Operator s Manual LN-5 TM PIPE For use with machines having Code Numbers: 779 Save for future reference Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Date Purchased Code: (ex: 0859) Serial: (ex: U0605345) IM009 Issue D ate 04/0 Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELECTRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received. 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 thoughtful 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. WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life. CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. KEEP YOUR HEAD OUT OF THE FUMES. DON T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials. USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area. IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below). USE NATURAL DRAFTS or fans to keep the fumes away from your face. If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked. WEAR CORRECT EYE, EAR & BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.). PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots. PROTECT others from splatter, flash, and glare with protective screens or barriers. IN SOME AREAS, protection from noise may be appropriate. BE SURE protective equipment is in good condition. Also, wear safety glasses in work area AT ALL TIMES. SPECIAL SITUATIONS DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous. DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases. Additional precautionary measures PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall. BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT. Safety 0 of 04-5/6/08
SAFETY SECTION A: WARNINGS CALIFORNIA PROPOSITION 65 WARNINGS WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects, or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an exposed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system. Do not idle the engine except as necessary. For more information go to www.p65 warnings.ca.gov/diesel WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code 549.5 et seq.) WARNING: Cancer and Reproductive Harm www.p65warnings.ca.gov ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of Safety in Welding & Cutting - ANSI Standard Z49. from the American Welding Society, P.O. Box 35040, Miami, Florida 3335 or CSA Standard W7.-974. A Free copy of Arc Welding Safety booklet E05 is available from the Lincoln Electric Company, 80 St. Clair Avenue, Cleveland, Ohio 447-99. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. FOR ENGINE POWERED EQUIPMENT..a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running..b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors..c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated..d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment..e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts..f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running..g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate..h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding..c. Exposure to EMF fields in welding may have other health effects which are now not known..d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:.d.. Route the electrode and work cables together - Secure them with tape when possible..d.. Never coil the electrode lead around your body..d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side..d.4. Connect the work cable to the workpiece as close as possible to the area being welded..d.5. Do not work next to welding power source. Safety 0 of 04-5/6/08
SAFETY ELECTRIC SHOCK CAN KILL. 3.a. The electrode and work (or ground) circuits are electrically hot when the welder is on. Do not touch these hot parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: Semiautomatic DC Constant Voltage (Wire) Welder. DC Manual (Stick) Welder. AC Welder with Reduced Voltage Control. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically hot. 3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded. 3.e. Ground the work or metal to be welded to a good electrical (earth) ground. 3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. 3.g. Never dip the electrode in water for cooling. 3.h. Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders. 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see It ems 6.c. and 8. 4.a. 4.b. 4.c. ARC RAYS CAN BURN. 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. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 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. FUMES AND GASES CAN BE DANGEROUS. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding hardfacing (see instructions on container or SDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel. 5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits. 5.c. 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. 5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. 5.e. Read and understand the manufacturer s instructions for this equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer s safety practices. SDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item.b. Safety 03 of 04-5/6/08
SAFETY WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to Safety in Welding and Cutting (ANSI Standard Z49.) and the operating information for the equipment being used. 6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been cleaned. For information, purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, AWS F4. from the American Welding Society (see address above). 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. 6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area. 6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. 6.h. Also see item.c. 6.I. Read and follow NFPA 5B Standard for Fire Prevention During Welding, Cutting and Other Hot Work, available from NFPA, Batterymarch Park, PO box 90, Quincy, MA 0690-90. 6.j. Do not use a welding power source for pipe thawing. CYLINDER MAY EXPLODE IF DAMAGED. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 7.c. Cylinders should be located: Away from areas where they may be struck or subjected to physical damage. A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. 7.d. Never allow the electrode, electrode holder or any other electrically hot parts to touch a cylinder. 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, Precautions for Safe Handling of Compressed Gases in Cylinders, available from the Compressed Gas Association, 450 George Carter Way Chantilly, VA 05. FOR ELECTRICALLY POWERED EQUIPMENT. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer s recommendations. Refer to http://www.lincolnelectric.com/safety for additional safety information. Safety 04 of 04-5/6/08
v SAFETY v Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 5 Dec 004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 004/08/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-0 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment. Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome. Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment. Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment; b) radio and television transmitters and receivers; c) computer and other control equipment; d) safety critical equipment, e.g., guarding of industrial equipment; e) the health of the people around, e.g., the use of pacemakers and hearing aids; f) equipment used for calibration or measurement g) the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; h) the time of day that welding or other activities are to be carried out.
vi SAFETY vi Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure. Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations. Welding Cables The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components. Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations. Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications. Portions of the preceding text are contained in EN 60974-0: Electromagnetic Compatibility (EMC) product standard for arc welding equipment.
viii TABLE OF CONTENTS Page Installation...Section A Technical Specifications...A- Safety Precautions...A- Location...A- High Frequency Protection...A- Weld cable Sizes...A- Analog Control Cable...A-3 Cable Connections and Control Cable Connector...A-4 Shielding Gas Connection...A-4 Wire Drive Configuration...A-5 Changing The Gun Receiver Bushing...A-5 Procedure to Install Drive Rolls and Wire Guides...A-5 Pressure Arm Adjustment...A-5 Loading Spools of Wire...A-5 Gun Connections...A-5 Power Source to LN-5 PIPE Connection Diagrams...A-6, A-7 Operation...Section B Safety Precautions...B- Graphic Symbols that appear on this Machine or in this Manual...B- Definition of Welding Terms...B- General Description...B- Recommended Processes, Equipment Limitations, Recommended Power Sources...B- Case Front Controls...B-3 thru B-6 Internal Controls...B-7 Internal Controls Decription...B-8 Rear Controls...B-9 Accessories...Section C Factory Installed Equipment...C- Drive Roll Kits used...c- Accessories Used...C- thru C-4 Maintenance...Section D Safety Precautions...D- Routine Maintenance...D- Periodic Maintenance...D- Troubleshooting...Section E How to Use Troubleshooting Guide...E- Error Codes...E- Troubleshooting Guide...E-3, E-4 viii Wiring Diagram & Dimension Prints...Section F Parts Pages...P-679 Series
A- INSTALLATION TECHNICAL SPECIFICATIONS LN-5 PIPE (K64-0) A- INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 0% 40 VDC INPUT AMPERES 4A GEARING K64-0 DUTY CYCLE 60% rating 00% rating RATED OUTPUT @ 04 F (40 C) PHYSICAL DIMENSIONS INPUT AMPERES 450 35 GEARING - WIRE FEED SPEED RANGE-WIRE SIzE GMAW FCAW WFS RANGE 50 700 ipm (.3 7.7m/min) WIRE SIzES.03 /6" (0.6.6mm) WFS RANGE 50 700 ipm (.3 7.7m/min) WIRE SIzES.030-5/64 (0.8 -.0mm) HEIGHT WIDTH DEPTH WEIGHT 4.8 Inches 8.7 Inches. Inches 4 lbs (376 mm) ( mm) (589 mm) (8.6 kg) Handle folded down TEMPERATURE RANGE OPERATION: STORAGE: -40 F to 04 F (-40 C to 40 C) -40 F to 85 F (-40 C to 85 C) LN-5 PIPE
A- SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. Turn the input power OFF at the disconnect switch or fuse box before attempting to connect or disconnect input power lines, output cables or control cables. Only qualified personnel should perform this installation. Do not touch metal portions of the LN-5 PIPE work clip when the welding power source is on. Do not attach the work clip to the wire feeder. Connect the work clip directly to the work, as close as possible to the welding arc. Turn power off at the welding power source before disconnecting the work clip from the work. Only use on power sources with open circuit voltages less than 0 VDC. ------------------------------------------------------------------------ LOCATION For best wire feeding performance, place the LN- 5 PIPE on a stable and dry surface. Keep the wire feeder in a vertical position. Do not operate the wire feeder on an angled surface of more than 5 degrees. Do not submerge the LN-5 PIPE. INSTALLATION WELD CABLE SIzE A- The LN-5 PIPE is rated IP3 and is suitable for outdoor use. The handle of the LN-5 PIPE is intended for moving the wire feeder about the work place only. When suspending a wire feeder, insulate the hanging device from the wire feeder enclosure. HIGH FREQUENCY PROTECTION CAUTION Locate the LN-5 PIPE away from radio controlled machinery. The normal operation of the LN- 5 PIPE may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment. ------------------------------------------------------------------------ Table A. located below are copper cable sizes recommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop. TABLE A. RECOMMENDED CABLE SIzES (RUBBER COVERED COPPER - RATED 67 F or 75 C)** CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES AMPERES PERCENT DUTY 0 to 50Ft. 50 to 00Ft. 00 to 50 Ft. 50 to 00 Ft. 00 to 50 Ft. CYCLE (0 to5m) (5 to 30m) (30 to 46m) (46 to 6m) (6 to 76m) 00 00 5 5 50 50 50 50 300 35 350 400 400 500 60 00 0 40 & 30 30 40 60 00 60 00 60 60 00 60 4 or 5 3 3 /0 /0 /0 3/0 /0 3 3 3 /0 /0 /0 3/0 /0 /0 /0 /0 3/0 3/0 /0 /0 /0 3/0 3/0 3/0 /0 /0 /0 /0 /0 /0 /0 /0 /0 3/0 3/0 4/0 4/0 4/0 ** Tabled values are for operation at ambient temperatures of 04 F(40 C) and below. Applications above 04 F(40 C) may require cables larger than recommended, or cables rated higher than 67 F(75 C). LN-5 PIPE
A-3 CABLE CONNECTIONS There is one circular connector for the gun trigger on the front of the LN-5 PIPE. INSTALLATION SHIELDING GAS CONNECTION WARNING CYLINDER may explode if damaged. A-3 Function Pin Wiring Keep cylinder upright and chained to support. 5-pin trigger connector for push-guns only. C D A B C D E E 5 volt supply Not used Trigger 83% WFS switch 5 volt supply B A Keep cylinder away from areas where it may be damaged. Never lift welder with cylinder attached. Never allow welding electrode to touch cylinder. Keep cylinder away from welding or other live electrical circuits. BUILD UP OF SHIELDING GAS MAY HARM HEALTH OR KILL. Shut off shielding gas supply when not in use. See American National Standard z-49., "Safety in Welding and Cutting Published by the American Welding Society. ------------------------------------------------------------------------ Maximum inlet pressure is 00 psi. (6.9 bar.) LN-5 PIPE Install the shielding gas supply as follows:. Secure the cylinder to prevent it from falling.. Remove the cylinder cap. Inspect the cylinder valves and regulator for damaged threads, dirt, dust, oil or grease. Remove dust and dirt with a clean cloth. DO NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Inform your gas supplier of this condition. Oil or grease in the presence of high pressure oxygen is explosive. 3. Stand to one side away from the outlet and open the cylinder valve for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet. 4. Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. Note: if connecting to 00% CO cylinder, insert regulator adapter between regulator and cylinder valve. If adapter is equipped with a plastic washer, be sure it is seated for connection to the CO cylinder. 5. Attach one end of the inlet hose to the outlet fitting of the flow regulator. Attach the other end to the welding system shielding gas inlet. Tighten the union nuts with a wrench. 6. Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released. 7. Standing to one side, open the cylinder valve slowly a fraction of a turn. When the cylinder pressure gage stops moving, open the valve fully. 8. The flow regulator is adjustable. Adjust it to the flow rate recommended for the procedure and process being used before making a weld.
A-4 WIRE DRIVE CONFIGURATION (See Figure A.) CHANGING THE GUN RECEIVER BUSHING WARNING ELECTRIC SHOCK can kill. Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work. ------------------------------------------------------------------------ Tools required: /4" hex key wrench. Note: Some gun bushings do not require the use of the thumb screw.. Turn power off at the welding power source.. Remove the welding wire from the wire drive. 3. Remove the thumb screw from the wire drive. 4. Remove the welding gun from the wire drive. 5. Loosen the socket head cap screw that holds the connector bar against the gun bushing. Important: Do not attempt to completely remove the socket head cap screw. 6. Remove the outer wire guide, and push the gun bushing out of the wire drive. Because of the precision fit, light tapping may be required to remove the gun bushing. 7. Disconnect the shielding gas hose from the gun bushing, if required. FIGURE A. INSTALLATION A-4 8. Connect the shielding gas hose to the new gun bushing, if required. 9. Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate. Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned. 0. Tighten the socket head cap screw.. Insert the welding gun into the gun bushing and tighten the thumb screw. PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work. ------------------------------------------------------------------------. Turn power off at the welding power source.. Release the idle roll pressure arm. 3. Remove the outer wire guide by turning the knurled thumbscrews counter-clockwise to unscrew them from the feed plate. 4. Rotate the triangular lock and remove the drive rolls. THUMB SCREW GUN RECEIVER BUSHING CONNECTOR BLOCK SOCKET HEAD CAP SCREW OUTER WIRE GUIDE 5. Remove the inner wire guide. 6. Insert the new inner wire guide, groove side out, over the two locating pins in the feed plate. 7. Install a drive roll on each hub assembly secure with the triangular lock. 8. Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews. 9. Close the idle arm and engage the idle roll pressure arm. Adjust the pressure appropriately. LOOSEN TIGHTEN LN-5 PIPE
A-5 PRESSURE ARM ADJUSTMENT ELECTRIC SHOCK can kill. Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work. ------------------------------------------------------------------------ The pressure arm controls the amount of force the drive rolls exert on the wire. Proper adjustment of the pressure arm gives the best welding performance. Set the pressure arm as follows: (See Figure A.3) Aluminum wires between and Cored wires between and 3 Steel, Stainless wires between 3 and 5 6 Al Fe, CrNi Fe, CrNi WARNING FIGURE A.3 LOADING SPOOLS OF WIRE ALUMINUM WIRES CORED WIRES STEEL, STAINLESS WIRES WARNING Keep hands, hair, clothing and tools away from rotating equipment. Do not wear gloves when threading wire or changing wire spool. Only qualified personnel should install, use or service this equipment. ------------------------------------------------------------------------ Loading 0 to 5 lb. (4.5 6.8kg) Spools. A K468 spindle adapter is required for loading " (5mm) wide spools on " (5mm) spindles. Use a K468 spindle adapter for loading -/" (64mm) wide spools. INSTALLATION LN-5 PIPE A-5. Squeeze the release bar on the retaining collar and remove it from the spindle.. Place the spindle adapter on the spindle, aligning the spindle brake pin with the hole in the adapter. 3. Place the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool. An indicator mark on the end of the spindle shows the orientation of the brake tab. Be certain the wire feeds off of the spool in the proper direction. 4. Re-install the retaining collar. Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle. GUN CONNECTION WARNING ELECTRIC SHOCK can kill. Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work. ------------------------------------------------------------------------ The LN-5 PIPE comes with a K500- gun adapter installed. (See Figure A.4) To install a gun,. Turn power OFF.. Remove the thumb screw. 3. Push the gun the completely into the gun bushing. 4. Secure the gun in place with the thumb screw. 5. Connect the trigger cable from the gun to the trigger connector on the front of the feeder. Note: Not all gun bushings require the use of the thumb screw. FIGURE A.4
A-6 INSTALLATION POWER SOURCE TO LN-5 PIPE CABLE CONNECTION DIAGRAMS A-6 CV Power Sources with Stud Connectors and Remote/Local Switch (See Figure A.6) FIGURE A.6 CV-400 CV-655 DC-400 DC-600 DC-655 V450-Pro Electrode LN-5 PIPE (Across the Arc) SAE 400 with CV adapter Engine Driven welder with Wire Feed Module Ranger 50 GXT Work K# Work clip Description Place the power source Remote/Local switch in the Local position. Place CV/CC switch in the feeder in the "CV" position. K64-0 KP695-XX KP696-XX KP697-XX See magnum Literature K803- LN-5 PIPE Drive Roll Kit Welding Gun CV power Source Welding Cables CV Power Sources with Stud Connectors and no Remote/Local Switch. (See Figure A.7) Place CV/CC switch in the feeder in the "CV" position. FIGURE A.7 Ranger 50, 50 LPG Ranger 305G, 305D Ranger 0,000 Ranger 3 Phase Ranger 5GXT Ranger 5 Commander 300 Vantage 300, 400, 500 Air Vantage 500 Jumper Electrode LN-5 PIPE Work clip Work K# Description K64-0 K484* KP695-XX KP696-XX KP697-XX See Magnum Literature K803- LN-5 PIPE Jumper Plug Kit Drive Roll Kit Welding Gun CV power Source Welding Cables *If Power Source has a 4-Pin Cable connector and no Output Terminal switch. LN-5 PIPE
A-7 CV Power Source with Twist-Mate Connectors and Remote/Local Switch. (See Figure A.8) INSTALLATION FIGURE A.8 A-7 CV-305 V350-Pro Electrode LN-5 PIPE Work Work clip Place CV/CC switch in the feeder in the "CV" position. K# Description K64-0 KP695-XX KP696-XX KP697-XX See Magnum Literature K84 LN-5 PIPE Drive Roll Kit Welding Gun CV power Source Welding Cables CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) CV-50 CV-300 Jumper Electrode FIGURE A.9 LN-5 PIPE Work Place CV/CC switch in the feeder in the "CV" position. K# K64-0 KP695-XX KP696-XX KP697-XX See Magnum Literature K84- K85-95 K484 Work clip Description LN-5 PIPE Drive Roll Kit Welding Gun CV power Source Welding Cables Twist-Mate Cable Plug Jumper Plug kit LN-5 PIPE
A-8 ELECTRODE CONNECTION The LN-5 PIPE (CCC) does not include the electrode cable. The customer is to install an AWG /0 to 4/0 cable. To install:. Turn off power at the welding power source. INSTALLATION A-8 4. Route the electrode lead through the feeder as shown. 5. Assemble the bolt, leads and washers as shown. Discard the extra washers. 6. Reassemble the rear cover panel and tighten the 4 screws.. With a 5/6 nut driver, remove the 4 screws holding the rear cover panel. Lift out the cover panel. 4 SCREWS BOLT LOCK WASHER WASHER 67 LEAD ELECTRODE LEAD Route the electrode through the opening this way. 7. Tighten the strain relief. 3. Using a 3/4 open end wrench, loosen the bolt for the electrode lead connection. Use 3/4 open end wrench to loosen here. TIGHTEN HERE LN-5 PIPE
B- SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. WARNING ELECTRIC SHOCK CAN KILL. Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.. Do not touch electrically live part or electrode with skin or wet clothing. Insulate yourself from work and ground. Always wear dry insulating gloves. Do not operate with covers, panels or guards removed or open. --------------------------------------------------------------------- FUMES AND GASSES can be dangerous. Keep your head out of fumes. Use ventilation or exhaust to remove fumes from breathing zone. --------------------------------------------------------------------- WELDING SPARKS can cause fire or explosion. Keep flammable material away. --------------------------------------------------------------------- ARC RAYS can burn. Wear eye, ear and body protection. --------------------------------------------------------------------- SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN- UAL. --------------------------------------------------------------------- OPERATION B- GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL U 0 U U I INPUT POWER ON OFF WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT INPUT POWER DIRECT CURRENT OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT I OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION LN-5 PIPE
B- OPERATION B- DEFINITION OF WELDING TERMS WFS Wire Feed Speed CC Constant Current CV Constant Voltage GMAW Gas Metal Arc welding SMAW Shielded Metal Arc welding FCAW Flux Core Arc Welding GENERAL DESCRIPTION General Physical Description The LN-5 PIPE is specially engineered to be the most rugged portable wire feeder available and meets the individual welder needs. This model includes a gas solenoid for flexibility to run most wire processes. The plastic case is molded from a high impact, flame retardant plastic for durability and low weight. The patent pending design keeps the internal components protected and dry. The heart of the LN-5 PIPE is the roll MAX- TRAC drive. The patented features on the wire drive offer tool-less changing of the drive rolls and wire guides for quick spool changes. A tachometer controlled motor powers the patent pending drive rolls for smooth, steady feeding without slippage. The LN-5 PIPE has only two p.c. boards that are designed to be simple, reliable and easy to service. General Functional Description The LN-5 PIPE as designed is a simple, robust feeder. Standard features include a calibrated wire feed speed dial, step/trigger interlock switch, Gas Purge and Cold Feed. RECOMMENDED PROCESSES GMAW FCAW PROCESS LIMITATIONS GMAW-P procedures must be qualified by the customer. Across-the-Arc models are not recommended for stitch or spot welding. EQUIPMENT LIMITATIONS The duty cycle of the wire feeder is 450A, 60%; 35A, 00%. Duty cycle is based upon the amount of welding performed in a 0 minute period. The maximum spool size is 45 lb, " diameter. Maximum FCAW gun length is 5 ft. Maximum GMAW gun length is 5 ft. K330- Timer Kits do not work with the feeder. Use K330- kits. Push-pull guns do not work with the wire feeder. The digital displays do not show preset voltage. Does not include an electrode cable. RECOMMENDED POWER SOURCES CV-50 CV-300 CV-305 CV-400 CV-655 DC-400 DC-600 DC-655 Invertec V-350 PRO Invertec V-450 PRO Multi-Weld 350 Ranger 0,000 Ranger 3 Phase Ranger 5 Ranger 5 GXT Ranger 50 Ranger 50 GXT Ranger 305 SAE-400 Pipeliner 00G Classic 300 Vantage 300 Vantage 400 Vantage 500 Air Vantage 500 Big Red s Eagle 0,000 Plus Classic s LN-5 PIPE
B-3 (See Customer Assistance Policy in the front of this Instruction Manual) CASE FRONT CONTROLS (See Figure B.) FIGURE B. OPERATION 7 WIRE FEED SPEED KNOB B-3 Wire Feed Speed, CV Operation When Across the Arc models are operated with CV power sources, the wire feed speed will remain a constant value, independent of arc voltage changes, as along as the arc voltage does not drop below the values per the following table. 3 4 5 8 9 0 83% Wire Feed Speed The 83% wire feed speed reduces the wire feed speed to 83% of the original set value when activated. For example, if the original wfs = 00 in/min, the feeder will regulate to 0.83 x 00 = 66 in/min. The 83% trigger requires a gun with a dual procedure switch. This feature is often useful when welding pipe, and a cooler procedure is required on the bottom portion. CV OPERATION Minimum Arc Volts Maximum WFS 6 5 V 7 V V 4 V 7 V 80 340 440 50 600 ITEM DESCRIPTION THERMAL LED, MOTOR OVERLOAD Wire Feed Speed/Amperage Display Wire Feed Speed LED 3 Amperage LED 4 Wire Feed Speed Knob 5 5 pin gun trigger connector 6 Work Clip Connection 7 Thermal LED 8 Voltage Display 9 Voltage LED 0 Set-up Push Button The thermal light illuminates when the wire drive motor draws too much current. If the thermal light illuminates, the wire drive will automatically shutdown for up to 30 seconds to allow the motor to cool. To start welding again, release the gun trigger, inspect the gun cable, liner (and conduit). Clean and make repairs as necessary. Start welding again when the problem has been safely resolved. For best results, keep the gun cable and conduit as straight as possible. Perform regular maintenance and cleaning on the gun liner, conduit and gun. Always use quality electrode, such as L-50 or L-56 from Lincoln Electric. LN-5 PIPE
B-4 POWER-UP SEQUENCE OPERATION SET-UP MENU B-4 All of the LED s will briefly illuminate during power-up. If the gun trigger is activated during power up, the feeder will not operate until the gun trigger is released. WIRE FEED SPEED/AMPERAGE DISPLAY Idle The left display shows the preset wire feed speed. The right display shows OCV. The wire feed speed LED is lit. WFS Preparation for WFS Calibration: Place the CV/CC switch in CV. Set the display to the desired wire feed speed (example: 400 inches per minute) Measure the actual wire feed speed (example: 405 inches per minute) Place the WFS knob in the o clock position. A VERTISSEMENT A Welding The value in the left display will be either amps or actual wire feed speed, depending upon the selection chosen in the set-up menu. The corresponding LED below the display will light. Note that actual WFS may not match preset WFS, if welding at low voltages with high wire feed speeds. The right display shows the arc voltage. If the wire feeder is connected for electrode negative welding, then the voltage display shows a minus sign. V Preparation for Amperage Calibration: Connect the feeder to a power source and grid. Adjust the power source and grid to the desired amperage. (example: 0 Amps) Record the amperage display on the wire feeder. (example: 0 amps) To enter the set-up menu, use paper clip to press the small button located on the case front. AMPS VOLTAGE BUTTON AVERTISSEMENT A V After Welding The display continues to hold the value of the amperage or WFS and arc voltage for five seconds after welding stops. The amperage or WFS and voltage displays flash. LN-5 PIPE
B-5 WIRE FEED SPEED UNITS To change the wire feed speed units: OPERATION B-5 WFS CALIBRATION WITH DIGITAL METERS Rotate the WFS knob to the left to use inches/minute for the wire feed speed units. US OO A V LN-5 PIPE, CCC OO WFS To calibrate the wire feed speed, before entering the set-up menu. When first entering WFS Calibration, the calibration factor displayed is based upon the position of the knob and does not reflect the actual calibration factor stored in memory. Rotate the WFS knob to the right to use meters/minute for the wire feed speed units. Then rotate the WFS knob to the o clock position. Press the set-up button again to enter the Run-In menu. RUN-IN EU r o O O A LN-5 PIPE, CCC O O WFS V Set the display to the desired wire feed speed (example: 400 inches per minute) Measure the actual wire feed speed (example: 405 inches per minute) While in the set-up menu, adjust the calibration factor as follows: Actual WFS =Calibration Factor Example 405 =.0 Set WFS 400 Press the set-up button. Run-in refers to the wire feed speed during the time from when the trigger is pulled to when an arc is struck. When Run-in is ON, the wire feed speed is reduced until an arc is struck. Factory setting is Run-In OFF. Model LN-5 PIPE Run-in Wire Feed Speed 50 in/min When Run-in is OFF, the wire feed speed is the same as the welding wire feed speed. Turn Run-In OFF for fast, crisp starts, especially when running with.035 or.045 (0.9 or.mm) solid steel wires at high wire feed speeds. To change the Run-in setting: Rotate the WFS knob to the left to turn Run-In OFF. r u n OO A OF F V LN-5 PIPE, CCC OO WFS Rotate the WFS knob to the right to turn Run-In ON. r u n OO A On V Then rotate the WFS knob to the o clock position. LN-5 PIPE, CCC OO WFS Press the set-up button again to enter the WFS cali- LN-5 PIPE
B-6 LEFT DISPLAY SELECTION OPERATION AMPERAGE CALIBRATION B-6 The left display can show either amperage or actual WFS during welding. Note that actual WFS is not the same as preset WFS. For example, the preset WFS may be set to 400 ipm, but the arc voltage is only 5V. The actual WFS will be approximately 80 ipm because there is not enough arc voltage to run at 400 ipm. To change the left display reading: Rotate the WFS knob to the left to display amperage (current). Rotate the WFS knob to the right to display actual WFS. Then rotate the knob to the o clock position. Press the set-up button. Measurements for adjusting the Amperage calibration must be made before entering the set-up menu. When first entering Amperage Calibration, the calibration factor displayed is the value in memory. If the knob is rotated, the calibration factor changes based upon the position of the knob. If no changes are being made to the calibration, then press the set-up button to enter Display Hold. While in the set-up menu, adjust the calibration factor as follows: Power Source Amperage 0 =Calibration Factor Example: =.0 Feeder Amperage 0 Press the set-up button again to enter the Amperage Calibration. d I SP OO A c u r r V d I SP OO A FEEd V Rotate the knob to the o clock position, then press the set-up button to enter Display Hold. LN-5 PIPE, CCC LN-5 PIPE, CCC DISPLAY HOLD OO WFS WFS KNOB RANGE For wire feeders equipped with standard torque gearing, the WFS range can be changed to provide better knob sensitivity at low wire feed speeds. This is often useful when welding with Innershield wires. To change the WFS knob range: OO WFS Rotate the WFS knob to the left for the low wire feed speed range of 40 405 ipm Rotate the WFS knob to the right for the high wire feed speed range of 40 75 ipm. After welding, the LN-5 will hold the last values from welding on the display. The values will continue to be displayed until the hold period is finished, the trigger is pulled again, or the cold feed/gas purge switch is activated. To change the Display Hold time: Rotate the WFS knob to the left for 5 seconds Hold. Rotate the WFS knob to the right for 300 seconds Hold Press the set-up button to exit the set-up menu. SPd OO A V I o SPd OO A V H I LN-5 PIPE, CCC LN-5 PIPE, CCC OO WFS OO WFS Then rotate the knob to the o clock position. Press the set-up button. LN-5 PIPE
B-7 INTERNAL CONTROLS OPERATION FIGURE B. B-7 3 4 5 6 7 8 9 0 ITEM DESCRIPTION Step Trigger Interlock Switch Pressure Adjustment Arm 3 Optional Timer Kit (See Accessories Section) 4 Spool Retainer 5 Spindle Brake 6 Gun Bushing 7 Thumb Screw for securing the welding Gun 8 Socket Head Cap Screw for securing the Gun Bushing 9 Drive Hubs 0 Inlet Wire Guide Cold Feed Pushbutton LN-5 PIPE
B-8 INTERNAL CONTROLS DESCRIPTION (See Figure B.) OPERATION B-8 Step - Trigger Interlock Switch The Step - Trigger Interlock switch changes the function of the gun trigger. Step trigger operation turns welding on and off in direct response to the trigger. Trigger Interlock operation allows welding to continue when the trigger is released for comfort on long welds. Place the toggle switch in the DOWN position for Step operation or in the UP position for Trigger Interlock operation. Step Trigger Step trigger operation is the most common. When the gun trigger is pulled, the welding power source energizes the electrode output and the wire feeder feeds wire for welding. The power source and wire feeder continue welding until the trigger is released. Trigger Interlock Trigger Interlock operation provides for operator comfort when making long welds. When the gun trigger is first pulled, the welding power source energizes the output and the wire feeder feeds wire for welding. The gun trigger is then released while the weld is made. To stop welding, the gun trigger is pulled again, and when it is released the welding power source output turns off and the wire feeder stops feeding wire. COLD FEED PUSHBUTTON (See Figure B.) When cold feeding, the wire drive will feed electrode but neither the power source nor the gas solenoid will be energized. Adjust the speed of cold feeding by rotating the WFS knob. Cold feeding, or "cold inching" the electrode is useful for threading the electrode through the gun. LN-5 PIPE
B-9 REAR CONTROLS: OPERATION B-9 3 ITEM DESCRIPTION Gas Purge Pushbutton Shielding Gas Inlet 3 Electrode Lead GAS PURGE PUSHBUTTON The gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on. The Gas Purge switch is useful for setting the proper flow rate of shielding gas. Flow meters should always be adjusted while the shielding gas is flowing. LN-5 PIPE
C- FACTORY INSTALLED EQUIPMENT K500- Gun Receiver Bushing. ACCESSORIES C- DRIVE ROLL KITS (See Parts Pages) K803- K840-xx Work and Feeder Cables Package. Weld Power Cable, Twist-Mate to Lug. Includes: Twist-Mate to Lug /0 cable 4' (.m) long with Ground Clamp, and Twist- Mate to Lug /0 Cable 9' (.7m) long. Includes: Twist-Mate to Lug, /0 cable of length "xx". K84-xx Weld Power Cable, Lug to Lug. Includes: Lug to Lug, 3/0 Cable of length "xx" for lengths up to 60' (8.3m). Lug to Lug, 4/0 Cable of length "xx" for lengths greater than 60' (8.3m). K484 Jumper Plug Kit. Includes: 4 pin circular connector with jumper for leads - 4. For use in power sources for turning the weld terminals "ON" at all times. K330- Timer Kit Includes: Panel and harness for adjusting preflow, burnback and postflow times K596- Plastic Case Includes: a complete engineered plastic case. LN-5 PIPE
C- ACCESSORIES C- K90- Ground Clamp Includes: One 300 Amp Ground Clamp. K90- Ground Clamp Includes: One 500 Amp Ground Clamp. K500- Gun Receiver Bushing (for guns with K466- Lincoln gun connectors; Innershield and Subarc guns) Includes: Gun receiver bushing, set screw and hex key wrench. K500- Gun Receiver Bushing (for guns with K466-, K466-0 Lincoln gun connectors; Magnum 00/300/400 guns and compatible with Tweco #-#4) Includes: Gun receiver bushing with hose nipple, set screw and hex key wrench. K500-3 Gun Receiver Bushing (for guns with K63-7 Lincoln gun connectors; Magnum 550 guns and compatible with Tweco #5) Includes: Gun receiver bushing with hose nipple, set screw and hex key wrench. LN-5 PIPE
C-3 ACCESSORIES C-3 K500-4 Gun Receiver Bushing (for gun with K466-3 Lincoln gun connectors; compatible with Miller guns.) Includes: Gun receiver bushing with hose nipple, set screw and hex key wrench. K500-5 Gun Receiver Bushing (compatible with Oxo guns.) Includes: Gun receiver bushing with hose nipple, 4 guide tubes, set screw and hex key wrench. K435 Spindle Adapter, for mounting 4 lb. (6.4 kg) Innershield Coils on in (5 mm) spindles. Includes: Spindle Adapter made from coil retainers. (Electrode not included.) K468 K590-6 Spindle Adapter, for mounting 8in (03mm) diameter spools on in (5 mm) spindles. Water Connection Kit (for European and Control cable models only) Includes: Spindle Adapters, one for " wide spools and the other for 3" wide spools. Includes: hoses with female quick connectors at each end, male connectors for 3/6" ID hose, male connectors for _" ID hose, and mounting hardware. K586- Deluxe Adjustable Gas Regulator Includes: Deluxe Gas Regulator for Mixed Gases, Adapter for CO and 0' (3.0m) Hose. K83 Wire Feed Speed Meter Includes: A wire feed speed meter with digital display. LN-5 PIPE
D- SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work. ----------------------------------------------------------------------- ROUTINE MAINTENANCE MAINTENANCE D- Check weld cables, control cables and gas hoses for cuts. Clean and tighten all weld terminals. PERIODIC MAINTENANCE Clean drive rolls and inner wire guide and replace if worn. Blow out or vacuum the inside of the feeder. LN-5 PIPE
E- TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE E- 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. LOCATE PROBLEM (SYMPTOM). Look under the column labeled PROBLEM (SYMP- TOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Step 3. RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility. If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility. Step. POSSIBLE CAUSE. The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom. WARNING ELECTRIC SHOCK can kill. Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes. Only qualified personnel should perform maintenance work. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. LN-5 PIPE
E- PROBLEMS (SYMPTOMS) TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE CAUSE ERROR CODES RECOMMENDED COURSE OF ACTION E- Err 8 Err 8 Motor overload, long term. Motor overload, short term.. The wire drive motor has overheated.. Check that the electrode slides easily through the gun and cable.. Remove tight bends from the gun and cable. 3. Check that the spindle brake is not too tight. 4. Verify a high quality electrode is being used. 5. Wait for the error to reset and the motor to cool (approximately minute).. The wire drive motor current draw. Check that motor can turn freely has exceeded limits, usually when idle arm is open. because the motor is in a locked. Verify that the gears are free of rotor state. debris and dirt. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. LN-5 PIPE
E-3 PROBLEMS (SYMPTOMS) The feeder does power up - no display, no cold feed. The wire feeder power up but there is no output when the trigger is pulled. The shielding gas is flowing and the drive rolls turn. TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE CAUSE Output Problems. The work sense lead is disconnected or is a poor electrical connection. (Across the arc models). The power source is OFF. 3. The circuit breaker for the wire feeder on power source have tripped. (control cable models) 4. The control cable may be loose or damaged. (control cable models). The contactor coil connections are loose.. The contactor has failed. RECOMMENDED COURSE OF ACTION E-3. Connect the work sense lead to the work in a location free of dirt, rust and paint.. Turn ON the power source. 3. Reset the circuit breakers. 4. Tighten, repair or replace the control cable.. Verify the contactor coil connections.. Replace the contactor. No shielding gas.. The gas supply is OFF or empty.. The gas hose is cut or crushed. 3. The flow meter valve is closed. 4. Dirt or debris is in the solenoid. 5. There is a loose solenoid connection. 6. The solenoid has failed.. Verify the gas supply is ON and flowing.. Route the gas hose so it avoids sharp corners and make sure nothing is on top of it. Repair or replace damaged hoses. 3. Open the flow meter valve. 4. Apply filtered shop at 80psi to the solenoid to remove dirt. 5. Remove the cover and check that all connections are in good condition. Inconsistent wire feeding or wire not feeding but drive rolls turning.. The gun cable is kinked and/or twisted.. The wire is jammed in the gun and cable. 3. The gun liner is dirty or worn. 4. The electrode is rusty or dirty. 5. The contact tip is partially melted or has spatter. 6. Improper gun liner, tip, drive rolls and/or inner wire guide.. Keep the gun cable as straight as possible. Avoid sharp corners or bends in the cable.. Remove the gun from the wire feeder and pull the jammed wire out of the gun and cable. 3. Blow dirt out of the liner with low pressure (40psi or less). Replace the liner if worn. 4. Use only clean electrode. Use quality electrode, like L-50 or L-56 from Lincoln Electric. 5. Replace the contact tip. 6. Verify the proper parts are installed. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. LN-5 PIPE
E-4 PROBLEMS (SYMPTOMS) TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION E-4 Output Problems 7. Incorrect tension arm pressure on 7. Adjust the tension arm per the the drive rolls. Instruction Manual. Most electrodes feed well at a tension arm setting of "3". 8. The spindle brake is too tight. 8. Verify the spool of wire moves with minimal effort. 9. Worn drive roll. 9. Replace the drive rolls if worn or filled with dirt. Wire feed speed consistently operates at the wrong value. The speed changes when the wire feed speed knob is adjusted. The wire feed speed stuck at 00-300 in/min and there is no change when the wire feed speed knob is adjusted.. The jumper lead for normal speed/extra torque is connected improperly.. The wrong gear is installed in the wire drive. 3. The brushes on the motor are worn.. The tachometer is connected improperly.. The tachometer has failed.. Properly connect the normal speed/extra torque jumper.. Install the proper pinion gear in the wire drive. 3. Replace the motor/gearbox assembly.. Verify all of the tachometer leads are properly connected.. Replace the motor and tachometer assembly. Variable or "hunting" arc.. Wrong size, worn and/or melted contact tip.. Worn work cable or poor work connection. 3. Wrong polarity. 4. The gas nozzle is extended beyond the contact tip or the wire stickout is too long. 5. Poor gas shielding on processes requiring gas.. Replace the contact tip.. Verify all work and electrode connections are tight and that the cables are in good condition. Clean/replace as necessary. 3. Adjust polarity to the recommended procedure. 4. Adjust the gas nozzle and shorten the stickout to 3/8 to / inches. 5. Check gas flow and mixture. Remove or block sources of drafts. When the trigger is pulled, the wire feeds slowly. The Run-In switch is ON Use the set-up Push-button to turn Run-in OFF. Poor arc starts with sticking or "blast-offs", weld porosity, narrow and ropy looking bead.. Improper procedures or techniques.. See " Gas Metal Arc Welding Guide" (GS-00). CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. LN-5 PIPE
F- DIAGRAMS F- LN-5 PIPE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
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Index of Sub Assemblies - 779 KEY PART NUMBER DESCRIPTION QTY INDEX OF SUB ASSEMBLIES AR P-679-B. MISCELLANEOUS ITEMS AR P-679-C FRONT PANEL ASSEMBLY AR P-679-D CONTROL BOX ASSEMBLY AR 3 P-679-E SPINDLE & MAST ASSEMBLY AR 4 P-679-F WIRE DRIVE ASSEMBLY AR 5 P-679-G CASE ASSEMBLY AR Printed 0//05 at 08:06:5. Produced by Enigma. P-679-A LN-5 Pipe - 779
Printed 0//05 at 08:06:5. Produced by Enigma. Index of Sub Assemblies - 779 P-679-A.jpg LN-5 Pipe - 779
Miscellaneous Items KEY PART NUMBER WIRING DIAGRAM QTY Printed 0//05 at 08:06:5. Produced by Enigma. 9SG6334- DESCRIPTION LN-5 Pipe - 779 3
No Image 4 Printed 0//05 at 08:06:5. Produced by Enigma. Miscellaneous Items LN-5 Pipe - 779