RETURN TO MAIN INDEX
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
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
v
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
K1496-1∆ DH-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)
K1497-2◊ 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)
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 10KΩ poten-
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 “Memory”Voltmeter
When the welding gun trigger is activated, the top DH-
10 display reads actual welding voltage from 0.0 to
60.0 VDC with automatic polarity indication 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
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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
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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.
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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.
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D-4
D-4
MAINTENANCE
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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
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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
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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
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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
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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.
---------------------------------------------------------------------------------------------------------
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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.
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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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