)  
• DH-10 Std. (Left)/Hi-Speed (Right) Heads  
(Same as K1497-2)  
• 16 ft (4.9 m) Control Cable (Same as K681-16)  
• 16 ft (4.9 m) Control and Weld Cable (Same as  
K1498-16)  
A gas purge key is provided, as well as cold feed for-  
ward and reverse keys with independently adjustable  
forward feed speed setting.  
All of these features are selected with a tactile-feel  
keypad, and are set independently for each head  
using one of two rotating knob encoders, setting levels  
are displayed on one of two digital LED displays.  
Also there are four additional Zipline Boom Packages  
(K1521-2, -3, -5, and -6). For specifications see  
IM596-4.  
The DH Wire Drive assemblies include two heavy duty  
heads with externally changeable gear ratio and 4 dri-  
ven roll drives housed together in a single combina-  
tion mounting and connection box. Gun adapters are  
available to permit use with a variety of standard weld-  
ing guns.  
RECOMMENDED PROCESSES  
AND EQUIPMENT  
The DH-10 Wire Feeder system is recommended for  
use with solid wire gas-metal-arc or CV Submerged  
arc processes, as well as cored wire for Outershield  
GMA or Innershield processes.  
AVAILABLE MODELS  
The wire type and size range for the wire drive used,  
and gear ratio change selected, are given in the  
Specifications.  
The DH-10 Wire Feeder system is available config-  
ured in both Bench and Boom models.  
Bench Models consists of a DH-10 control and a DH  
double header wire drive assembly premounted on a  
platform with a dual 2 in. O.D. spindle mounting.  
Recommended power sources are Lincoln Electric  
Company constant voltage power sources with 42  
VAC auxiliary power and a 14-pin connector recepta-  
cle. At the time of printing these include: CV 250,  
CV300-I, CV-300, CV400-I, CV-400, CV500-I, DC-  
400, CV-655, Invertec V300-PRO, DC-650 PRO and  
DC-655.  
Boom Models consist of a DH-10 control and a choice  
of wire drives designed to be mounted separately and  
joined by available head to control cable assemblies.  
The head to control cable assemblies are available in  
two types; one control cable is required for each head:  
The DC-250, DC-600, DC-1000 and the Pulse Power  
500 (Non-Pulsed CV mode only) may also be used  
with the DH-10 if the optional K1520-1 115V / 42V  
Transformer Kit is used.  
K1498-“L” Includes a control cable with a 14-pin  
ms style connection on each end, and  
DH-10  
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A-4  
A-4  
INSTALLATION  
Mounting Single Head Wire Drive Unit  
(K679-1 or -2)  
SAFETY PRECAUTIONS  
WARNING  
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.  
ELECTRIC SHOCK can kill.  
• Turn the input power off at the power  
source disconnect switch before  
attempting to connect the input power  
to the DH-10 Control.  
• Only qualified personnel should perform this  
installation.  
----------------------------------------------------------------------------------------  
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.  
INSTALLATION OF THE DH-10  
BOOM MOUNT WIRE FEEDER  
COMPONENTS  
Mounting the DH-10 Control Box (K1496-1)  
The same control box is used for both a DH double  
header drive, or up to two single head drives. The back  
plate of the control box has two keyhole slots and one  
bottom slot for mounting. See Figure A.2 for the size  
and location of these slots. Mount the box at some con-  
venient location close to the wire drive unit which will  
enable the desired control cable to reach between the  
control box and the wire drive unit.  
Mounting the DH Double Header Wire  
Drive Unit (K1497-1 or -2)  
Mount the DH wire drive unit to the boom or structure  
using the four 5/16-18 threaded mounting holes locat-  
ed on the bottom of the DH drive connection box.  
See Figure A.1 for the size and location of the mount-  
ing holes. The feed plate assembly is electrically “hot  
when the gun trigger is pressed. Therefore, make  
certain the feed plate does not come in contact with  
the structure on which the unit is mounted.  
1. Drill the required holes in the mounting surface, par-  
tially install 1/4-20 screws.  
2. Mount the box.  
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.  
3. Tighten the screws.  
FIGURE A.2  
10.50  
CLEARANCE  
FOR 1/4 BOLT  
.50  
FIGURE A.1  
5/16-18 THREAD  
2.25  
13.75  
14.00  
12.75  
6.00  
10.00  
11.00  
CLEARANCE  
FEED PLATE  
DOOR OPEN  
FOR 1/4 BOLT  
3.00  
BOTTOM FRONT  
5.00  
10.50  
18.50  
2.63  
2.63  
5.25  
14.50  
DH-10  
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A-5  
A-5  
INSTALLATION  
mum, and also that the force required to pull the  
wire from the reel into the wire drive unit is kept  
at a minimum.  
Connecting Wire Drive Unit to Control Box  
One head to control cable assembly is required for each  
head being used; however, only one electrode cable is  
required if an electrode cable jumper (provided) is con-  
nected between the two heads. The Head to Control  
cable assemblies are available in two types:  
2. The electrode is “hot when the gun trigger is  
pressed and must be insulated from the boom  
and structure.  
3. If more than one wire feed unit shares the same  
boom and are not sharing the some power  
source output stud, their wire and reels must be  
insulated from each other as well as insulated  
from their mounting structure.  
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 “L  
of 16 ft (4.9 m)  
and 25 ft (7.6 m).  
K681-L”  
- Same as K1498, but does not include weld  
cable. Available in lengths of 12 ft (3.6  
m), 16 ft (4.9 m) and 25 ft (7.6 m).  
WIRE DRIVE SPEED RANGE  
SELECTION  
L”  
The rated speed and wire size range for each wire  
drive head is shown in Specifications in the front of  
this section.  
1. Making certain the cables are protected from any  
sharp corners which may damage their jackets,  
mount the cable assembly along the boom so the  
end with the female amphenol connector pins is at  
the wire feed unit.  
Control Speed Range Setting  
2. Connect the 14-socket cable connectors to the mat-  
ing receptacles on the back of the wire feed unit  
connection box. Feeder Head 1 uses the left recep-  
tacle and Feeder Head 2 uses the right receptacle,  
when facing the front of the wire drive.  
The speed range is set up to match each wire feed  
head connected to the DH-10 control by properly set-  
ting the switch (S2) code on the control board inside  
the control box. See Operation, Setting the DIP  
Switches for setting instructions.  
3. At the same end, connect the electrode lead to the  
1/2 in. connection bolt on the rear of the left wire  
drive head feed plate. If only one electrode cable is  
being used, comparable size electrode cable  
jumper (provided) must be connected between the  
two heads.  
Double Header (DH) Wire Drive Ratio  
Selection  
The Double Head type drives include two external  
gear sizes; a 1 in. diameter gear and a 1-1/2 in.  
diameter gear. The smaller gear provides the low  
speed range ratio, and the larger gear provides the  
high speed range ratio per Specifications in the front  
of this section.  
4. At the control box end, connect the 14-pin connec-  
tors of the cables to the mating receptacles on the  
bottom of the control box. Feeder Head 1 should  
be connected to the left receptacle and Feeder  
Head 2 should be connected to the right receptacle,  
when facing the front of the control box.  
The following procedure is for changing ratio of the  
DH drive:  
1. Pull open the Pressure Door.  
5. 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.  
2. Remove the Phillips head screw retaining the pin-  
ion gear to be changed and remove the gear. If  
the gear is not easily accessible or difficult to  
remove, remove the feedplate from the gear box.  
Electrode Routing  
The electrode supply may be either from reels, Readi-  
Reels, spools, or bulk packaged drums or reels.  
Observe the following precautions:  
1. The electrode must be routed to the wire drive  
unit so that the bends in the wire are at a mini-  
DH-10  
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A-6  
A-6  
INSTALLATION  
To remove feedplate:  
WIRE FEED DRIVE ROLL KITS  
a. Loosen the clamping collar screw using a  
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.  
3/16 in. 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.  
b. Loosen the retaining screw, which is also  
accessed from bottom of feeder, using a  
3/16 in. Allen wrench. Continue to loosen  
the screw until the feedplate can be easily  
pulled off of the wire feeder.  
The electrode sizes that can be fed with each roll and  
guide tube are stenciled on each part. Check the kit  
for proper components.  
Single Head Drives (K679) use 4-Roll drive roll kits  
with 2 driven rolls, per Table C.1 in Accessories.  
These kits are common with those used for the 4-Roll  
LN-7 GMA and LN-9 GMA Lincoln Wire Feeders, but  
are not common with those used with the DH wire  
drive units. Installation instructions are included with  
the kits.  
3. Loosen, but do not remove, the screw on the  
lower right face of the feedplate with a 3/16 in.  
Allen wrench.  
4. Remove the screw on the left face of the feed-  
plate. If changing from high speed (larger gear)  
to low speed (smaller gear), line the lower hole  
on the left face of the feedplate with the threads  
on the clamping collar. Line the upper hole with  
the threads to install larger gear for high speed  
feeder. If feedplate does not rotate to allow holes  
to line up, further loosen the screw on right face  
of feedplate.  
DH Double Head Drives use 4-Roll drive roll kits with  
4 driven rolls, per Table C1 in Accessories. Each  
head requires a separate drive roll kit.  
PROCEDURE TO INSTALL DRIVE  
ROLL AND WIRE GUIDES  
WARNING  
5. Install gear onto output shaft and secure with flat  
washer, lock washer, and Phillips head screw  
which were previously removed.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
such as output terminals or internal  
wiring.  
6. Tighten the screw on lower right face of feed-  
plate.  
• When inching with gun trigger, elec-  
trode and drive mechanism are  
“hot” to work and ground and could  
remain energized several seconds  
after the gun trigger is released.  
7. Install gear onto output shaft and secure with flat  
washer, lock washer, and Phillips head screw  
which were previously removed.  
8. Re-attach feedplate to wire feeder if removed in  
Step 2.  
• Turn OFF input power at welding  
power source before installation or  
changing drive roll and/or guide  
tubes.  
9. Feedplate will be rotated out-of-position due to  
the gear change. To re-adjust angle of feedplate:  
a. Loosen the clamping collar using a 3/16 in.  
Allen wrench. The clamping collar screw is  
accessed from the bottom of the feedplate.  
It is the screw which is perpendicular to the  
feeding direction.  
• Welding power source must be con-  
nected to system ground per the  
National Electrical Code or any  
applicable local codes.  
b. Rotate feedplate to the desired angle and  
tighten clamping collar screw.  
• Only qualified personnel should per-  
form this installation.  
10. Make sure to properly set the switch (S2) code  
on the control board inside the control box for  
the new gear size installed. See Operation,  
Setting the DIP Switches for setting  
instructions.  
Observe all additional Safety Guidelines detailed  
throughout this manual.  
DH-10  
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A-7  
A-7  
INSTALLATION  
5. Insert inner Wire Guide, groove side out, over the  
two locating pins in the feedplate.  
Single Drive 4-Roll Kits (KP655 and KP656)  
1. Turn OFF welding power source.  
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).  
2. Release both quick release levers by sliding the  
levers sideways into the open positions.  
3. Remove clamping screw & clamping collar from  
the drive shaft closest to the incoming side of the  
feeder.  
7. Install Outer Wire Guide by sliding over locating  
pins and tightening in place.  
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.  
8. Engage upper drive rolls if they are in the “open”  
position and close Pressure Door.  
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.  
To set idle roll pressure, see Idle Roll Pressure  
Setting in Operation.  
GUN AND CABLE ASSEMBLIES  
WITH STANDARD CONNECTION  
6. Install the outgoing drive roll following the same  
procedure as steps 3 & 4.  
The DH Wire Drive Heads each require a K1500 Gun  
Adapter installed See Gun Adapters in Accessories  
section.  
7. Center the middle guide between the two drive  
rolls and tighten in place.  
8. Back out the screws for the incoming and outgo-  
ing guide tubes.  
GMAW Guns  
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.  
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 0.025 in.  
(0.6 mm) to 3/32 in. (2.4 mm). The entire line of  
Magnum Fast-Mate gun and cable assemblies can  
also be used by installing a K489-2 Fast-Mate adapter  
kit. See Gun and Cable Assemblies with Fast-Mate  
Connection in this section for details.  
10. Install the remaining guide tube in the front hole.  
Be certain that the proper plastic insert is used.  
Fine wire chisel point tube must have largest  
radius next to drive roll. Tighten in place.  
11. Re-latch both quick release levers.  
12. To start new electrode, straighten the first 6 in.  
(150 mm) and cut off the first 1 in. (25 mm).  
Insert free end through the incoming tube. Press  
gun trigger and push wire into the drive roll.  
Innershield Guns  
To set idle pressure, see Idle Roll Pressure Setting  
in Operation.  
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  
0.062 in. (1.6 mm) to 3/32 in. (2.4 mm). The 450  
ampere K115 will feed 5/64 in. (2.0 mm) to 3/32 in.  
(2.4 mm) electrode.  
DH Drive Roll Kit Installation  
(KP1505 and KP1507)  
1. Turn OFF Welding Power Source.  
2. Pull open Pressure Door to expose rolls and wire  
guides.  
Three smoke extraction gun and cable assemblies are  
available, 250 ampere K309, 350 ampere K206 and  
the 500 ampere K289. All gun cable lengths are 15 ft  
(4.5 m). These guns will feed electrode sizes 0.062 in.  
(1.6 mm) to 3/32 in. (2.4 mm) and require the use of  
the K184 vacuum unit for use with the DH-10.  
3. Remove Outer Wire Guide by turning knurled  
thumb screws to unscrew from Feedplate.  
4. Remove drive rolls, if any are installed, by pulling  
straight off shaft. Remove inner guide.  
DH-10  
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A-8  
A-8  
INSTALLATION  
Gun Cable Connection with Standard  
Connection  
Gun Cable Connection with Fast-Mate  
Connection  
1. Check that the drive rolls, feeder guide tubes and  
gun connector guide tube are appropriate for the  
electrode size being used. If necessary, change  
them per Wire Drive Roll Kits in this section.  
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.  
2. Connect gun to gun connector making sure all  
pins and gas tube line up with appropriate holes  
in connector. Tighten gun by turning large nut on  
gun cable clockwise.  
2. Lay the cable out straight. Insert the connector  
on the welding conductor cable into the brass  
conductor block on the front of the wire drive  
head. Make sure it is all the way in and tighten  
the hand clamp. Keep this connection clean and  
bright. Connect the trigger control cable polar-  
ized plug into the mating 5 cavity receptacle on  
the front of the wire drive unit.  
DH DOUBLE HEAD DRIVES WATER  
CONNECTIONS (FOR WATER  
COOLED GUNS)  
3. For GMA Gun Cables with separate gas fitting  
(DH Drive using K1500-1 Gun Adapter), connect  
the 3/16 in. I.D. gas hose from the wire drive unit  
to the gun cable barbed fitting.  
DH Double Head Drives: must have a K590-4  
Water Connection Kit installed for each water cooled  
gun. (See Accessories).  
Using male quick-connect fittings, connect the water  
hoses to the coolant inlet and outlet on the back of the  
wire drive. Connect the other ends of these hoses to  
the appropriate ports on the water cooling units.  
GUN AND CABLE ASSEMBLIES  
WITH FAST-MATE CONNECTION  
(Requires K489-2 Fast Mate™ Adapter Kit used with  
the DH K1500-1 Gun Adapter)  
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 in. (5 mm) I.D. hose  
(Customer to provide appropriate clamps). The feeder  
connectors self seal when disconnected.  
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 0.025 in. (0.6 mm) to 5/64 in. (20 mm).  
Single Head Drives (K679): Must have a  
K682-2 Water Connection Kit installed. (See  
Accessories).  
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.  
An expanding line of Magnum X-Tractor gun and  
cable assemblies provides fume extraction capability  
for welding with solid and cored electrodes using the  
GMAW process. See the appropriate Magnum litera-  
ture for descriptions of the 250 to 400 ampere air  
cooled gun and cables that are available. Gun cable  
lengths range from 10 ft (3.0 m) to 15 ft (4.5 m) and  
feed electrode sizes 0.035 in. (0.9 mm) to 1/16 in.  
(1.6 mm). These guns require the use of either the  
K173-1 or K184* vacuum units.  
In the event the water line fittings on your water  
cooled gun are incompatible with the female quick  
connects on the front of the K682-2 Kit male quick-  
connects are provided with the kit for installation on  
3/16 in. (5 mm) I.D. hose (Customer to provide appro-  
priate clamps). The feeder connectors self seal when  
disconnected.  
*Requires S14927-8 connector hose and an S20591  
hose adapter.  
DH-10  
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A-9  
A-9  
INSTALLATION  
GMAW Shielding Gas  
ELECTRICAL INSTALLATION  
WARNING  
WARNING  
CYLINDER may explode if damaged.  
ELECTRIC SHOCK can kill.  
• Keep cylinder upright and chained to  
support.  
• Do not touch electrically live parts  
such as output terminals or internal  
wiring.  
• Keep cylinder away from areas where it may be  
damaged.  
• When inching with gun trigger, elec-  
trode and drive mechanism are  
“hot” to work and ground and could  
remain energized several seconds  
after the gun trigger is released.  
• Never lift welder with cylinder attached.  
• Never allow welding electrode to touch cylinder.  
• Keep cylinder away from welding or other live electri-  
cal circuits.  
• Turn OFF input power at welding  
power source before installation or  
changing drive roll and/or guide  
tubes.  
BUILDUP OF SHIELDING GAS may  
harm health or kill.  
• Welding power source must be con-  
nected to system ground per the  
National Electrical Code or any  
applicable local codes.  
Shut off shielding gas supply when not  
in use.  
SEE AMERICAN NATIONAL STANDARD Z-49.1,  
“SAFETY IN WELDING AND CUTTING” PUB-  
LISHED BY THE AMERICAN WELDING SOCIETY.  
------------------------------------------------------------------------  
• Only qualified personnel should per-  
form this installation.  
Observe all additional Safety Guidelines detailed  
throughout this manual.  
The 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.  
Input Cable: DH-10 Control to Power  
Source  
Available Cable Assemblies:  
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).  
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).  
Gas Guard Regulator - The Gas Guard Regulator is  
an optional accessory (K659-1) on these models.  
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) elec-  
trode cable.  
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.  
DH-10  
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A-10  
A-10  
INSTALLATION  
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.  
OPTIONAL FEATURES  
INSTALLATION  
K1501, K1502 and K1503 Input Cable Assemblies  
See Electrical Installation for instructions.  
K1520-1 115V/42V Transformer Kit. Required to use  
DH-10 with Lincoln Power Sources without 42 VAC  
auxiliary and a 14-pin connector receptacle. These  
power sources include the DC-250, DC-600, DC-1000  
and Pulse Power 500. Also can be used with older  
DC-400 models. Mounts on power source per installa-  
tion instructions included with the kit.  
With input power disconnected from the power  
source, install the input cable per the following:  
1. Connect the end of the control cable with  
the 14-pin cable plug to the mating receptacle on  
the power source.  
2. Connect the electrode lead to the power source  
output terminal of the desired polarity.  
Spindle Adapters  
K162H Spindle for boom mounting Readi-Reels and  
2 in. (51 mm) I.D. spools with 60 lb (27.2 kg) capacity.  
User mounted to appropriately prepared boom frame-  
work. Includes an easily adjustable friction brake for  
control of overrun (Two 2 in. spindles standard on DH-  
10 Bench models).  
3. Connect the 9-socket plug of the control cable to  
the mating receptacle on the bottom of the DH-10  
control box.  
4. Slip the current sensor cover off enough to  
expose the input connector stud. Connect the  
electrode cable from the power source to this  
stud with the nut provided, then reclose the cur-  
rent sensor cover.  
When a 2 in. (51 mm) spindle is used with Readi-  
Reels, or coils not on 12 in. (305 mm) O.D. spools, an  
adapter is required:  
Work Cable  
Coil Adapter  
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.  
K1504-1 Permits 50 to 60 lb (22.7 to 27.2 kg) coils to  
be mounted on 2 in. (51 mm) O.D. spindles.  
K435 Permits 14 lb (6 kg) Innershield coils to be  
mounted on 2 in. (51 mm) O.D. spindles.  
Current  
60% Duty  
Cycle  
Copper Work Cable Size, AWG  
K468 Permits 8 in. (203 mm) O.D. spools to be  
mounted on 2 in. (51 mm) O.D. spindles.  
Up to 100 ft Length (30 m)  
00 (67 mm2)  
Readi-Reel Adapters  
400 Amps  
000 (85 mm2)  
000 (85 mm2)  
K363P Adapts Lincoln Readi-Reel coils of electrode  
30 lb (14 kg) and 22 lb (10 kg) to a 2 in. (51 mm) spin-  
dle. Durable molded plastic one piece construction.  
Designed for easy loading; adapter remains on spin-  
dle for quick changeover.  
500 Amps  
600 Amps  
K438 Adapts Lincoln Readi-Reel coils of electrode 50  
to 60 lb (22.7 to 27.2 kg) to a 2 in. (51 mm) spindle.  
K1634-1 Wire Reel Enclosure Kit. Provides the neces-  
sary parts to cover the wire and protect if from exces-  
sive dirt and contamination. This kit is not for use with  
60 lb coils (most 30 lb, 15 kg, 44 lb fiber spools, and  
smaller coils will work). The kit includes a two-part reel  
cover, a Magnum conduit adapter for the incoming  
end of the wire feeder feed plate and a short length of  
DH-10  
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A-11  
A-11  
INSTALLATION  
Magnum conduit to go between the reel cover and the  
feedplate.  
K590-4 Water Connection Kit (For DH Drive Only).  
Install per the instructions shipped with the kit. One  
used per gun.  
Gun Adapters (For DH Wire Drive Heads)  
K682-2 Water Connection Kit (K679 Single Head  
Drive Only). Install to either side of wire feed unit  
mounting bracket per instructions shipped with the kit.  
Adapts DH heads for desired gun connection  
K489-7 for Fast-Mate (or European style) gun connec-  
tions, including Dual Schedule Fast-Mate guns.  
K659-1 Gas Guard Regulator (One used per gun).  
Adjustable flow regulator with removable adjustor key  
for CO2 and Argon blend gases. Mounts onto feeder  
inlet, and reduces gas waste and arc start “blow” by  
reducing surge caused by excess pressure in supply  
hose.  
K1500-1 for standard Lincoln Innershield gun connec-  
tion, or with Fast-Mate™ guns with K489-2 Fast-Mate  
Adapter Kit. Also for Magnum 200/300/400 with  
K466-1 Connection Kit or Magnum 550 with K613-1.  
K1500-2 for Magnum 200/300/400 gun with K466-10  
Connection Kit. (Also Tweco 4).  
Install the 5/8-18 male outlet of the regulator to one, or  
both of the 5/8-18 female gas inlets on the back panel  
of the wire drive. Secure fitting with flow adjuster key  
at top. Attach gas supply to 5/8-18 female inlet of reg-  
ulator per GMAW Shielding Gas in this section.  
K1500-3 for Magnum 550 gun with K613-7  
Connection Kit. (Also Tweco 5).  
Install to either Head of the DH drive per instructions  
shipped with the Gun Adapter.  
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 DH-10 Procedure  
key. The DH-10 A or B procedure light will also be on  
to indicate which procedure is selected by the remote  
control.  
Dual Procedure Switch Options  
K683-1 Dual Procedure Switch (One per gun) -  
Requires K686-2 Adapter for DH-10. Kit includes gun  
switch, and mountings for Lincoln Innershield and  
Magnum guns, with 15 ft (4.5 m) control cable and  
3-pin plug. K686-2 Adapter permits 3-pin plug and  
5-pin gun trigger plug to be connected to DH-10 5-pin  
Trigger/Dual Procedure receptacle.  
The 4-pin plug of the remote control connects to the  
mating receptacle on the bottom of the DH-10 Control  
box. Only one remote is used with a DH-10 control.  
The K1450-“L” Extension cable is used to extend the  
16 ft (5 m) cable attached to the remote control.  
Lengths “L” are available to match the Length of the  
control to boom mount wire drive cable being used.  
Connect the 5-pin plug of the K686-2 Adapter to the  
DH-10 Wire Feeder Trigger/Dual Procedure 5-socket  
receptacle.  
The 3-pin plug of the K683-1 Dual Procedure switch  
connects to the 3-socket receptacle of the Adapter,  
and the 5-pin plug of the welding gun connects to the  
5-socket receptacle of the Adapter.  
K1558-1 Remote Switch Interface Module, can be  
used with the DH-10, using a G3041-2 (or higher)  
Control Board.  
The module provides for user interface connection of  
an external switch (flow switch, etc) which must be  
closed to enable the feeder welding operation. Also,  
the module provides for interface connection of exter-  
nal equipment (fume extractor, etc.) To the module’s  
isolated relay contacts which actuate when the feeder  
welding gas solenoid is activated (representing weld-  
ing operation in process).  
K683-3 Dual Procedure Switch (One per gun) Kit  
includes gun switch, and mountings for Lincoln  
Innershield and Magnum guns, with 15 ft (4.5 m) con-  
trol cable and 5-pin plug with two leads to connect to  
gun trigger.  
Connect the 5-pin plug of the K683-3 Dual procedure  
Switch to the DH-10 Wire Feeder Trigger/Dual  
Procedure 5-socket receptacle.  
When used with the DH-10, the module provides  
these input and output switch function connections  
independently for each head operation.  
The two lead plug cord extending out of the 5-pin plug  
of the Dual Procedure switch is to be connected to the  
two trigger leads of the welding gun per the instruc-  
tions shipped with the kit.  
This module is necessary when using the K1536-1  
waterflow sense kit with the DH-10.  
DH-10  
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A-12  
A-12  
INSTALLATION  
DH-10  
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SECTION B-1  
SECTION B-1  
OPERATION  
TABLE OF CONTENTS  
-OPERATION SECTION-  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
DH-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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Low Security Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
High Security 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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-5  
B-5  
B-5  
B-5  
B-5  
B-6  
B-6  
B-7  
B-7  
B-7  
B-8  
B-8  
B-8  
(Using the Molded Plastic K363-P Readi-Reel Adapter) (FIGURE B.1) . . . . . . . . . . . . . . . . . . .  
To Mount 10 to 44 lb (4.5 to 20 kg) Spools (12 in/300 mm Diameter) or  
14 lb (6 kg) Innershield Coils (FIGURE B.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
To Mount a 50 to 60 lb (22.7 to 27.2 kg) Coil:  
B-8  
B-9  
(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-9  
B-10  
B-10  
B-10  
B-10  
B-10  
B-11  
B-11  
B-11  
B-12  
B-12  
DH-10  
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B-2  
B-2  
OPERATION  
Setting the DIP Switches  
SAFETY PRECAUTIONS  
WARNING  
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:  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
such as output terminals or internal  
wiring.  
Security  
Pwr Sources  
HEAD 2  
HEAD 1  
M 4  
S1  
S2  
ON  
S1  
ON  
S2  
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
• Unless using cold feed feature when  
inching with gun trigger, electrode  
and drive mechanism are “hot” to  
work and ground and could remain  
energized several seconds after the  
gun trigger is released.  
Wire Drive Head Selection  
The DH-10 control is set up for proper presettable  
wire feed speed by setting S2 DIP switches (1 to 4) for  
Head 1 (left side head) and DIP switches (5 to 8) for  
Head 2 (right side head) as appropriate per the follow-  
ing examples for the head specification and DH drive  
external gear selection being used:  
• Turn OFF input power at welding  
power source before Control switch  
setup or changing drive roll and/or  
guide tubes.  
• Welding power source must be con-  
nected to system ground per the  
National Electrical Code or any  
applicable local codes.  
NOTE: Set the proper 4 switches labelled for Head 1  
(Left Head) or Head 2 (Right Head) as appropriate for  
the way that Head is being used.  
DH-10 HEADS:  
• Only qualified personnel should  
operate this Equipment.  
For K1497-1 (DH-10 Boom) or K1499-1 (DH-10  
Bench) with 35-500 IPM (0.89-12.7 m/m) Low  
Speed Ratio set S2 DIP switches as follows:  
Observe all additional Safety Guidelines detailed  
throughout this manual.  
HEAD 2  
HEAD 1  
S2  
ON  
S2  
1
2
3
4
5
6
7
8
DUTY CYCLE  
The DH-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).  
For K1497-1 (DH-10 Boom) or K1499-1 (DH-10  
Bench) with 50-750 IPM (1.25-19.0 m/m) High  
Speed Ratio set S2 DIP switch as follows: (initial fac-  
HEAD 2  
HEAD 1  
tory setting)  
DH-10 CONTROL SWITCH SETUP  
S2  
ON  
S2  
1
2
3
4
5
6
7
8
Initial set up of the DH-10 control for the system com-  
ponents being used and for general operator prefer-  
ences is done using a pair of 8-pole DIP switches  
located inside the DH-10 control box.  
For K1497-2 (DH-10 Boom) or K1499-2 (DH-10  
Bench) with Left Head 35-500 IPM (0.89-12.7 m/m)  
& Right Head 55-825 IPM (1.40-21.0 m/m) Low  
Speed Ratio set S2 DIP switch as follows:  
Setup DIP Switch Access  
HEAD 2  
HEAD 1  
1. Shut off the input power to the DH-10 control by  
turning off the power at the welding power  
source it is connected to.  
S2  
ON  
S2  
1
2
3
4
5
6
7
8
2. Remove the two screws on the top of the DH-10  
control box door and swing the door down to  
open.  
For K1497-2 (DH-10 Boom) or K1499-2 (DH-10  
Bench) with Left Head 50-750 IPM (1.25-19.0 m/m)  
& Right Head 80-1250 IPM (2.00-31.8 m/m) High  
Speed Ratio set S2 DIP switch as follows: (initial fac-  
tory setting)  
3. Locate the two 8-pole DIP switches, near the top  
left corner of the DH-10 Control P.C. board,  
labeled S1 and S2.  
HEAD 2  
HEAD 1  
S2  
ON  
1
2
3
4
5
6
7
8
4. Switch settings are only programmed during  
input power-up restoration.  
S2  
DH-10  
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B-3  
B-3  
OPERATION  
SINGLE HEADS:  
Welding Power Source Selection  
For K1563-1 (LN-10 Boom) with 35-500 IPM (0.89-  
12.7 m/m) Low Speed Ratio set S2 DIP Switches as  
follows:  
The DH-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:  
HEAD 2  
HEAD 1  
S2  
ON  
S2  
1
2
3
4
5
6
7
8
CV-250/CV 300-I:  
Security  
Pwr Sources  
M 4  
For K1563-1 (LN-10 Boom) with 50-750 IPM (1.25-  
19.0 m/m) High Speed Ratio set S2 DIP Switch as  
follows: (initial factory setting)  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
CV-300/CV 400-I:  
HEAD 2  
HEAD 1  
Security  
S1  
Pwr Sources  
S2  
ON  
S2  
1
2
3
4
5
6
7
8
M 4  
ON  
S1  
1
2
3
4
5
6
7
8
For K1563-2 (LN-10 Boom) with 55-825 IPM (1.40-  
21.0 m/m) Low Speed Ratio set S2 DIP Switch as  
follows:  
CV-400/CV 500-I:  
Security  
S1  
Pwr Sources  
M 4  
ON  
S1  
HEAD 2  
1
2
3
4
5
6
7
8
HEAD 1  
S2  
ON  
S2  
1
2
3
4
5
6
7
8
CV-655/DC-655: (initial factory setting)  
Security  
Pwr Sources  
M 4  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
For K1563-2 (LN-10 Boom) 80-1250 IPM (2.00-31.8  
m/m) High Speed Ratio set S2 DIP Switch as fol-  
lows: (initial factory setting)  
DC-250:  
DC-400:  
DC-600:  
Security  
S1  
HEAD 2  
HEAD 1  
Pwr Sources  
M 4  
ON  
S1  
1
2
3
4
5
6
7
8
S2  
ON  
S2  
1
2
3
4
5
6
7
8
Security  
S1  
Pwr Sources  
M 4  
For K679-1 (Single Head Boom) with 50-770 IPM  
(1.27-19.5 m/m) Low Speed Ratio set S2 DIP Switch  
as follows:  
ON  
S1  
1
2
3
4
5
6
7
8
HEAD 2  
HEAD 1  
S2  
ON  
S2  
1
2
3
4
5
6
7
8
Security  
S1  
Pwr Sources  
M 4  
ON  
S1  
1
2
3
4
5
6
7
8
For K679-2 (Single Head Boom) with 80-1200 IPM  
(2.00-30.5 m/m) High Speed Ratio set S2 DIP  
Switch as follows:  
DC-650 PRO:  
DC-1000:  
Security  
S1  
HEAD 2  
HEAD 1  
Pwr Sources  
M 4  
S2  
ON  
S2  
1
2
3
4
5
6
7
8
ON  
S1  
1
2
3
4
5
6
7
8
NOTE: Any single drive may be connected to the  
Head 1 or Head 2 connector. Both settings are con-  
figured the same way.  
Security  
S1  
Pwr Sources  
M 4  
ON  
S1  
1
2
3
4
5
6
7
8
DH-10  
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B-4  
B-4  
OPERATION  
Pulse Power 500:  
Metric/English Wire Feed Speed  
Display Selection  
Security  
S1  
Pwr Sources  
M 4  
ON  
1
2
3
4
5
6
7
8
The DH-10 Control is set up for Wire Feed Speed dis-  
play in Metric units (m/min) or English units (IPM) by  
setting S1 DIP switch 6 (Labeled “M”):  
S1  
V300 PRO:  
Security  
S1  
Pwr Sources  
M 4  
ON  
S1  
1
2
3
4
5
6
7
8
S1 switch 6 OFF = IPM (as shipped)  
Security  
Pwr Sources  
M 4  
Other Power Source Independent:  
Security  
S1  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Pwr Sources  
M 4  
ON  
S1  
1
2
3
4
5
6
7
8
S1 switch 6 ON = m/min  
Set the DIP switches as shown for all other power  
sources which can be controlled with a 10Kpoten-  
tiometer circuit.  
Security  
S1  
Pwr Sources  
M 4  
ON  
S1  
1
2
3
4
5
6
7
8
All DH-10 features operate as described elsewhere in  
this manual except for the following differences:  
4-Step Trigger Mode Operation Selection  
1. Instead of displaying a preset value in volts, the  
top display will show a number from “0.00” to  
“10.00” in increments of “0.02”. The number can  
be used for setting run-in “voltage” as well as  
“weld preset voltage”. When the trigger is closed  
or while welding, the top display will display actu-  
al arc voltage. The voltage displayed while weld-  
ing can be used to determine the arc voltage to  
be expected for a given number setting. Actual  
arc voltage display will still flash for 5 seconds  
after a weld has been completed.  
The DH-10 Control is set up for 4-Step Trigger mode  
operation with or without weld current interlock by set-  
ting S1 DIP switch 7 (Labeled “4”).  
When 4-Step trigger mode is selected on the DH-10  
keypad (See Keypad and Display Operation in this  
section) S1 DIP switch setting determines the 4-step  
trigger operation:  
S1 switch 7 OFF = 4-Step with current interlock  
operation: (As shipped)  
2. If a loss of arc voltage occurs, wire will NOT stop  
feeding. The Loss of Voltage Sense Shutdown  
feature is disabled to permit the use of the DH-10  
with power source connections that do not con-  
nect the work voltage back to the DH-10 through  
the input power cable. The actual weld voltage  
while welding will NOT properly be shown on the  
top display if the work voltage is not available to  
the DH-10 through the input power cable.  
Security  
Pwr Sources  
M 4  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
1. Closing Trigger initiates gas preflow time followed  
by Run-in speed and strike voltage until arc strike  
initiates welding.  
2. Opening Trigger after welding arc is established  
continues welding with weld current interlock.  
(Breaking arc stops the feeder operation).  
3. Reclosing Trigger continues welding but shuts off  
current interlock function.  
4. Reopening Trigger stops wire feed and initiates  
burnback time, then gas postflow time.  
DH-10  
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B-5  
B-5  
OPERATION  
S1 switch 7 ON = 4-Step without current interlock  
operation:  
KEYPAD AND DISPLAY OPERATION  
Security  
R
Pwr Sources  
LINCOLN  
M 4  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
V
COLD FEED  
FORWARD  
COLD FEED  
REVERSE  
GAS PURGE  
1. Closing Trigger initiates gas flow.  
WFS  
A
REMOTE  
B
1
2
2. Opening Trigger initiates gas preflow timer fol-  
lowed by Run-in speed and strike voltage until  
arc strike initiates welding. (Trigger is released  
before arc is struck, but once established break-  
ing arc stops the feeder operation).  
PROCEDURE  
FEEDER  
V
VOLTS  
COLD FEED  
2-STEP STD  
4-STEP LOCK  
TRIGGER  
SPOT  
3. Reclosing Trigger stops wire feed and initiates  
burnback time, then gas postflow time.  
PREFLOW  
1
RUN-IN  
VOLTS WFS  
/
SPOT  
BURNBACK  
POSTFLOW  
WIRE FEED SPEED  
2
4. Reopening Trigger stops gas flow if, or when,  
postflow time is over.  
CONTROL  
TIMER  
Low Security Mode Selection  
THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A.  
G3030  
The DH-10 Control is set up for Low Security Mode  
(See “Security Modes” in this section) by setting S1  
DIP Switch 8 (Labeled “S”):  
Keypad and Display Description  
Keypad - Eight key, membrane type with “snap” tac-  
tile feel and embossed domes. Long life design.  
Spatter resistant surface.  
S1 switch 8 ON = Low Security mode ON  
Security  
Pwr Sources  
M 4  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
Displays - Two digital LED displays with 0.56 in.  
(14.2 mm) character height. Top (3-1/2 digit) displays  
Preset and Actual (while welding) arc voltage in volts  
with (+) or (-) polarity indicators, and also displays all  
timers in seconds. Bottom (4 digit) displays preset  
wire feed speed in IPM, or m/m, and acceleration  
selection.  
S1 switch 8 OFF = Low Security mode OFF (as  
shipped)  
Security  
Pwr Sources  
M 4  
S1  
ON  
1
2
3
4
5
6
7
8
S1  
NOTE: High Security mode must be OFF for Low  
Security mode to function.  
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.  
High Security Mode Selection  
The DH-10 Control is set up for High Security Mode  
(See Security Modes in this section) by setting S1  
DIP switch 5 (Not labeled):  
Rotating Encoders - Knob controls increase or  
decrease settings of volts and wire feed speed  
(initially factory set to minimum). Alternately, the top  
encoder adjusts timer settings and bottom selects  
acceleration settings when selected for these  
parameters to be displayed.  
S1 switch 5 ON = High Security mode ON  
Security  
Pwr Sources  
M 4  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
S1 switch 5 OFF = High Security mode OFF (as  
Power-Down Save  
shipped)  
Security  
Pwr Sources  
M 4  
Power to the DH-10 is supplied and controlled from  
the power source. The DH-10 automatically senses  
the loss of power when the power source is turned off.  
S1  
ON  
S1  
1
2
3
4
5
6
7
8
DH-10  
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B-6  
B-6  
OPERATION  
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.  
Trigger Mode Selection  
Trigger Mode Select key -  
enables operator to choose  
mode of operation shown by  
the indicator lights. Pressing  
key causes mode lights to  
sequence (top to bottom)  
starting from the current indi-  
cated selection.  
COLD FEED  
2-STEP STD  
4-STEP LOCK  
TRIGGER  
SPOT  
Operation Keys  
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.  
1
2
Feeder Lights - Indicate the wire feed  
head selected for procedure, mode,  
timer and cold feed functions settings.  
The feeder may be selected by press-  
ing the Feeder select key, or by the last  
feeder gun trigger that was closed.  
FEEDER  
Second Light - indicates 2-step (standard) trigger  
mode.  
Procedure Lights - Indicate which  
procedure (A or B) is selected for the  
selected feeder. A and B procedure for  
Feeder 1 is independently set from A  
and B Procedure for Feeder 2. The  
Procedure select key selects A or B, or  
if REMOTE Light is selected, the pro-  
cedure selection light is controlled by  
A
REMOTE  
B
1. Trigger closure energizes the solenoid valve, then  
the wire feeder and the power source after  
Preflow time.  
PROCEDURE  
2. Releasing the trigger turns off the wire feeder,  
then power source after burnback time and then  
the gas solenoid valve after Postflow time.  
connection of an optional Dual Procedure gun switch  
(K683-1, -3) or Dual Procedure Remote Control  
(K1449-1).  
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)  
COLD FEED  
FORWARD  
COLD FEED  
REVERSE  
Cold Feed Keys - energize  
the wire feeder but not the  
power source or gas sole-  
noid valve. Cold Feed  
Forward speed is factory  
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 ener-  
gizes the gas solenoid valve, then wire feeder and the  
power source. The spot timer starts when current  
flows. The wire feeder and power source then sole-  
noid valve are all turned off when the spot on timer  
times out even though the trigger is opened or is still  
closed. Preflow/Postflow and burnback timers are  
also functional in spot mode. (See Display Control  
Keys in this section).  
set at 200 IPM, but is adjustable with WFS encoder  
knob and displayed on WFS display (with “Cld” shown  
on the Voltage display) only while pressing Cold Feed  
Forward, and the last speed set is stored in memory  
for the next cold feeding, unless changed in Cold  
Feed trigger mode (see following section). Cold Feed  
Reverse retracts wire at a fixed 80 IPM speed which is  
not adjustable.  
GAS PURGE  
Gas Purge key - energizes the gas  
solenoid valve but not the wire feeder or  
power source.  
DH-10  
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B-7  
B-7  
OPERATION  
If set below minimum rated speed “---” will show on  
the WFS display, indicating Run-in speed is set to  
match weld speed setting.  
Display Control Keys  
TIMER  
Timer Select key - enables operator to  
choose burnback, spot or gas timers, as  
indicated by the appropriate light.  
Pressing the key causes lights to  
sequence (top to bottom, then all off) starting from the  
current indicated selection.  
The Run-in (strike) voltage can be set above or below  
the Weld voltage setting up to a max of 60 V. If set  
below a min of 10 V, the Run-In (strike) voltage dis-  
play shows “---”, indicating the Run-In Voltage is set to  
match the weld voltage setting. Also, the difference  
between Run-in voltage and Weld voltage settings is  
maintained automatically if the Weld voltage setting is  
changed, so the run-in voltage encoder knob does not  
need to be changed to follow the Weld voltage setting.  
When 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.  
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.  
Top Light - indicates preflow time  
PREFLOW  
1
is being displayed, settable 0.0 to  
2.5 seconds (0.2 sec as shipped).  
This is the time the shielding gas  
flows before the wire feed and  
power source are activated.  
SPOT  
BURNBACK  
POSTFLOW  
If the arc does not strike within about 2 seconds, the  
Run-In speed automatically changes to Weld speed to  
permit “Hot” feeding at higher speed setting for load-  
ing wire.  
2
Second Light - indicates spot time is being displayed,  
settable 0.0 (as shipped) to 199.9 seconds.  
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.  
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.  
Digital “MemoryVoltmeter  
When the welding gun trigger is activated, the top DH-  
10 display reads actual welding voltage from 0.0 to  
60.0 VDC with automatic polarity indication for posi-  
tive (+) or negative (-) electrode.  
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.  
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.  
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.  
The last welding voltage monitored at the end of the  
weld is displayed for 5 seconds after the weld has  
stopped, as indicated by a 5 second “blinking” display.  
This allows checking actual weld voltage after weld  
has stopped.  
CONTROL  
Control Select key - enables  
operator to choose Run-In  
procedure as indicated by the light  
turning on. When light is on, the  
settings of Run-In Wire Feed  
Any keypad or trigger operation will interrupt the 5  
second memory display.  
Speed and Voltage are displayed.  
RUN-IN  
VOLTS / WFS  
After Weld procedure is set, Run-  
Acceleration Selection  
in procedure should be set to  
optimize arc starting.  
GAS PURGE  
To provide optimum starting of various  
processes and procedures, the wire  
feed acceleration of the DH-10 can be  
set to five levels; 1 thru 5, for each feed-  
er and procedure. 1 is the slowest  
acceleration and 5 is the fastest.  
Speed encoder knob can adjust run-in speed between  
min. rated speed and up to the procedure Weld speed  
setting. Run-in speed setting can not exceed Weld  
speed setting. Run-in speed setting of 100 IPM or less  
is recommended for optimum starting. Factory setting  
is near min. rated speed.  
CONTROL  
DH-10  
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B-8  
B-8  
OPERATION  
To change acceleration hold the Gas Purge Key  
closed, then press the Control key. The top (Voltage)  
display shows “Acc” indicating acceleration setting, 1  
thru 5, is displayed on the bottom (Speed) display.  
Use the speed encoder knob to change setting of 1  
thru 5.  
DUAL PROCEDURE REMOTE  
CONTROL (K1449-1)  
When this option is connected to the DH-10 Control  
Box receptacle, and the Procedure Key selects  
“REMOTE” the front panel knob controls and proce-  
dure selection is transferred to the knob encoder con-  
trols and Procedure Selector Switch of the remote,  
which function in the exact same manner. Remote  
knob encoders set Weld voltage and wire feed speed,  
as well as Trigger Cold Feed Speed, but not Timers or  
Run-In.  
To exit this function, and enter the acceleration setting  
into the procedure memory, press both keys again or  
close the trigger.  
Security Modes  
Both Low and High Security modes are provided to  
capture and prevent changing of procedure settings.  
Both modes are activated, or deactivated by setting  
S1 DIP switch located inside the DH-10 Control Box.  
If using the optional K683-1, -3 Dual Procedure  
Switch, for either or both wire drives, to select A or B  
along with the (K1449-1) remote, both the front panel  
and remote Procedure selector and switch must be  
set to “REMOTE” and “Gun Switch” (center) positions.  
Low security mode is used to capture timer,  
acceleration and control selections and settings, then  
to disable these selections until low security mode is  
deactivated. Encoder knob setting changes of cold  
feed, weld speed and weld voltage are not disabled.  
The DH-10 Procedure lights indicate whether A or B is  
remotely selected.  
WIRE REEL LOADING -  
READI-REELS, SPOOLS OR COILS  
To Mount a 30 lb (14 kg) Readi-Reel Package  
(Using the Molded Plastic K363-P Readi-Reel  
Adapter) (FIGURE B.1):  
Low Security mode is activated, or deactivated, by  
shutting off the input power to the DH-10 with all  
Timer and Control settings as desired for both proce-  
dures for both Feeders. Then setting S1 DIP switch 8  
inside the DH-10 Control Box ON or OFF and restor-  
ing input power (See Low Security Mode Selection  
in this section).  
The Spindle should be located in the LOWER mount-  
ing hole.  
When activated, the Timer and Control selections no  
longer light, but function with the captured settings.  
All other keys and encoder knob controls function nor-  
mally.  
1. Depress the Release Bar on the Retaining Collar  
and remove it from the spindle.  
2. Place the Adapter on the spindle.  
NOTE: High Security mode must be OFF for Low  
Security mode to function.  
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.  
High Security mode functions the same as Low  
Security mode, but the Voltage and Wire Feed Speed  
encoder knob controls are also deactivated, including  
setting Cold Feed Speed (See Operation Keys and  
Trigger Mode Selection in this section).  
4. Rotate the spindle and adapter so the retaining  
spring is at the 12 o'clock position.  
5. Position the Readi-Reel so that it will rotate in a  
direction when feeding so as to be de-reeled from  
bottom of the coil.  
High Security mode can only be activated, or deacti-  
vated, by shutting off the input power to the DH-10  
with all settings as desired for both Procedures for  
both Feeders. Then setting S1 DIP Switch 5, inside  
the DH-10 Control Box, ON, or OFF, and restoring  
input power. (See High Security Mode Selection in  
this section).  
6. Set one of the Readi-Reel inside cage wires on  
the slot in the retaining spring tab.  
7. Lower the Readi-Reel to depress the retaining  
spring and align the other inside cage wires with  
the grooves in the molded adapter.  
8. Slide cage all the way onto the adapter until the  
retaining spring “pops up” fully.  
DH-10  
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B-9  
B-9  
OPERATION  
To Mount a 50 to 60 lb (22.7 to 27.2 kg)  
CAUTION  
Coil: (Using K1504-1 Coil Reel) (For 50 to 60  
lb Readi-Reels a K438 Readi-Reel Adapter must be  
used).  
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.  
The Spindle must be located in the UPPER mounting  
hole.  
___________________________________________  
1. With the K1504-1 Coil Reel mounted on to the  
2 in. (51 mm) spindle (or with reel laying flat on  
the floor) loosen the spinner nut and remove the  
reel cover. (See Figure B.2).  
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.  
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.  
FIGURE B.1 — READI-REEL MOUNTING.  
3. Tighten the spinner nut against the reel cover as  
much as possible by hand using the reel cover  
spokes for leverage. DO NOT hammer on the  
spinner nut arms.  
4. Cut and remove only the tie wire holding the free  
end of the coil. Hook the free end around the rim  
of the reel cover and secure it by wrapping it  
around. Cut and remove the remaining tie wires.  
CAUTION  
Always be sure the free end of the coil is securely  
held while the tie wires are being cut and until the wire  
is feeding through the drive rolls. Failure to do this will  
result in “backlashing” of the coil, which may tangle  
the wire. A tangled coil will not feed so it must either  
be untangled or discarded.  
To Mount 10 to 44 lb (4.5 to 20 kg) Spools  
(12 in/300 mm Diameter) or 14 lb (6 kg)  
Innershield Coils (FIGURE B.1):  
___________________________________________  
5. Be sure the coil reel is engaged with the spindle  
brake pin and the Release Bar on the Retaining  
Collar “pops up” and that the collar retainers fully  
engage the retaining groove on the spindle.  
The Spindle should be located in the LOWER mount-  
ing hole.  
FIGURE B.2 — KI504-1 COIL REEL.  
(For 8 in. (200 mm) spools, a K468 spindle adapter  
must first be slipped onto spindle.)  
SPINNER NUT  
COVER  
PLATE  
(For 13-14 lb. (6 kg) Innershield coils, a K435 Coil  
Adapter must be used).  
1. Depress the Release Bar on the Retaining Collar  
and remove it from the spindle.  
SLOTS  
CARDBOARD  
COIL LINER  
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.  
COIL  
TIE WIRE  
SPRING  
LOADED ARM  
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.  
REEL  
DH-10  
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B-10  
B-10  
OPERATION  
2. If the wire “birdnests  
, jams, or breaks at the drive  
FEEDING ELECTRODE AND BRAKE  
ADJUSTMENT  
roll, the drive roll pressure is too great. Back the  
pressure setting out turn, run new wire through  
gun, and repeat above steps.  
1. Turn the Reel or spool until the free end of the  
electrode is accessible.  
3. If the only result is drive roll slippage, disengage  
the gun, pull the gun cable forward about 6 in.  
(150 mm). There should be a slight waviness in  
the exposed wire. If there is no waviness, the  
pressure is too low. Increase the pressure set-  
ting turn, reconnect the gun, tighten locking  
clamp and repeat the above steps.  
2. While tightly holding the electrode, cut off the  
bent end and straighten the first 6 in. (150 mm).  
Cut off the first 1 in. (25 mm). (If the electrode is  
not properly straightened, it may not feed or may  
jam causing a “birdnest”.)  
3. Insert the free end through the incoming guide  
tube.  
PROCEDURE FOR SETTING ANGLE  
OF FEEDPLATE  
4. Press the Cold Inch key or the Cold Feed Mode  
gun trigger and push the electrode into the drive  
roll.  
1. Loosen the clamping collar screw using a 3/16 in.  
Allen wrench. The clamping collar screw is  
accessed from the bottom of the feedplate. It is  
the screw which is perpendicular to the feeding  
direction.  
WARNING  
When feeding with the gun trigger, unless “COLD  
FEED” trigger mode is selected, the electrode and  
drive mechanism are always “HOT” to work and  
ground and could remain “HOT” several seconds after  
the gun trigger is released.  
2. Rotate feedplate to the desired angle and tighten  
clamping collar screw.  
___________________________________________  
GAS GUARD REGULATOR SETTING  
5. Feed the electrode through the gun.  
1. With the gas supply shut off, the Gas Guard reg-  
ulator flow adjusting Key should be set to maxi-  
mum (full clockwise) which is rated to be 60  
SCFH (28 l/min).  
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.  
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.  
DRIVE ROLL PRESSURE SETTING  
The DH-10 pressure is factory pre-set to about posi-  
tion “2” as shown on the pressure indicator on the  
front of the feedplate door. This is an approximate  
setting.  
MAKING A WELD  
The optimum drive roll pressure varies with type of  
wire, surface condition, lubrication, and hardness.  
Too much pressure could cause “birdnesting”, but too  
little pressure could cause wire feed slippage with  
load and/or acceleration. The optimum drive roll set-  
ting can be determined as follows:  
1. Use only a Lincoln Electric recommended con-  
stant voltage DC power source compatible with  
the DH-10 Wire Feeder.  
2. Properly connect the electrode and work leads  
for the correct electrode polarity.  
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.  
3. Use the Trigger Mode Selection key to set  
desired trigger mode for each feeder head and  
procedure. (Refer to Trigger Mode Selection in  
this section.)  
DH-10  
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B-11  
B-11  
OPERATION  
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 procedure if using front panel, remote control  
or optional dual procedure switch.) (Refer to  
Operation Keys and Display Control Keys in this  
section.)  
WIRE REEL CHANGING  
At the end of a coil, remove the last of the old elec-  
trode coil from the conductor cable by either pulling it  
out at the nozzle end of the gun or by using the follow-  
ing procedure:  
1. Cut the end of the electrode off at the gun end.  
Do not break it off by hand because this puts a  
slight bend in the wire making it difficult to pull it  
back through the nozzle.  
5. Adjust the wire feed acceleration, if desired,  
for each feeder and procedure. (Refer to  
Acceleration Selection in this section.)  
2. Disconnect the gun cable from the gun connector  
on the DH-10 wire drive unit and lay the gun and  
cable out straight.  
6. Use Timer Select and Voltage Encoder knob to  
set desired timers. (Refer to Trigger Mode  
Selection in this section.)  
3. Using pliers to grip the wire, pull it out of the  
cable from the connector end.  
7. Feed the electrode through the gun and cable  
and then cut the electrode within approximately  
0.38 in. (9.5 mm) of the end of the contact tip for  
solid wire and within approximately 0.75 in.  
(19 mm) of the extension guide for cored wire.  
4. After the electrode has been removed, reconnect  
the gun cable to the drive. Load a new reel of  
electrode per the instructions in Wire Reel  
Loading in this section.  
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.  
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  
DH-10 is opened or faulty, so Loss of Voltage Sense  
Shutdown occurs until the trigger is released.  
WARNING  
When using an Open Arc process, it is  
necessary to use correct eye, head, and  
body protection.  
This shutdown stops the motor, shuts off the gas flow  
and disables the power source output to prevent the  
DH-10 voltage control from driving the power source  
output too high due to loss of proper feedback sensing  
via #21 (WORK) and #67 (ELECTRODE) sensing  
leads.  
____________________________________  
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.  
WIRE FEED OVERLOAD PROTECTION  
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.  
The DH-10 has solid-state overload protection of the  
wire drive motor. If the wire drive motor becomes  
overloaded for an extended period of time, the protec-  
tion circuitry turns off the power source, wire feed and  
gas solenoid, and then displays “H30” on the WFS  
display (with blank Voltage display). This indicates  
the wire drive motor is overloaded and will remain  
shut down for about 30 seconds before the unit will  
automatically reset. The “H30” display decrements  
every second until it reaches “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).  
12. To stop welding, release the gun trigger and then  
pull the gun away from the work after the arc  
goes out and Postflow time, if used, is over.  
13. If necessary to optimize arc starting, readjust wire  
speed acceleration, (Refer to Acceleration  
Selection in this section) and/or Run-In speed,  
(Refer to Display Control Keys in this section).  
DH-10  
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B-12  
B-12  
OPERATION  
is activated the wire feeder is disabled (the  
trigger output to the power source is opened  
up, the motor is stopped, and the gas  
solenoid is turned off). To resume normal  
operation, release the trigger, make sure that  
the electrode is not touching the wire feeder  
frame, and then either press a key on the  
GROUNDING LEAD PROTECTOR  
The frame of the DH-10 Control is grounded to the  
frame of the power source by a lead in the control  
cable. An overload protector prevents welding current  
from damaging this lead if the electrode circuit touch-  
es the wire feeder frame while the electrode is electri-  
cally hot.  
keypad or close the trigger.  
(See  
Grounding Lead Protector in this section.)  
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.  
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.)  
EXPLANATION OF PROMPTING  
AND ERROR MESSAGES  
Display  
Prompt or Error  
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.)  
Acc  
Displayed on Voltage display, indicates WFS  
display is showing acceleration setting, “1” to  
“5” (see Acceleration Selection 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.)  
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.  
Displayed on WFS display, indicates that the  
Grounding Lead Protector circuit was  
activated due to excessive current flow into  
the wire feeder frame. When the GLP circuit  
DH-10  
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SECTION C-1  
SECTION C-1  
ACCESSORIES  
TABLE OF CONTENTS  
-ACCESSORIES SECTION-  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Drive Roll and Guide Tube Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Spindle Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun Adapters (For DH Wire Drive Heads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
C-2  
C-3  
C-4  
C-4  
C-5  
C-5  
DH-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 DH-10 Dual Head Wire Feeder. A  
description of each item is given later in the section.  
TABLE C.1 — DH-10 DUAL HEAD WIRE FEEDER ACCESSORIES.  
KP1505 Series  
KP1507 Series  
KP655 Series  
KP656 Series  
KP647 Series  
K1501  
DRIVE ROLL AND GUIDE TUBE KITS  
DRIVE ROLL AND GUIDE TUBE KITS  
DRIVE ROLL AND GUIDE TUBE KITS  
DRIVE ROLL AND GUIDE TUBE KITS  
DRIVE ROLL AND GUIDE TUBE 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  
155V/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  
K1504-1  
K435  
COIL ADAPTER  
COIL ADAPTER  
K468  
COIL ADAPTER  
K363P  
READI-REEL ADAPTER  
K438  
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  
K684  
K498  
K534  
K478  
K479  
DH-10  
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C-3  
C-3  
ACCESSORIES  
DRIVE ROLL AND GUIDE TUBE KITS  
Table C.2 gives a listing of all of the Drive Roll and  
Guide Tube Kits that are available for the DH-10  
Dual Head Wire Feeder.  
TABLE C.2 — DRIVE ROLL AND GUIDE TUBE KITS.  
Wire Size  
4-Roll  
4-Roll  
DH Drive  
(4-Driven)  
Single Drive  
(2-Driven)  
Solid Steel Electrode  
0.023 in. - 0.025 in. (0.6 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 in.  
0.035 in.  
0.040 in.  
0.045 in.  
0.052 in.  
1/16 in.  
(0.8 mm)  
(0.9 mm)  
(1.0 mm)  
(1.2 mm)  
(1.4 mm)  
(1.6 mm)  
(2.0 mm)  
(2.4 mm)  
5/64 in.  
3/32 in.  
KP1505-3/32  
Cored Electrode  
0.030 in.  
0.035 in.  
0.040 in.  
0.045 in.  
0.052 in.  
1/16 in.  
(0.8 mm)  
(0.9 mm)  
(1.0 mm)  
(1.2 mm)  
(1.4 mm)  
(1.6 mm)  
(1.7 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  
---------------  
KP655 - 035C  
KP655 - 035C  
KP655 - 052C  
KP655 - 052C  
KP655 - 1/16  
KP655 - 3/32  
KP655 - 3/32  
---------------  
0.068 in.  
5/64 in.  
3/32 in.  
7/64 in. Lincore Hard Facing (2.8 mm)  
---------------  
7/64 in.  
(2.8 mm)  
(3.0 mm)  
---------------  
0.120 in.  
---------------  
Aluminum Electrode  
0.035 in.  
(0.9 mm)  
(1.0 mm)  
(1.2 mm)  
(1.6 mm)  
(2.2 mm)  
KP1507 - 035A  
KP1507 - 040A  
KP1507 - 3/64A  
KP1507 - 1/16A  
KP1507 - 3/32A  
KP656 - 035A  
---------------  
0.040 in.  
3/64 in.  
1/16 in.  
3/32 in.  
KP656 - 3/64A  
KP656 - 1/16A  
---------------  
Aluminum Electrode  
(For use with Binzel Guns Only)  
0.040 in.  
(1.0 mm)  
(1.2 mm)  
(1.6 mm)  
---------------  
---------------  
---------------  
KP647 - 040A  
KP647 - 3/64A  
KP647 - 1/16A  
3/64 in.  
1/16 in.  
DH-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 m) to match the  
control to Feeder cable length used.  
INPUT CABLE ASSEMBLIES  
(One required per DH-10 Control Box.)  
K1501 (Control Cable Only) - Consists of a 9-conduc-  
tor control cable with a 14-pin control cable plug, with-  
out electrode cable, and is available in lengths of 10 ft  
(3 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m), 50 ft  
(15 m) and 100 ft (30 m).  
K1558-1 - Remote Switch Interface Module, can be  
used with the DH-10, using a G3041-2 (or higher)  
Control Board. The module provides for user interface  
connection of an external switch (flow switch, etc)  
which must be closed to enable the feeder welding  
operation. Also, the module provides for interface con-  
nection of external equipment (fume extractor, etc.) To  
the module’s isolated relay contacts which actuate  
when the feeder welding gas solenoid is activated  
(representing welding operation in process).  
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) elec-  
trode cable.  
When used with the DH-10, the module provides  
these input and output switch function connections  
independently for each head operation.  
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.  
This module is necessary when using the K1536-1  
waterflow sense kit with the DH-10.  
K683-1 DUAL PROCEDURE SWITCH  
(One per gun) - Requires K686-2 Adapter for DH-10.  
Kit includes gun switch, and mountings for Lincoln  
Innershield and Magnum guns, with 15 ft (4.5 m) con-  
trol cable and 3-pin plug. K686-2 Adapter permits  
3-pin plug and 5-pin gun trigger plug to be connected  
to DH-10 5-pin Trigger/Dual Procedure receptacle.  
K1520-1 115V/42V TRANSFORMER KIT  
Required to use DH-10 with Lincoln Power Sources  
without 42VAC auxiliary and a 14-pin connector  
receptacle. These power sources include the DC-250,  
DC-600, DC-1000 and Pulse Power 500. Also can be  
used with older DC-400 models.  
K683-3 DUAL PROCEDURE SWITCH  
(One per gun) Kit includes gun switch, and mountings  
for Lincoln Innershield and Magnum guns, with 15 ft  
(4.5 m) control cable and 5-pin plug with two leads to  
connect to gun trigger.  
K590-4 WATER CONNECTION KIT  
(One per gun) Includes water cooled gun tube fittings  
and self-sealing outlet and inlet quick-connectors for  
mounting into the DH wire drive connection box.  
SPINDLE ADAPTERS  
K659-1 GAS GUARD REGULATOR  
K162H - (Not required for DH-10 Bench Models)  
Spindle for boom mounting Readi-Reels and 2 in.  
(51 mm) I.D. spools with 60 lb (27.2 kg) capacity.  
User mounted to appropriately prepared boom frame-  
work. Includes an easily adjustable friction brake for  
control of overrun.  
(One per gun) Adjustable flow regulator with remov-  
able 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.  
When a 2 in. (51 mm) spindle is used with Readi-  
Reels or coils not on 12 in. (305 mm) O.D. spools, an  
adapter is required:  
K1449-1 DUAL PROCEDURE REMOTE CONTROL  
(One per DH-10 Control Box) Includes a remote con-  
trol box with a 16 ft (5 m) length control cable with  
4-pin plug for the mating receptacle on the bottom of  
the DH-10 control box. The remote control box con-  
tains a procedure selector switch and 2 rotating knob  
encoders, one controls arc voltage and the other con-  
trols wire feed speed, which function the same as  
comparable controls on the DH-10 front panel, when  
the remote is connected and selected by the DH-10  
Procedure Key.  
Coil Adapters  
K1504-1 - Permits 50 lb to 60 lb (22.7-27.2 kg) Coils  
to be mounted on 2 in. (51 mm) O.D. spindles.  
K435 - Permits 14 lb (6 kg) Innershield coils to be  
mounted on 2 in. (51 mm) O.D. spindles.  
K468 - Permits 8 in. (203 mm) O.D. spools to be  
mounted on 2 in. (51 mm) O.D. spindles.  
DH-10  
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C-5  
C-5  
ACCESSORIES  
Readi-Reel Adapters  
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.)  
K363P - Adapts Lincoln Readi-Reel coils of electrode  
30 lb (14 kg) and 22 lb (10 kg) to a 2 in. (51 mm) spin-  
dle. Durable molded plastic one piece construction.  
Designed for easy loading; adapter remains on spin-  
dle for quick changeover.  
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.)  
K438 - Adapts Lincoln Readi-Reel coils of electrode  
50 to 60 lb. (22.7 to 27.2 kg) to a 2 in. (51 mm)  
spindle.  
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.)  
GUN ADAPTERS (FOR DH WIRE DRIVE  
HEADS)  
The following Lincoln gun and cable assemblies are  
equipped with a Fast-Mate™ connector. They can be  
used with DH wire feed models by installing a K489-7  
Adapter, or a K489-2 Fast-Mate™ adapter kit and a  
K1500-1 Lincoln Gun adapter.  
Adapts DH heads for desired gun connection:  
K489-7 for Fast-Mate (or European style) gun connec-  
tions, including Dual Schedule Fast-Mate guns.  
K1500-1 for standard Lincoln Innershield gun connec-  
tion, or with Fast-Made™ guns with K489-2 Fast-Mate  
Adapter Kit. Also for Magnum 200/300/400 with  
K466-1 connection kit, or Magnum 550 with K613-1.  
K684 Magnum “Super Cool” FM water cooled GMAW  
gun and cable assemblies are rated 450 amps, 100%  
duty cycle (CO2). (Consult sales specifications for  
appropriate models.)  
K1500-2 for Magnum 200/300/400 gun with K466-10  
connection kit. (Also Tweco 4.)  
K498 Magnum 200 FM GMAW gun and cable assem-  
blies 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 DH Wire Feed heads with appropriate  
K1500 Gun Adapter:  
K478 Magnum 300 FM GMAW gun and cable assem-  
blies 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 assem-  
blies 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.)  
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.  
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.)  
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.)  
DH-10  
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C-6  
C-6  
ACCESSORIES  
K1556-1 LIGHT DUTY CASTER KIT  
K1634-1 WIRE REEL ENCLOSURE 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.  
Provides the necessary parts to cover the wire and  
protect if from excessive dirt and contamination. This  
kit is not for use with 60 lb coils (most 30 lb, 15 kg,  
44 lb fiber spools, and smaller coils will work) The kit  
includes a 2-part reel cover, a Magnum conduit  
adapter for the incoming end of the wire feeder feed  
plate and a short length of Magnum conduit to go  
between the reel cover and the feedplate.  
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.  
DH-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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
D-2  
D-2  
D-2  
D-2  
D-2  
D-3  
D-3  
D-3  
D-3  
DH-10  
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D-2  
D-2  
MAINTENANCE  
of teeth so they can be reversed for additional life.  
Drive rolls for 0.023 in. (0.6 mm) through 0.052 in.  
(1.3 mm) solid electrodes and aluminum sizes have  
no teeth, but use two grooves so they also can be  
reversed for additional life.  
SAFETY PRECAUTIONS  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
such as output terminals or internal  
wiring.  
See Procedure to Install Drive Roll and Guide  
Tubes in the Installation section for roll changing  
instructions.  
• When inching with gun trigger, elec-  
trode and drive mechanism are  
“hot” to work and ground and could  
remain energized several seconds  
after the gun trigger is released.  
WIRE REEL MOUNTING -  
READI-REELS AND 10 TO 30 lb  
(4.5 TO 14 kg) SPOOLS  
• Turn OFF input power at welding  
power source before installation or  
changing drive roll and/or guide  
tubes.  
No routine maintenance required. Do not lubricate  
2 in. (51 mm) spindle.  
AVOIDING WIRE  
FEEDING PROBLEMS  
• Welding power source must be con-  
nected to system ground per the  
National Electrical Code or any  
applicable local codes.  
Wire feeding problems can be avoided by observing  
the following gun handling and feeder set up  
procedures:  
• Only qualified personnel should per-  
form this installation.  
a) Do not kink or pull cable around sharp corners.  
Observe all additional Safety Guidelines detailed  
throughout this manual.  
b) Keep the electrode cable as straight as possible  
when welding or loading electrode through cable.  
c) Do not allow dolly wheels or trucks to run over  
cables.  
ROUTINE MAINTENANCE  
Drive Rolls and Guide Tubes  
d) Keep cable clean by following maintenance  
instructions.  
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.  
e) Use only clean, rust-free electrode. The Lincoln  
electrodes have proper surface lubrication.  
f) Replace contact tip when the arc starts to become  
unstable or the contact tip end is fused or  
deformed.  
g) Do not use excessive wire spindle brake settings.  
The drive rolls for 0.035 in. (0.9 mm) through 0.052 in.  
(1.3 mm) cored electrode and 1/16 in. (1.6 mm)  
through 3/32 in. (2.4 mm) electrode have a double set  
h) Use proper drive rolls, guide tubes and drive roll  
pressure settings.  
DH-10  
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D-3  
D-3  
MAINTENANCE  
PERIODIC MAINTENANCE  
Wire Drive Motor and Gearbox  
PROCEDURE FOR REMOVING  
FEEDPLATE FROM WIRE FEEDER  
1. Loosen the clamping collar screw using a 3/16 in.  
Allen wrench. The clamping collar screw is  
accessed from the bottom of the feedplate. It is  
the screw which is perpendicular to the feeding  
direction.  
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 in. long.  
2. Loosen the retaining screw, which is also  
accessed from bottom of feeder, using a 3/16 in.  
Allen wrench. Continue to loosen the screw until  
the feedplate can be easily pulled off of the wire  
feeder.  
Gun and Cable Maintenance  
See appropriate Operator’s Manual.  
DH-10  
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D-4  
D-4  
MAINTENANCE  
DH-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 Heads and Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
E-2  
E-3  
E-4  
DH-10  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.1 — GENERAL DESCRIPTION.  
SOLENOID  
SOLENOID  
TO GUN TRIGGER  
TO GUN TRIGGER  
AND  
AND  
DUAL PROCEDURE  
DUAL PROCEDURE  
RIGHT  
LEFT  
WIRE DRIVE  
RECEPTACLE  
WIRE  
DRIVE  
WIRE  
DRIVE  
WIRE DRIVE  
RECEPTACLE  
MOTOR  
MOTOR  
TACH FEEDBACK  
TACH FEEDBACK  
INPUT  
CABLE  
RECEPTACLE  
CURRENT SENSING  
REED SWITCH  
CONTROL BOARD  
42VDC  
GROUND  
LEAD  
PROTECTOR  
WFS  
ENCODER  
VOLTS  
ENCODER  
DISPLAY  
BOARD  
KEYPAD  
offered are four independently selectable gun trigger  
modes for each head procedure; cold feed, 2-step and  
4-step trigger, and spot weld. The user can also pre-  
set timers for each head procedure: preflow, postflow,  
burnback, and spot weld times. Five selectable wire  
feed acceleration rates can be used to optimize arc  
starting. Refer to Figure E.1.  
GENERAL DESCRIPTION  
The DH-10 is a 42 VAC, dual head, 4-roll wire feeder.  
A single control for each head is utilized, with dual  
procedure presettablility of wire feed speed and arc  
voltage. The DH-10 models have controls providing  
keypad or remote selectability of wire drive head and  
either one or two procedures for each head. Also  
DH-10  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.2 — INPUT RECEPTACLE, CONTROL BOARD AND OPERATOR CONTROLS.  
SOLENOID  
SOLENOID  
TO GUN TRIGGER  
TO GUN TRIGGER  
AND  
AND  
DUAL PROCEDURE  
DUAL PROCEDURE  
LEFT  
WIRE DRIVE  
RECEPTACLE  
RIGHT  
WIRE DRIVE  
RECEPTACLE  
WIRE  
DRIVE  
MOTOR  
WIRE  
DRIVE  
MOTOR  
TACH FEEDBACK  
TACH FEEDBACK  
INPUT  
CABLE  
RECEPTACLE  
CURRENT SENSING  
REED SWITCH  
CONTROL BOARD  
42VDC  
GROUND  
LEAD  
PROTECTOR  
VOLTS  
ENCODER  
WFS  
ENCODER  
DISPLAY  
BOARD  
KEYPAD  
feed speed (WFS) encoder, and the keypad. It also  
receives feedback information from the active wire  
feed head as to the wire feed speed and the arc volt-  
age. The control board compares the feedback infor-  
mation with the user command signals and generates  
the appropriate signals to control wire feed speed, arc  
voltage, and gas flow.  
INPUT RECEPTACLE, CONTROL  
BOARD, AND OPERATOR  
CONTROLS  
The 42 VAC input voltage is applied to the DH-10  
through a 9-pin amphenol type receptacle. The  
remote control and trigger leads are also accessed  
through this 9-pin receptacle. The 42 VAC is rectified  
by a full wave bridge and sent to the control board.  
This DC voltage is coupled to an onboard switching  
power supply. The switching power supply manufac-  
tures regulated ±12.8 VDC and +5.0 VDC regulated  
supplies for the control board. Refer to Figure E.2.  
The current sensing switch and ground lead protector  
are connected to the control board via plug J1. The  
current sensing reed switch closes when welding cur-  
rent is established which signals the control board to  
change from the run-in welding parameters to the pre-  
set welding wire feed speed and arc voltage. If the  
ground lead protector is activated, the trigger circuit  
will be disabled and the WFS display will show “GLP”.  
The control board receives commands from the user  
operated controls such as the volts encoder, the wire  
DH-10  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.3 — WIRE FEED HEADS AND RECEPTACLES.  
SOLENOID  
SOLENOID  
TO GUN TRIGGER  
AND  
DUAL PROCEDURE  
TO GUN TRIGGER  
AND  
DUAL PROCEDURE  
LEFT  
RIGHT  
WIRE  
DRIVE  
WIRE  
DRIVE  
WIRE DRIVE  
RECEPTACLE  
WIRE DRIVE  
RECEPTACLE  
MOTOR  
MOTOR  
TACH FEEDBACK  
TACH FEEDBACK  
INPUT  
CABLE  
RECEPTACLE  
CURRENT SENSING  
REED SWITCH  
CONTROL BOARD  
42VDC  
GROUND  
LEAD  
PROTECTOR  
VOLTS  
ENCODER  
WFS  
ENCODER  
DISPLAY  
BOARD  
KEYPAD  
When the gun trigger is activated, the control board  
energizes the gas solenoid, then the welding drive  
motor and welding power source. The control board  
receives tach feedback information and adjusts the  
motor armature voltage to match the preset wire feed  
speed.  
WIRE FEED HEADS AND  
RECEPTACLES  
The leads to the drive motor, gas solenoid, and the  
tach (hall effect device) are brought into the control  
box via the wire drive receptacles. These two 14-pin  
receptacles also house the gun trigger leads, the elec-  
trode voltage sense lead, and the leads for the option-  
al remote with dual procedure capability. Refer to  
Figure E.3.  
DH-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 . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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  
DH-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 216-383-2531 or 1-800-833-9353.  
---------------------------------------------------------------------------------------------------------  
DH-10  
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F-3  
F-3  
TROUBLESHOOTING AND REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
WARNING  
PC board can be  
damaged by static  
electricity.  
ELECTRIC SHOCK  
can kill.  
- 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 con-  
nected to a grounded  
part of the equipment  
frame.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
Workstations  
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.  
Reusable  
Container  
-------------------------------------------------  
Do Not Destroy  
- If you don’t have a  
CAUTION  
wrist strap, touch an unpainted, grounded,  
part of the equipment frame. Keep touching  
the frame to prevent static build-up. Be sure  
not to touch any electrically live parts at the  
same time.  
Sometimes machine failures appear to be  
due to PC board failures. These problems  
can sometimes be traced to poor electrical  
connections. To avoid problems when trou-  
bleshooting and replacing PC boards,  
please use the following procedure:  
- Tools which come in contact with the PC  
board must be either conductive, anti-static  
or static-dissipative.  
-------------------------------------------------  
- Remove the PC board from the static-  
shielding bag and place it directly into the  
equipment. Don’t set the PC board on or  
near paper, plastic or cloth which could  
have a static charge. If the PC board cannot  
be installed immediately, put it back in the  
static-shielding bag.  
1. Determine to the best of your technical  
ability that the PC board is the most  
likely component causing the failure  
symptom.  
2. Check for loose connections at the PC  
board to assure that the PC board is  
properly connected.  
- If the PC board uses protective shorting  
jumpers, don’t remove them until installation  
is complete.  
3. If the problem persists, replace the sus-  
pect PC board using standard practices  
to avoid static electrical damage and  
electrical shock. Read the warning inside  
the static resistant bag and perform the  
following procedures:  
- 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.  
DH-10  
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F-4  
F-4  
TROUBLESHOOTING AND REPAIR  
4. Test the machine to determine if the fail-  
ure symptom has been corrected by the  
replacement PC board.  
connections in the control wiring har-  
ness, junction blocks, and terminal  
strips.  
NOTE: It is desirable to have a spare  
(known good) PC board available for PC  
board troubleshooting.  
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.  
NOTE: Allow the machine to heat up so  
that all electrical components can reach  
their operating temperature.  
6. Always indicate that this procedure was  
followed when warranty reports are to be  
submitted.  
5. Remove the replacement PC board and  
substitute it with the original PC board to  
recreate the original problem.  
NOTE: Following this procedure and writing  
on the warranty report, “INSTALLED AND  
SWITCHED PC BOARDS TO VERIFY  
PROBLEM,” will help avoid denial of legiti-  
mate PC board warranty claims.  
a. If the original problem does not reap-  
pear by substituting the original  
board, then the PC board was not the  
problem. Continue to look for bad  
DH-10  
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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  
Neither drive motor turns when the 1. If an error message “HXX” 1. For feeders using the Remote  
gun triggers are activated. The dis-  
plays are lit and the correct input  
voltage (42 VAC) is applied to the  
DH-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. Also check that there is  
continuity in the circuit connect-  
ing the two terminals marked  
2A.  
2. Make certain the dip switches  
are set correctly for the power  
source being used. See  
2. Make sure the gun trigger cir-  
cuits are working properly. See  
the Wiring Diagram.  
Welding  
Selection.  
Power  
Source  
3. If the control board is a G3041-2  
or later, a jumper plug or a  
K1558-1 remote switch interface  
module must be installed into  
connector J5 on the control  
board.  
3. Perform the Wire Drive Motor  
Test.  
4. The control board may be faulty.  
One side’s drive motor does not  
turn, although the arc voltage is  
present and the gas solenoid  
works and the gun trigger is acti-  
vated.  
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 on one side only. Both  
motors turn, both gas solenoids  
operate and arc voltage is present.  
The WFS can be preset.  
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.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-10  
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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)  
No control of wire feed speed on 1. Check the tach leads between 1. Perform the Tach Adjustment  
both sides. Both motors run, both  
solenoids operate and arc voltage  
is present. The WFS can be preset  
on both sides.  
the tach (hall effect devices)  
and the control board. See the  
Wiring Diagram.  
and Feedback Test.  
2. Perform the wire Drive Motor  
Test.  
3. The control board may be  
defective.  
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 DH- 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.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-10  
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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 3Jl to 4J1 should  
be approximately 12 VDC.  
The reed switch should be  
open. If the 12 VDC is miss-  
ing either the reed switch is  
stuck closed or the control  
board is defective.  
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 0VDC, 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 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-10  
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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. Both  
motors operate 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  
corrections.  
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 “Feeder” button does not func- 1. Check the connectors and wires 1. Perform the Keypad Resis-  
tion. The feeder head can be  
selected by pulling the appropriate  
gun trigger.  
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 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-10  
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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”, "Control” and/or 1. Make certain the DIP switches 1. Perform the Keypad Resis-  
“Trigger” buttons do not function  
correctly.  
on the control board are not set  
for the security mode. DIP  
tance Test.  
switch S1 position 5 and posi- 2. The display board may be  
tion 8 must be in the OFF posi-  
tion.  
faulty.  
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.  
One of the encoder control knobs 1. The unit maybe in a mode that 1. Perform the Encoder Board  
functions but the other one does  
not.  
utilizes only one display. To  
check if this is the problem,  
Test.  
make sure that both knobs 2. The control board may be  
change the display when both  
displays are showing a number  
and the high security mode is  
disabled.  
faulty.  
2. Check the wiring and plug con-  
nections between the encoder  
boards and the control board.  
(Plug J2) See the Wiring  
Diagram.  
Neither encoder control knob 1. Make sure the DIP switches on 1. Perform the Encoder Board  
functions.  
the control board are NOT set  
for the high security mode. The  
Test.  
high security mode disables the 2. The control board may be  
encoder controls. See the  
faulty.  
Operation Section.  
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 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-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)  
The DH-10 is dead. The displays 1. Make sure the DH-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 DH-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 DH-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 DH-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 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-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. The control board may be  
functioning at the gun on either  
side of the DH-10.  
switch is installed and connect-  
ed properly.  
faulty.  
2. The “Remote LED” on the  
keypad must be lit and the  
toggle switch on the remote  
control (if used) must be in the  
gun position.  
The dual procedure switch func- 1. Check the connections and 1. The control board may be  
tions properly when attached to  
one side of the DH-10 but will not  
operate on the other side.  
wiring between the dual  
procedure switch and the gun  
trigger connector.  
faulty.  
2. Check the connections and  
wiring between the wire drive  
unit and the control box. Check  
leads #519 and #520 through  
the shielded cable to the control  
board. See the Wiring Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-10  
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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)  
An “Er” message is displayed when 1. This indicates an EEPROM 1. The control board may be  
the DH-10 is powered up.  
error has been detected. Press  
any key to return to normal  
operation. Check all the settings  
to make sure they are within the  
acceptable ranges. If the “Er”  
message is still displayed  
remove the input power. While  
pressing the Timer and Control  
keys, turn on the input power.  
The message “Ln” should be  
displayed. Leave on for 5 sec-  
onds. Remove the input power.  
Note: All the settings will be  
removed.  
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.  
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 DH-10.  
Test.  
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 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-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)  
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 DH-10 control board are set  
correctly for the power source  
being used.  
power source and the DH-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. Make sure the DIP switches on  
the DH-10 control board are set  
correctly.  
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 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-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  
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 lubricant  
(such as Lincoln Electric E2067  
graphite grease) to the tip’s  
threads.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric  
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-10  
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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 be 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 216-383-2531 or 1-800-833-9353.  
-----------------------------------------------------------------------------------------------------------------------------  
DH-10  
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F-16  
F-16  
NOTES  
DH-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 dan-  
ger to the technician or machine operator and will invalidate your factory warran-  
ty. For your safety and to avoid electrical shock, please observe all safety notes  
and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This test will help determine if the wire drive motor is receiving the correct voltage and  
is capable of running properly. Either motor can be checked with this procedure.  
MATERIALS NEEDED  
5/16 in. nutdriver  
Volt-Ohmmeter  
DH-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  
LINCOLN  
ELECTRIC  
(-)BLACK  
LEAD  
LINCOLN  
ELECTRIC  
DRIVE  
MOTOR  
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.  
TEST PROCEDURE  
1. Remove input power to the DH-10 unit.  
2. Using the 5/16 in. nutdriver, 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 DH-10. Activate the gun trigger.  
With the motor running, check the  
armature voltage at the black (-) and  
white (+) leads. The normal voltage  
range is approximately 1 to 25 VDC  
depending on motor speed. When the  
armature voltage is increased the motor  
speed should also increase.  
7. Install the wire drive cover.  
DH-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 war-  
ranty. For your safety and to avoid electrical shock, please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This test will determine if the hall effect module (tach) is functioning correctly. Either  
tach can be checked using this procedure.  
MATERIALS NEEDED  
5/16 in. nutdriver  
Volt-Ohmmeter  
9/16 in. wrench  
DH-10  
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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  
LINCOLN  
ELECTRIC  
#512  
RED  
HALL EFFECT  
DEVICE (TACH)  
LINCOLN  
ELECTRIC  
the control board or associated leads or  
plugs may be faulty. See the Wiring  
Diagram.  
TEST PROCEDURE  
1. Remove input power to the DH-10 unit.  
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.  
2. Using the 5/16 in. nutdriver, remove the  
wire drive cover.  
3. Locate the three hall effect leads (blue,  
red and black). See Figure F.2.  
4. Apply the correct input power (42 VAC)  
to the DH-10.  
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.  
5. Check for approximately 12 VDC from  
red lead #512 (+) to black lead #500 (-).  
If the 12 VDC is NOT present or low,  
DH-10  
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F-21  
F-21  
TROUBLESHOOTING AND REPAIR  
TACH ADJUSTMENT AND FEEDBACK TEST (continued)  
3. Using the 9/16 in. wrench loosen the  
locking nut.  
TACH ADJUSTMENT  
PROCEDURE  
4. Gently screw the hall effect module into  
the mounting plate until it just touches  
and stops against the rotating part  
inside the gearbox. See Figure F.2.  
Proper positioning of the module is critical  
to the proper operation the DH-10 wire  
feeder. If the device is not screwed in far  
enough the motor speed could be unstable  
or run at full speed with no control. If  
screwed in too far it will rub a moving part  
inside the gearbox.  
5. Back the module out 1/2 turn. Using the  
9/16 in. wrench and carefully snug the  
locknut without rotating the module  
position.  
1. Remove input power to the DH-10 wire  
feeder.  
6. Install the wire drive cover.  
2. Make sure the module is securely  
attached to the gearbox.  
DH-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 war-  
ranty. For your safety and to avoid electrical shock, please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This test will determine if any key is not functioning properly.  
MATERIALS NEEDED  
5/16 in. nutdriver  
Analog Volt-Ohmmeter  
Small screwdriver  
DH-10  
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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 DH-10 unit.  
7. The resistances are checked at plug  
J10 on the keypad. See Figure F.3.  
2. Using the 5/16 in. nutdriver, remove the  
two screws from the top of the control  
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.  
DH-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  
FROM PIN  
ALLOWABLE RESISTANCE  
(TYPICAL RESISTANCE)  
TO PIN  
2J10  
3J10  
4J10  
5J10  
6J10  
7J10  
8J10  
9J10  
KEY PRESSED  
CONTROL  
TIMER  
TRIGGER  
FEEDER  
PROCEDURE  
COLD FEED FORWARD  
COLD FEED REVERSE  
GAS PURGE  
1J10  
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)  
100 OHMS (50 OHMS TYPICAL)  
DH-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 war-  
ranty. For your safety and to avoid electrical shock, please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This test will help determine if the encoder PC boards are functioning properly.  
MATERIALS NEEDED  
5/16 in. nutdriver  
Volt-Ohmmeter (analog recommended)  
DH-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 DH-10 unit.  
2. Using the 5/16 in. nutdriver, remove the  
two screws from the top of the control  
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 DH-10 unit.  
6. Carefully check or 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 DH-10 unit.  
10. Reassemble the control panel.  
DH-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 dan-  
ger to the technician or machine operator and will invalidate your factory war-  
ranty. For your safety and to avoid electrical shock, please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
TEST DESCRIPTION  
This procedure will help determine if the gas solenoids are receiving the correct volt-  
ages and if the solenoids are functional. This test can be used for either gas solenoid.  
MATERIALS NEEDED  
5/16 in. nutdriver  
Volt-Ohmmeter  
12 VDC @ 1 amp power source  
DH-10  
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F-30  
F-30  
TROUBLESHOOTING AND REPAIR  
GAS SOLENOID TEST (continued)  
FIGURE F.5 — GAS SOLENOID TEST.  
GAS SOLENOID  
LEADS  
GAS  
SOLENOID  
NOTE: WIRE FEEDER SHOWN  
WITH DRIVE MOTOR ASSEMBLY  
REMOVED FOR CLARITY  
6. If the 10 VDC is missing or low, check  
the leads and connections between the  
solenoid and the control board. See the  
Wiring Diagram. If the leads and con-  
nections are OK the control board may  
be faulty.  
TEST PROCEDURE  
1. Remove input power to the DH-10 unit.  
2. Using the 5/16 in. nutdriver, 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 solenoids and lead  
quick connects. See Figure F.5. Do not  
disconnect the leads.  
4. Apply the correct input power (42 VAC)  
to the DH-10 unit.  
8. The solenoid(s) can be further checked  
by disconnecting the solenoid leads  
from the DH-10 wiring harness and  
applying an external 12 VDC supply to  
the leads. If the solenoid does not acti-  
vate the solenoid is faulty.  
5. While pressing the gas purge button or  
activating the appropriate gun trigger,  
check for approximately 10 VDC at the  
solenoid leads. If the 10 VDC is present  
the gas solenoid should activate.  
9. Reconnect all disconnected leads.  
10. Install the wire drive cover.  
DH-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 dan-  
ger to the technician or machine operator and will invalidate your factory war-  
ranty. For your safety and to avoid electrical shock, please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
This will aid the technician in the removal and replacement of the display PC board.  
MATERIALS NEEDED  
5/16 in. nutdriver  
Small screwdriver  
DH-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 DH-10 unit.  
1. Install plug J10 into the new display  
board.  
2. Using the 5/16 in. nutdriver, remove the  
two screws from the top of the control  
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.  
DH-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  
personnel. Unauthorized repairs performed on this equipment may result in dan-  
ger to the technician or machine operator and will invalidate your factory war-  
ranty. For your safety and to avoid electrical shock, please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of either of the  
gas solenoids.  
MATERIALS NEEDED  
5/16 in. nutdriver  
5/16 in. wrench  
Pliers  
Phillips head screwdriver  
DH-10  
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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.  
SOLENOIDS  
CLAMPS  
MOUNT  
LINCOLN  
ELECTRIC  
GAS  
HOSES  
NOTE: WIRE FEEDER SHOWN WITH  
DRIVE MOTOR ASSEMBLY  
REMOVED FOR CLARITY  
PROCEDURE  
7. Remove the solenoid assembly from  
the DH-10 unit.  
1. Remove input power to the DH-10 unit.  
8. Using the Phillips head screwdriver  
remove the two screws holding the  
solenoid to the bracket. Remove the  
solenoid.  
2. Using the 5/16 in. nutdriver, remove the  
wire drive cover.  
3. Locate the gas solenoid assembly and  
remove the input gas lines. See Figure  
F.7.  
9. Mount the new solenoid onto the  
bracket using the two Phillips head  
screws.  
4. Label and remove the four leads (two  
for each solenoid) connected to the  
solenoids.  
10. Install the solenoid assembly into the  
DH-10.  
5. Remove the two rubber hoses and  
clamps from the gas solenoids. Be  
careful not to damage the rubber  
hoses.  
11. Connect the two gas hoses.  
12. Connect the four wires previously  
removed. Be sure the leads are  
connected to the correct solenoid.  
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 lines.  
DH-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  
personnel. Unauthorized repairs performed on this equipment may result in dan-  
ger to the technician or machine operator and will invalidate your factory war-  
ranty. For your safety and to avoid electrical shock, please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of either the  
WFS or Volts control encoder boards.  
MATERIALS NEEDED  
5/16 in. nutdriver  
5/64 in. Allen wrench  
1/2 in. wrench  
DH-10  
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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  
6. Carefully remove the PC board from  
the front panel.  
PROCEDURE  
1. Remove input power to the DH-10 unit.  
7. Remove the harness plug from the  
encoder PC board.  
2. Using the 5/16 in. nutdriver remove the  
two screws from the top of the control  
panel.  
8. Install the harness plug into the new  
encoder PC board.  
3. Lower the control panel.  
9. Assemble the PC board into the front  
panel and secure with the washer and  
nut previously removed.  
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.  
DH-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 dan-  
ger to the technician or machine operator and will invalidate your factory war-  
ranty. For your safety and to avoid electrical shock, please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to per-  
form the test/repairs safely, contact the Lincoln Electric service department for  
technical troubleshooting assistance before you proceed. Call 216-383-2531 or  
1-800-833-9353(WELD).  
------------------------------------------------------------------------------------------------  
DESCRIPTION  
The procedure will aid the technician in the removal and replacement of either the  
motor or gear box. These instructions are applicable for either the left or right side wire  
feed assemblies.  
MATERIALS NEEDED  
5/16 in. nutdriver  
Pliers  
3/16 in. Allen wrench  
7/16 in. socket wrench and extension  
3/4 in. wrench  
5/16 in. wrench  
Slot head screwdriver  
DH-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  
7. Disconnect the motor armature leads.  
8. Remove any necessary cable ties.  
PROCEDURE  
1. Remove input power to the DH-10 unit.  
9. Using the 3/4 in. wrench remove the  
electrode cable from the wire feed  
assembly.  
2. Remove the electrode wire from the  
wire drive.  
3. Using the 5/16 in. nutdriver 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 DH-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.  
11. Remove the wire feed assembly.  
6. Disconnect the tach (hall effect device)  
leads.  
DH-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 slot 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 screw 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 slot 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.  
DH-10  
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F-40  
F-40  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT (continued)  
8. Place the entire assembly into the  
REPLACEMENT PROCEDURES  
DH-10 unit. Align the mounting holes  
with wire feeder base.  
1. Carefully slide the wire drive assembly  
and gear box together.  
9. Secure the assembly to the wire feeder  
base using the four screws, lock wash-  
ers and flat washers previously  
removed.  
2. Tighten the two Allen type screws at  
the bottom of the wire drive unit using  
the 3/16 in. Allen wrench.  
10. Connect the gas hose to the brass gun  
conductor block.  
3. Attach lead #67 to the conductor block.  
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.  
11. Connect the motor armature leads.  
12. Connect the tach (hall effect device)  
leads.  
5. Install the slot head screws that mount  
the “top” of the drive motor to the gear  
box.  
13. Connect lead #67 quick connects  
together.  
14. Connect the electrode cable to the to  
the wire feed assembly.  
6. Install the mounting screw located  
inside the gear box using the 5/16 in.  
wrench.  
15. Replace any cut or removed cable ties.  
16. Install the wire drive cover.  
7. Install the gear box inspection cover  
and secure it with the slot head screws  
and nut previously removed.  
DH-10  
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F-41  
F-41  
TROUBLESHOOTING AND REPAIR  
RETEST AFTER REPAIR  
If a failed test indicates that any mechanical  
part which could affect the machine's elec-  
trical characteristics must be replaced, or if  
any electrical components are repaired or  
replaced, the machine must be retested and  
meet the following standards.  
Check the Feeder selection and Procedure  
keys for proper operation.  
1. Press the Trigger key. The LEDs  
should toggle through the various trig-  
ger selections as the key is pressed  
and released.  
Apply the correct input power (42 VAC) to  
the DH-10 unit. The following checks should  
be performed for both wire drive units (left  
and right):  
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 control 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.  
DH-10 with low speed gear installed:  
35-500 IPM  
DH-10 with high speed gear installed:  
50-750 IPM  
DH-10  
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F-42  
F-42  
NOTES  
DH-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 addi-  
tional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
ELECTRICAL DIAGRAMS SECTION  
Electrical Diagrams Section...........................................................................................Section G  
Wiring Diagram (Control) (L10218)..............................................................................................G-2  
Wiring Diagram (Wire Drive) (M17871) .......................................................................................G-3  
Control Board Schmatic (Sheet 1) (G3040-1) .............................................................................G-4  
Control Board Schmatic (Sheet 2) (G3040-2) .............................................................................G-5  
Display Board Schematic (L10138) .............................................................................................G-6  
Encoder Board Schematic (S22066)...........................................................................................G-7  
Control Board Layout (G3041-2) .................................................................................................G-8  
Display Board Layout (L10139-1) ................................................................................................G-9  
Encoder Board Layout (M17797-1) ...........................................................................................G-10  
DH-10  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
Wiring Diagram (Control) (L10218)  
WIRING DIAGRAM (DH-10 CONTROL)  
ELECTRICAL SYMBOLS PER E1537.  
CAVITY NUMBERING SEQUENCE  
PIN NUMBERING SEQUENCE  
*
**  
(COMPONENT SIDE OF P.C. BOARD)  
(COMPONENT SIDE OF P.C. BOARD)  
1 2  
1
1
3
5
J10  
J11  
1
8
J17  
J3  
J8  
J1  
J4  
4
6
3
4
6
10  
CONNECTOR CAVITY  
NUMBERING SEQUENCE  
(NON LEAD SIDE OF CONNECTOR)  
1
1
7
1
4
8
6
***  
J2  
J6  
J7  
J5  
J19***  
U
14  
8
12  
5
7
1
2
1
CASE  
GROUNDING  
STUD  
2
P10  
P11  
P17  
LEAD COLOR CODING  
B - BLACK  
GROUNDING  
LEAD  
P19  
J19  
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
2
G
3
F
4
D
5
E
6
A
7
B
W
1
8
J10  
ARC  
CURRENT  
SENSOR  
CONTROL P.C BOARD  
KEYPAD  
500  
C
W
1
C
500  
A
B
2
3
4
5
6
7
8
505  
J8  
J2  
J7  
J4  
J5  
8
J6  
8
J3  
5
B
A
J1  
J17**  
VOLTS  
517  
516  
E
121314  
12  
1
2
3
1
4
2
1
2
3
4
5
6
7
8
1
2
3
4
6
1
2
3
4
1
2
3
4
5
6
7
9
10 11  
1
2
3
4
5
6
7
9
10 1112  
1
2
3
4
5
6
7
8
9
10 11  
1
2
3
4
5
6
7
8
9
10  
505  
D
500  
E
D
N.A.  
1
2
3
4
5
6
7
8
3
4
F
J18  
J17**  
WFS  
BRIDGE  
542  
F
527  
526  
H
+
G
H
G
R
AC AC  
-
R
500  
67  
N.B.  
R.F. TOROID  
ASSEMBLY  
L
N.B.  
R.F. CHOKE  
OPTIONAL REMOTE  
CONTROL KIT  
A
J14  
J
I
B
A
J
I
B
A
E
D
C
L
G
M
N
H
F
E
D
C
L
G
J13  
K
M
N
H
F
K
B
C
D
J15  
RIGHT  
LEFT  
J12  
INPUT CABLE  
RECEPTACLE  
WIRE DRIVE  
WIRE DRIVE  
RECEPTACLE  
RECEPTACLE  
A
C
D
B
CABLE TO RIGHT  
WIRE DRIVE  
CABLE TO LEFT  
WIRE DRIVE  
A
A
TO MOTOR  
TO MOTOR  
TO MOTOR TACHOMETER  
TO MOTOR TACHOMETER  
TO MOTOR TACHOMETER  
539(L)  
541(L)  
U(L)  
R(L)  
539(R)  
541(R)  
U(R)  
R(R)  
TO MOTOR  
TO MOTOR  
TO MOTOR TACHOMETER  
TO MOTOR TACHOMETER  
B
F
G
H
K
L
B
F
G
H
K
L
SHIELDED  
CABLE  
A
SHIELDED  
CABLE  
A
B(L)  
B(R)  
TO MOTOR TACHOMETER  
TO BRASS BLOCK VOLTAGE SENSE  
512(R) TO SOLENOID  
TO SOLENOID  
TO DUAL PROCEDURE SWITCH  
520(R) TO DUAL PROCEDURE SWITCH  
TO BRASS BLOCK VOLTAGE SENSE  
TO SOLENOID  
N
C
D
E
M
I
N
C
D
E
M
I
67(L)  
67(R)  
NOTES:  
512(L)  
522(L)  
519(L)  
520(L)  
560(L)  
561(L)  
N.A. FOR G3041-2 AND HIGHER CONTROL  
P.C. BOARDS: THE JUMPER (SHOWN) OR  
THE OPTIONAL REMOTE SWITCH INTERFACE  
MODULE (NOT SHOWN) MUST BE INSTALLED  
IN J5 ON THE CONTROL P.C. BOARD FOR  
THE DH-10 TO OPERATE.  
SHIELDED  
CABLE  
SHIELDED  
CABLE  
TO SOLENOID  
TO DUAL PROCEDURE SWITCH  
TO DUAL PROCEDURE SWITCH  
TO TRIGGER  
522(R)  
519(R)  
B
B
560(R)  
561(R)  
TO TRIGGER  
TO TRIGGER  
CONTROL  
CABLE  
CONTROL  
CABLE  
TO TRIGGER  
J
J
(G3041-1 CONTROL P.C. BOARDS DO NOT  
HAVE THIS CONNECTOR.)  
N.B. THESE CHOKES MAY NOT BE PRESENT ON  
NEWER MODELS.  
N.C. WHITE LEADS 560 AND 561 MAY NOT BE  
LABELED ON EARLIER MODELS.  
11-21-97J  
L10218  
L10218  
11-21-97J  
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 enclo-  
sure panels of your machine.  
DH-10  
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G-3  
G-3  
ELECTRICAL DIAGRAMS  
Wiring Diagram (Wire Drive) (M17871)  
5 2 0  
5 1 9  
5 6 1  
A S S E M B L Y  
H E A D  
5 6 0  
5 2 0  
5 1 9  
5 6 1  
5 2 0  
5 1 9  
5 6 1  
5 6 0  
6 7  
5 6 0  
6 7  
B
B
R
U
R
U
5 3 9  
5 4 1  
5 2 2  
5 3 9  
5 4 1  
5 2 2  
5 1 2  
5 1 2  
5 1 2  
5 2 2  
5 1 2  
5 2 2  
5 3 9  
5 4 1  
U
5 3 9  
5 4 1  
U
R
R
B
B
6 7  
6 7  
5 6 1  
5 6 0  
5 2 0  
5 6 1  
5 6 0  
5 2 0  
5 1 9  
5 1 9  
A S S E M B L Y  
H E A D  
5 2 0  
5 1 9  
5 6 1  
5 6 0  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your  
code is pasted inside one of the enclosure panels of your machine.  
DH-10  
M17871  
11-21-97J  
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G-4  
G-4  
ELECTRICAL DIAGRAMS  
Control Board Schematic (Sheet 1) (G3040-1)  
5-2-97  
G
3040-1  
G3040-1  
5-2-97  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-  
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in  
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.  
DH-10  
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G-5  
G-5  
ELECTRICAL DIAGRAMS  
Control Board Schematic (Sheet 2) (G3040-2)  
512  
CR1  
541(L)  
J6  
BLACK  
541(R)  
J7  
BLACK  
5
4
11  
11  
R189  
512  
5.62K  
512  
3
5
M
M
D46  
CR1  
R187  
J6  
MOTOR REVERSING  
CIRCUITRY  
5.11K  
7
6
505  
C73  
RED  
505  
0.1  
1
50V  
3.32K  
R169  
X7  
J6  
J6  
539(L)  
539(R)  
6
TACH.  
1
9
9
3
R170  
332  
4.75K  
R149  
WHITE  
MOTOR  
WHITE  
BLUE  
J6  
J7  
512  
1
MOTOR  
2
512  
1
C72  
.0047  
50V  
C64  
0.1  
C62  
330p  
50V  
BLACK  
4
5
4
5
D45  
X7  
50V  
2
6
X17  
500  
500  
512  
12  
542  
4.75K  
R112  
11  
10  
500  
505  
11  
TACHS  
X3  
X4  
R148  
D39  
1N4936  
D24  
1N4936  
1
13  
R173  
2.21K  
512  
3
6.19K  
X17  
TACH  
FWD  
REV  
2
Q10  
33A  
Q11  
33A  
200V  
C61  
330p  
50V  
D
S
D
S
9
6
7
3
4
5
1
6
7
3
4
5
1
9
C71  
0.1  
Vdd  
Vb  
Vb  
HO  
Vcc  
nc  
Vdd  
SD  
nc  
100  
200V  
R183  
G
G
12  
10  
14  
8
11  
C42  
0.1  
50V  
LIN  
HIN  
nc  
X27  
HO  
X26  
512  
R151  
R111  
50V  
5.62K  
500  
8
C65  
0.1  
50V  
C63  
0.1  
50V  
C43  
0.1  
50V  
C46  
Vcc  
9
100  
R154  
15.0  
0.1  
505  
8
14  
13  
X17  
nc  
Vs  
nc  
Vss  
HIN  
LIN  
15.0  
50V  
10  
C
E
C
E
512  
REV  
FWD  
500  
6
nc  
Vs  
4.75K  
R155  
R152  
D44  
11  
13  
10  
R185  
5.11K  
SD  
Vss  
LO  
LO  
J7  
G
G
2
2
12  
COM  
COM  
D40  
D23  
1N4936  
D20  
4A  
200V  
C66  
IR2110  
C40  
1.0  
35V  
IR2110  
Q13  
Q12  
40A  
600V  
C74  
1N4936  
9
8
.33  
RED  
C68  
1.0  
35V  
505  
40A  
0.1  
200V  
500  
14  
R157  
150  
600V  
50V  
C41  
0.1  
50V  
3.32K  
R166  
X7  
J7  
J7  
R110  
150  
C67  
0.1  
50V  
TACH.  
2
D22  
12  
R164  
332  
D42  
4A  
3W  
3W  
0.05  
BLUE  
475  
1N4936  
0.05  
200V  
1
500  
4.75K  
R106  
C70  
.0047  
50V  
BLACK  
10  
PWM  
D43  
X7  
13  
C45  
330p  
50V  
500  
11  
10  
9
X4  
500  
8
6
1
500  
512  
3
X4  
R107  
PROC  
PROC  
B
A
100  
2
DIR  
505  
+5REF  
6.19K  
R119  
C44  
330p  
50V  
R171  
2.21K  
R186  
5
4
475  
D21  
1N4936  
X4  
2.21K  
R121  
13.7K  
D49  
R92  
505  
6
7
4
5
J6  
J6  
+5REF  
DUAL PROCEDURE  
GUN  
519L  
3.32K  
8
9
X16  
DPG1  
500  
1
2
13  
12  
5
X5  
X5  
R103  
100  
1
X5  
14  
13  
14  
X6  
D31  
R126  
10K  
D19  
C48  
330p  
50V  
R120  
13.7K  
C31  
AVE  
10  
11  
520L  
6
6
C53  
0.1  
50V  
12  
R90  
C69  
0.1  
7
1
1.00K  
R130  
4.75K  
X6  
X5  
7
50V  
500  
5
D29  
R118  
10K  
C49  
0.1  
50V  
512  
C51  
PROC  
PROC  
B
A
500  
C54  
D28  
505  
1.0  
35V  
R91  
2.21K  
C50  
1.0  
542  
542  
35V  
D17  
C52  
330p  
50V  
500  
R89  
1
4
5
J7  
519R  
3.32K  
C29  
X16  
DPG2  
DUAL PROCEDURE  
GUN  
D30  
2
5
J8  
2
VL  
D18  
500  
C60  
.022  
200V  
488  
-12.8 VDC  
J7  
512  
520R  
8
R95  
512  
4.75K  
J5  
J5  
1.00K  
500  
1
512  
2
R143  
SWITCHING  
10  
T1  
A
B
505  
T1  
C59  
1.8  
2
C58  
SOLENOID  
1
R114  
2.21K  
POWER SUPPLY  
GAS SOLENOID  
1
D36  
1N4936  
9
512(L)  
D35  
4
SOLENOID  
DRIVER  
20V  
2
500  
1N4936  
J6  
J6  
D27  
WHITE  
8
TRIGGER 1  
D26  
FAULT1  
FAULT2  
J5  
R116  
GAS  
SOLENOID  
1N4936  
8
9
500  
D34  
3
4
J6  
3.32K  
5
4
X16  
TRIG1  
+12.8 VDC  
512  
14  
522(L)  
Q5  
600mA  
40V  
7
2
505  
X10  
D
D25  
500  
+5 VDC  
D48  
1N4936  
J5  
C47  
Q4  
WHITE  
10  
15A  
60V  
D
R141  
100  
Q14  
J6  
G
S
26.7  
R134  
TO  
J5  
J5  
J5  
J5  
J5  
J5  
J5  
J5  
J5  
J5  
18A  
200V  
G
X29  
7
8
4
5
6
2
3
Q7  
600mA  
40V  
VCC  
OUT  
VFB  
512  
5
1.00K  
R182  
IN  
S
OUT  
CR1-  
INTERFACE  
P.C. BOARD  
DZ8  
16V  
1W  
2
VREF  
RT/CT  
GND  
505  
1
C78  
1200  
100V  
COMP  
CS  
500  
7
GND  
1
D47  
4A  
200V  
R133  
2.21K  
3
C57  
18  
15V  
X28  
8
C77  
2700p  
50V  
500  
D32  
C79  
20  
WHITE  
10  
TRIGGER 2  
C56  
1200  
100V  
512  
C80  
5600  
35V  
DZ9  
16V  
1W  
R132  
50V  
9
10  
11  
J7  
J7  
3.32K  
X16  
TRIG2  
13  
10  
11  
12  
13  
14  
6
332  
SOLENOID  
2
C75  
2700p  
50V  
D33  
500  
6
T1  
C81  
0.1  
50V  
GAS SOLENOID  
2
R175  
C55  
C
505  
512(R)  
SOLENOID  
DRIVER  
WHITE  
3
2
7
7
C76  
2700p  
50V  
512  
J7  
J7  
R101  
D37  
1N4936  
1.00K  
GAS  
11  
SOLENOID  
522(R)  
Q8  
13  
X10  
600mA  
D
S
10  
40V  
7
6
D51  
500  
500A  
Q9  
ARC  
CURRENT  
SENSE  
1
15A  
60V  
X10  
CURRENT  
2
WHITE  
3
R135  
100  
G
R99  
2.21K  
J1  
J1  
J8  
CR2-  
Q6  
600mA  
40V  
500  
C33  
DZ7  
16V  
1W  
4.7  
D50  
35V  
WHITE  
4
500  
R232  
2.21K  
505  
500  
500  
512  
512  
505  
512  
GENERAL INFORMATION  
LAST NO. USED  
R-  
C-  
D-  
ELECTRICAL SYMBOLS PER E1537  
9
8
12  
13  
D53  
D52  
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
11  
X17  
GROUND  
FAULT  
PROTECT  
14  
LABELS  
SUPPLY  
=
Ohms  
(
4
3
14  
14  
X10  
GLP  
BLUE  
1
3
3
3
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
VOLTAGE NET  
R233  
2.21K  
J1  
J1  
X4  
X17  
C36  
C37  
C34  
0.1  
50V  
C175  
C38  
0.1  
50V  
C32  
C39  
0.1  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
X6  
X5  
SHEET 2 OF 2  
X10  
X16  
X7  
0.1  
0.1  
0.1  
0.1  
C100  
74HC132  
74HC132  
4.7  
50V  
50V  
50V  
50V  
50V  
LM224  
11  
LM2901  
12  
500  
BLUE  
2
LM2901  
LM2901  
12  
LM2901  
12  
35V  
FRAME CONNECTION  
7
7
R234  
2.21K  
EARTH GROUND CONNECTION  
12  
FILE: G3040_2BA  
NOTES  
:
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
500  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY  
A
5-2-97  
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
500  
500  
488  
G
3040-2  
N.B PRESENT ON THE DH12 MODELS ONLY.  
G3040-2  
5-2-97  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-  
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in  
DH-10  
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
Display Board Schematic L10138)  
L10138  
5-2-97  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-  
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in  
SQUARE WAVE TIG 275  
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
Encoder Board Schematic (S22066)  
DH-10  
S22066  
4-7-95  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
ELECTRICAL DIAGRAMS  
Control Board Layout (G3041-2)  
~.04  
9.00  
8.82  
ITEM  
REQ'D.  
PART NO.  
DESCRIPTION  
ITEM  
REQ'D.  
PART NO.  
DESCRIPTION  
R 3 3  
R 9  
R 6  
R 1 0  
D 3 5  
D Z 9  
R 1 7 9  
R 3 1  
R 3 0  
R 9 5  
R 6 0  
D 3 4  
R 1 5 6  
R 1 5 8  
R 1 5 4  
C 5 7  
C 7 5  
R 1 5 1  
C 6 8  
R 1 1 9  
C 6 4  
D 2 3  
R 1 5 2  
R 7 0  
R 6 9  
R 1 1 0  
R 1 7 5  
C 7 7  
R 1 8 1  
R 1 7 6  
R 1 7 8  
R 1 5 5  
R 1 4 9  
C 6 2  
D 2 1  
R 1 1 4  
R 1 1 6  
C 5 5  
C 4 1  
R 1 5 0  
R 1 0 9  
R 1 5 7  
D 4 0  
C 6 1  
R 1 0 7  
C 4 4  
C 4 5  
5.48  
R 1 4 8  
R 1 4 7  
R 1 5 3  
R 1 3 4  
R 1 0 6  
D 2 2  
C 3 4  
C 6 7  
R 1 0 8  
R 1 1 2  
R 3 6  
C 1 7  
R 2 4  
C 7  
R 1 8  
R 2 5  
4.97  
R 1 6 4  
D 3  
D 2  
R 1 6 3  
R 1 6 6  
D 2 4  
R 1 6 5  
R 1 8 9  
R 1 6 7  
C 4 2  
D 4 4  
R 1 5 9  
R 1 6 1  
D 1  
D 6  
R 2 0  
R 1 2 4  
C 5 2  
R 1 6 8  
R 1 8 3  
R 1 8 5  
R 1 8 4  
R 1 7 3  
R 1 8 8  
C 6  
C 3 6  
C 4 9  
C 8 2  
C 2 7  
N.B.  
N.B.  
N.B.  
N.B.  
N.B.  
N.B.  
R 1 2 2  
R 1 0 5  
R 1 2 8  
C 4 8  
C 2 6  
R 2 1  
R 4 2  
D 2 7  
D 3 2  
C 7 1  
R 2 3  
C 1  
R 7 4  
R 2 2  
R 1 7  
D 2 5  
R 1 2 5  
D 1 8  
D 1 9  
C 3 9  
C 4 7  
R 1 4 4  
R 1 1 3  
C 3 7  
R 1 2 3  
R 1 2 0  
R 2 2 4  
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  
D 4 9  
D 2 9  
D 4  
R 1 1 7  
R 1 2 1  
D 5  
R 5 7  
R 5 5  
R 1 2 9  
C 5 1  
3.13  
D 1 5  
D 1 6  
C 1 9  
D 3 1  
R 1 3 0  
C 3 8  
R 1 8 6  
C 3 0  
R 9 3  
R 1 0 2  
R 2 3 6  
R 1 1  
C 1 0  
C 1 2  
R 5 3  
R 5 6  
R 5 1  
R 4 4  
D Z 2  
D Z 1  
D 1 2  
C 2 2  
R 5 8  
R 2 2 8  
R 2 1 9  
R 2 1 8  
R 2 1 7  
R 2 1 6  
D 9  
C 3 2  
R 2 2 9  
R 2 7  
R 2 9  
R 2 6  
R 3 2  
R 2 8  
R 2 3 0  
R 2 3 1  
D 1 0  
N.A.  
N.A.  
N.A.  
C 2 0  
R 5 0  
R 1 6  
D 1 4  
R 9 4  
D 1 1  
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  
R 5 4  
R 2 4 3  
D 7  
R 2 4 1  
R 2 4 0  
R 2 4 2  
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 2 3 2  
R 2 3 4  
D 1 3  
R 2 4 4  
R 5 2  
R 7  
R 4 9  
R 1 0 0  
D 5 1  
R 2 3 5  
D 5 3  
D 8  
R 4 1  
R 7 5  
R 7 2  
D 5 6  
D 5 5  
C 8 4  
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  
D 5 0  
D 5 2  
C 3 3  
R 8 6  
R 6 8  
R 6 1  
R 8 4  
R 6 5  
C 1 0 0  
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  
.18  
0
CAPACITORS  
=
MFD/VOLTS  
OHMS, 1/4 WATT UNLESS OTHERWISE SPECIFIED.  
HENRYS  
RESISTORS  
=
INDUCTANCE  
=
0
2-20-98M  
3041-2  
G
.18  
5.17  
5.85  
9.82  
~.04  
10.00  
G3041-2  
2-20-98M  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-  
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in  
DH-10  
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-9  
G-9  
ELECTRICAL DIAGRAMS  
Display Board Layout (L10139-1)  
DH-10  
L10139-1  
5-2-97  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-10  
G-10  
ELECTRICAL DIAGRAMS  
Encoder Board Layout (M17797-1)  
ENCODER  
M17797-1  
ITEM  
REQ'D  
PART NO  
DESCRIPTION  
4-7-95  
M17797-1  
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 provided  
for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design  
and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.  
DH-10  
M17797-1  
4-7-95  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTES  
DH-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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