Lincoln Electric IM812-A manual

LN-35 C V/CC SEMIA UTOMA TIC WIRE FEEDER OPERA TOR’S MANUAL IM812-A January, 2005 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 EQUIPM[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y 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 C[...]

iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page INSTALLATION SECTION ......................................................................................................................A Technical Specifications .....................................................................................................................A-1 Safety Precautions ..............[...]

A-1 INST ALLA TION LN-35 A-1 TEMPERA TURE RANGE OPERA TION: - 40 o C to +40 o C (- 40 o F to +104 o F) STORAGE: - 40 o C to +85 o C (- 40 o F to +185 o F) OPERA TING ARC VOL T AGE Constant Voltage (CV) or 15-40 VDC (110VDC Maximum OCV) Constant Current (CC) RA TED CURRENT Rated current 500 Amps 60% Duty Cycle WIRE SPEED RANGE 50 – 500 Inches Per [...]

A-2 INST ALLA TION LN-35 A-2 ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off at the fuse box before working in the terminal strip. • Only qualified personnel should install, u[...]

A-3 INST ALLA TION LN-35 A-3 c. Set ELECTRODE POLARITY switch to constant voltage polarity required by electrode. d. Set toggle switch to “Constant Voltage” and set the Constant Voltage Control on welder and the portable field control on #5 for initial start. SA-200, —250 OR SAE-300, —400 (WITH CV ADAPTER) a. For electrode negative welding,[...]

A-4 INST ALLA TION LN-35 A-4 WELD CABLE CONNECTION The size of the electrode cable and work cable must be sufficient for the maximum weld current and total cable length to be used. Refer to table A.1. TABLE A.1 Total Cable Length Weld Current 60% Duty Cycle 50’-100’ 100’-150’ 150’-200’ 200’-250’ 200Amps 2 AWG 2 AWG 1 AWG 1/0 300Amps[...]

B-1 OPERA TION LN-35 B-1 ELECTRIC SHOCK can kill. • Do not touch electrically live part or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulat- ing gloves. ARC RAYS can burn. • Wear eye, ear and body protection. ------------------------------------------------------------------ FUMES AND [...]

B-2 OPERA TION B-2 LN-35 TO MOUNT A 50 OR 60 LB COIL: 1. To remove the wire reel from its shaft. 2. Lay the reel flat on the floor. Loosen the spinner nut and remove the cover plate. See Figure B.1. 3 . Place the coil of electrode on the reel so it unwinds as the reel rotates clockwise. DO NOT cut the tie wires at this time. 4. Be sure the coil is [...]

B-3 OPERA TION B-3 e. Press the gun trigger and push the electrode until it just enters the drive roll. When inching with gun trigger, the electrode and drive mechanism are always “hot” to work and ground. --------------------------------------------------------------------- f. Inch the electrode through the gun. IDLE ROLL PRESSURE SETTING The [...]

B-4 OPERA TION B-4 LN-35 PRESETTING WIRE FEED SPEED The LN-35 permits accurate presetting of the desired wire feed speed, before welding, in both CV and CC wire feed modes. SETTING CONSTANT WIRE FEED SPEED ( C V MODE) a. Set Wire Feed Mode switch to CV position. b . Set Wire Feed dial to the desired wire feed speed on the selected calibrated dial r[...]

B-5 OPERA TION B-5 MAKING A WELD SETUP a. 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.” b. Check that the LN-35 is properly connected to the power source for the polarity and process to be used, and appropriate pow[...]

B-6 OPERA TION B-6 a . Cut the electrode within approximately 3/8”(9.5mm) of the end of the contact tip for solid wire and within approximately 3/4”(19.1mm) of the extension guide for cored wire. b. Position electrode over joint. End of electrode should be slightly off the work. c . Lower welding helmet, close gun trigger, and begin welding. Ho[...]

B-7 OPERA TION B-7 CC (formerly VV) power sources, on the other hand, permit the arc voltage to decrease with increases in welding current. The output characteristics of these power sources can range from a “drooping slope,” which provide minor arc voltage changes with weld current variations, to “steep slope” which provide broad voltage ch[...]

D-1 MAINTENANCE D-1 LN-35 SAFETY PRECAUTIONS Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. 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.[...]

D-2 MAINTENANCE D-2 ADJUSTING SPEED SENSOR MODULE The LN-35 Speed Sensor Module is a three lead Hall Effect switch device encased in an externally threaded housing which is screwed into a mounting plate on the motor side of the wire drive gearbox. Proper positioning of this module is critical to proper operation of the LN-35 wire feed speed control[...]

E-1 TROUBLESHOOTING E-1 LN-35 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. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible m[...]

E-2 TROUBLESHOOTING E-2 LN-35 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS (SYMPTOM[...]

E-3 TROUBLESHOOTING E-3 LN-35 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS (SYMPTOM[...]

F-1 DIAGRAMS F-1 LN-35 632 633 631 10KW R1 WIRE SPEED CONTROL RHEOSTAT S3 S1 TO WORK CABL E BLACK POS 667 621 NEG A B C D E 622A 500A J5 TRIGGER CONNECTOR 7 * * J3 J14 3 2 1 4 2 1 3 4 621 500A 667 622A } } * * J2 J1 3 6 1 4 10 8 11 2 9 509 632 523 522 633 523 524 631 BLACK BLUE RED 524 523 509 V V CV WHI T E 539 BLACK 541 BLACK RED BLUE HALL EFFECT[...]

NOTES LN-35[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

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