Lincoln Electric LF-72 WIRE FEEDER IM847-D manual

• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • LF- 72 WIRE FEEDER OPERA TOR’S MANUAL IM847-D March, 2010 Safety Depends on You L i n c o l n a r c w e l di[...]

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 R A Y S can b urn. 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 [...]

iii SAFETY iii FOR ELECTRIC ALL Y pow ered 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. Na[...]

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 T ABLE OF CONTENTS T T h h a a n n k k Y Y o o u u 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 a[...]

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

vii T ABLE OF CONTENTS LF-72 vii Page Maintenance ....................................................................................................Section D Safety Precautions .......................................................................... ......................D-1 Routine Maintenance...................................................[...]

A-1 INST ALLA TION LF-72 A-1 TECHNICAL SPECIFICA TIONS : LF-72 Wire Feeder SPEC.# TYPE WIRE FEED SPEED RANGE  Dimensions do not include wire reel. Wire Size LF-72 Speed Solid Cored K2327-1 K2327-4 K2327-2 Bench Model 50-800 IPM .023 - 1/16 in. .035 - 5/64 in K2327-5 Standard Duty (1.27-20.3 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm) K2327-3 K2327-6 Benc[...]

A-2 INST ALLA TION LF-72 A-2 SAFETY PRECAUTION LOCA TION The LF-72 may be placed on a bench or mounted on top of a welding power source. Place the LF-72 in a clean and dry location. Do not stack the LF-72. ELECTRIC SHOCK can kill. • Only qualified personnel shou ld perform this installation. • T u r n o f f t h e i n p u t p o w e r t o t h e p[...]

A-3 INST ALLA TION LF-72 A-3 BENCH MOUNT The LF-72 mounts in a variety of configurations. As shipped from the factory, the LF-72 is suitable for bench mounting or placing directly on top of the weld- ing power source (CV-xxx and DC-xxx product family only). SWIVEL MOUNT Both the standard duty bench model and heavy duty bench model may be mounted on[...]

A-4 INST ALLA TION LF-72 A-4 SAFETY PRECAUTION ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn off the input power to the power source at the disconnect switch or fuse box before work- ing on this equipment. Turn off the input power to any other equipment connected to the weld- ing system at the disc[...]

A-5 INST ALLA TION LF-72 A-5 COAXIAL WELD CABLES Coaxial welding cables are specially designed welding cables for pulse welding or STT welding. Coaxial weld cables feature low inductance, allowing fast changes in the we ld current. Regular cables have a higher inductance which may distort the pulse or STT wave shape. Inductance becomes more severe [...]

A-6 INST ALLA TION LF-72 A-6 ANALOG CONTROL CABLE CONTROL CABLE CONNECTI ONS • All control cables can be connected end to end to extend their length. The control cable connecting the wire feeder to the power source is specially made for the welding envi- ronment. The wire feeder power requires overcurrent protec- tion. Connect the wire feeder onl[...]

A-7 INST ALLA TION LF-72 A-7 ANALOG MILLER CONTROL CABLE ADAPTER K2335-1 This Lincoln Electric wire feeder may be mounted to a limit- ed number of Miller Electric power sources. The Miller power source must have the amphenol pin definition shown in the table below for proper operation of the wire feeder. Operation of Lincoln wire feeders on Miller [...]

WELDING GUN/WIRE FEEDER TRIGGER CONNECTOR Wire Feeder Pin Function A Gun Trigger B- C Common D- E- HIGH FREQUENCY PROTECTIO N Locate the LF-72 away from radio controlled machin- ery. The normal operation of the LF-72 may adverse- ly affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment W el d [...]

LF-72 LF-72 A-9 INST ALLA TION LF-72 A-9 WELDING GUNS, TORCHES AND ACCES- SORIES GUN RECEIVER BUSHING The LF-72 wire feeder comes with a K1500-2 gun receiver bushing. MAGNUM GUN AND CABLE ASSEMBLIES The LF-72 wire feeder model will accept a number of optional gun and cable assemblies. An example of installing the Gun and Cable is shown in Figure A.[...]

WIRE DRIVE CONFIGURA TION (See Figure A.5) Changing the Gun Receiver Bushing ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch or fuse box before attempting to connect or discon- nect input power lines, output cables or control cables. • Only qualified personnel should perform this installation. --------------------[...]

A-11 INST ALLA TION LF-72 A-11 PRESSURE ARM ADJUSTMENT ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before instal- lation 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 an[...]

3. 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. Loading 30 lb. (13.6 kg) Readi-Reels (See Figure A.9) A K363-P Readi-Reel adapter is required for loading these spools on 2" (51mm) spindles. 1. Squeeze the release bar on the retaining collar and [...]

A-13 INST ALLA TION LF-72 A-13 WELD WIRE ROUTING The electrode supply may be either from reels, Readi- Reels, spools, or bulk packaged drums or reels. Observe the following precautions: a) The electrode must be routed to the wire drive unit so that the bends in the wire are at a mini- mum, and also that the force required to pull the wire from the [...]

A-14 INST ALLA TION LF-72 A-14 SHIELDING GAS CONNECTION CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder aw ay from welding or other live el[...]

A-15 INST ALLA TION LF-72 A-15 INST ALLING ELECTRODE CONDUIT KITS ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch before working on this equipment. • Do not touch electrically hot parts. ------------------------------------------------------------------------ Electrode conduit is used when feeding wire drums, from[...]

A-16 INST ALLA TION LF-72 A-16 ALUMINUM WIRE PREP ARA TIONS ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch before working on this equipment. • Do not touch electrically hot parts. ------------------------------------------------------------------------ Welding with aluminum filler wires requires extra care. Alumi[...]

A-17 INST ALLA TION LF-72 A-17 BENCH MODEL ST ANDARD DUTY BENCH MODEL HEA VY DUTY BASE MODEL[...]

A-18 INST ALLA TION LF-72 A-18 TYPICAL SYSTEM CONFIGURA TIONS The LF-72 is capable of welding with many different welding processes. These processes may require reconfigur- ing the LF-72 with other products that may or may not be included with the model you purchased. Use the Table 1 and 2 below to identify the basic items which are included in the[...]

B-1 OPERA TION B-1 LF-72 COLD FEED POSITIVE OUTPUT NEGA TIVE OUTPUT PROTECTIVE GROUND W ARNING OR CAUTION DANGEROUS VOL T AGE SHOCK HAZARD WELDING FUMES EXPLOSION GAS INPUT WORK CONNECTION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, [...]

B-2 OPERA TION B-2 LF-72 COMMON WELDING ABBREVIA TIONS WFS • Wire Feed Speed CV • Constant Voltage GMAW (MIG) • Gas Metal Arc Welding FCAW (Cable Innershield or Outershield) • Flux Core Arc Welding PRODUCT DESCRIPTION General Physical Description The LF-72 is optimized for .035 through .045 (0.9mm through 1.2mm) GMAW welding. The powerful 2[...]

B-3 OPERA TION B-3 ITEM DESCRIPTION 1 Location for Optional Remote Voltage Control (See Accessory Section For Kit Number) . 2 Location for Optional Burnback and Postflow Timer Kit (See Accessory Section For Kit Number). 3 Thermal LED, Motor Overload. 4 Cold Feed - Gas Purge Switch, press the switch up to feed wire with weld output off. Press the sw[...]

B-4 OPERA TION B-4 LF-72 1. REMOTE VOL T AGE CONTROL KIT The optional remote voltage control kit adjusts the arc voltage from the minimum to the maximum volt- age of the welding power source. Rotate the knob counterclockwise to reduce the arc voltage and rotate the knob clockwise to raise the arc voltage. 2. BURNBACK AND POSTFLOW TIMER KIT The opti[...]

B-5 OPERA TION B-5 Trigger Interlock Trigger Interlock operation provides for operator com- fort 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. Th e gu n tr i gg e r i s t h e n r e le a s ed wh i le th e we l d i s made. To stop welding, the gu[...]

C-1 ACCESSORIES C-1 LF-72 OPTIONAL KITS: K2329-1 K2330-1 K2328-1 K2331-1 K2332-1 K1796-xx K1803-1 K1840-xx K1841-xx K1842-xx Remote Voltage Control Kit. Timer Kit. Standard Duty Wire Reel Stand. Lift Bail Kit. Swivel Kit. (for use with Standard Duty Bench Models) Co-Axial Power Cable. Work and Feeder Cables Package. Weld Power Cable, Twist-Mate to [...]

C-2 ACCESSORIES C-2 LF-72 OPTIONAL KITS: K1797-xx K2335-1 K1520-1 K1798 K910-1 K910-2 K1500-1 K1500-2 (standard on all LF-72's) K1500-3 K1500-4 K1500-5 Control Cable. Adapter for Miller Power Sources. 42 Volt Transformer Kit. Adapter Cable for Control Cable to Terminal Strip Power Sources. Ground Clamp. Ground Clamp. Gun Receiver Bushing (for [...]

C-3 ACCESSORIES C-3 LF-72 OPTIONAL KITS: K489-7 K466-2 K613-7 K1546-1 K1546-2 K435 K468 K363P K438 K1504-1 Gun Receiver Bushing (for Lincoln Fast-Mate guns.) Magnum 200/300/400 to K1500-2 Adapter. Magnum 550 to K1500-3 Adapter Lincoln Conduit. Incoming Bushing, for Lincoln Conduit .025- 1/16" (0.6 - 1.6mm) wire. Incoming Bushing, for Lincoln C[...]

C-4 ACCESSORIES C-4 LF-72 OPTIONAL KITS: K1634-1 K1634-2 K659-1 3000290 K586-1 K1524-3 K163 K1557-1 K1556-1 K1555-1 Plastic Wire Cover for 30-44 lb. (13.6 - 20.0 kg) Wire packages. (For use with Standard Duty Bench Models and Heavy Duty Bench Models.) Plastic Wire Cover for up to 60 lb. (27.2kg) Wire packages. (For use with Heavy Duty Bench Models.[...]

D-1 MAINTENANCE D-1 LF-72 MAINTENANCE Safety Precautions ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or inter- nal wiring. • 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. • [...]

D-2 MAINTENANCE D-2 6. Adjust the WFS knob to 300 ipm. Center the knob pointer with the name plate graphics. Activate the gun trigger. 7. Insert the shorting plug into connector J2 on the p.c. board. The shorting plug shorts pins 1 & 5. (See Figure D.2) 8. Remove the shorting plug. Set aside. (For Codes below 11289 use 9 thru 17) 9. Adjust the [...]

E-1 TROUBLESHOOTING E-1 LF-72 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 LF-72 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 LF-72 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 WIRING DIAGRAM F-1 LF-72 LF- 72 FEEDER (11075, 11076, 11077) L12146 A CAVITY NUMBERING SEQUENCE (COMPO NENT SIDE OF P.C. BOARD) J3 2 1 J5,J8 J9,J60 4 3 6 1 GENERAL INFORMATION ELECTRI CAL SYMBO LS PER E153 7 COLOR C ODE B - BLACK R - RED U - BLUE COMMON ANALOG P.C. BOARD A D C B E 554 556 TRIG GER CONNECT OR J4 559 515 558 COL D FEE D S1 FEE D [...]

F-2 WIRING DIAGRAM F-2 LF-72 LF- 72 FEED ER (FOR CODES 11209, 11210, 11211 11227) L12146-1 A CAVITY NUMBERING SEQUENCE (COMPON ENT SIDE OF P.C. BO ARD) J3 2 1 J5,J8 J9,J60 4 3 6 1 GENERAL INFORMATION ELECTRI CAL SYMBO LS PER E1537 COLOR C ODE B - BLACK R - RED U - BLUE COMMON ANALOG P.C. BOARD A D C B E 554 556 TRIG GER CONNECT OR J4 559 515 558 CO[...]

F-3 DIAGRAMS F-3 LF-72 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.[...]

F-4 DIAGRAMS F-4 LF-72 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.[...]

F-5 DIMENSION PRINTS F-5 LF-72 BENCH MODEL BENCH MODEL ST ANDARD DUTY[...]

F-6 DIMENSION PRINTS F-6 LF-72 BENCH MODEL HEA VY DUTY[...]

W ARNING A VISO DE 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 EL [...]

W ARNING A VISO DE 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 yo ur h ead out of fum es. ● Use ven tila tio n or ex haus t t o remo v[...]

• 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 • World's Leader in Welding and Cutting Products •[...]