Lincoln Electric LN-7 GMA WIRE FEEDERS manual

LN-7 and LN-7 GMA Wire Feeders (2 and 4 Roll Models) OPERA TOR’S MANUAL 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. D O NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHO[...]

FOR ENGINE pow ered 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. _______________________________________________[...]

ARC R A Y S can bur n. 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 and tha[...]

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. National Electri[...]

PRÉC A UTIONS 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 circuits à l’élec[...]

v v Thank Y ou 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. Pa[...]

LN-7 & LN-7 GMA vi T ABLE OF CONTENTS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . .[...]

A-1 LN-7 & LN-7 GMA A-1 INST ALLA TION TECHNICAL SPECIFICA TIONS – LN-7 and LN-7 GMA DUTY CYCLE: INPUT VOL T AGE WIRE FEED SPEED WIRE DIAMETERS PHYSICAL DIMENSIONS Supplied by power source: 115 VAC, 50/60 Hz, 2.5 Amps LN-7 GMA 75 to 700 in. per minute (1.90 to 17.8 m/min) LN-7 50 to 500 in. per minute (1.27 to 12.7 m/min) LENGTH TOTAL WEIGHT [...]

A-2 INST ALLA TION LN-7 & LN-7 GMA A-2 MOUNTING LOCA TION The LN-7 and LN-7 GMA wire feeder can be mounted directly on top of the power source providing that it is secure and level. It can also be mounted to an undercarriage when portability is required. MACHINE GROUNDING The LN-7 and LN-7 GMA wire feeders are ground to the power source through[...]

A-3 INST ALLA TION LN-7 & LN-7 GMA A-3 1. For K291 and K404 cables, connect the end of the control cable with the lugged leads to the power source. If lead #21 is extended to work, do not connect leads to terminal #21 on terminal strip. For K584, K594 or K480 cables connect the 14 pin amphenol connector to the power source. Include any jumpers [...]

A-4 INST ALLA TION LN-7 & LN-7 GMA A-4 5. Connect the input control cable polarized Amphenol plug into the mating 6-pin receptacle on the rear of the control section. 6. Referring to Figure A.2, install the input cable under the wire reel mounting stand strain relief clamp. Remove the screws holding the clamp to the base of the wire reel mounti[...]

A-5 INST ALLA TION LN-7 & LN-7 GMA A-5 FIGURE A.3 – LN-7 & LN-7 GMA TO DC-400, DC-250 AND CV/CVI POWER SOURCES WITH TERMINAL STRIP - CONNECTION DIAGRAM. 77 – + CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-6 INST ALLA TION LN-7 & LN-7 GMA A-6 FIGURE A.4 – LN-7 & LN-7 GMA TO PULSED POWER 500 - CONNECTION DIAGRAM. – + CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-7 INST ALLA TION LN-7 & LN-7 GMA A-7 FIGURE A.5 – LN-7 & LN-7 GMA TO CV/CVI POWER SOURCES WITH 14 PIN AMPHENOL CONNECTOR - CONNECTION DIAGRAM. ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING CLEVELAND, OHIO U.S.A – +[...]

A-8 INST ALLA TION LN-7 & LN-7 GMA A-8 FIGURE A.6 – LN-7 & LN-7 GMA TO CV/CVI POWER SOURCES WITH TWIST-MATE CONNECTOR AND 14 PIN AMPHENOL/REMOTE CONTROL - CONNECTION DIAGRAM. CLEVELAND, OHIO U.S.A – + ELECTRIC SHOCK CAN KILL TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH A T THE FUSE BOX BEFORE CONNECTING T[...]

A-9 INST ALLA TION LN-7 & LN-7 GMA A-9 FIGURE A.7 – LN-7 & LN-7 GMA TO CV/CVI POWER SOURCE (K867/K775) - CONNECTION DIAGRAM. – + CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-10 INST ALLA TION LN-7 & LN-7 GMA A-10 FIGURE A.8 – LN-7 & LN-7 GMA TO R3S-250 OR R3S-325 - CONNECTION DIAGRAM. – + CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-11 INST ALLA TION LN-7 & LN-7 GMA A-11 FIGURE A.9 – LN-7 & LN-7 GMA TO SAM MOTOR GENERATOR OR ENGINE WELDER - CONNECTION DIAGRAM. CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-12 INST ALLA TION LN-7 & LN-7 GMA A-12 FIGURE A.10 – LN-7 & LN-7 GMA TO DC-600 - CONNECTION DIAGRAM. – + CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-13 INST ALLA TION LN-7 & LN-7 GMA A-13 FIGURE A.11 – LN-7 & LN-7 GMA TO R3S-400, 600, OR 800 - CONNECTION DIAGRAM. CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-14 INST ALLA TION LN-7 & LN-7 GMA A-14 FIGURE A.12 – LN-7 & LN-7 GMA TO MOST LINCOLN MOTOR GENERATORS - CONNECTION DIAGRAM. 32 CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-15 INST ALLA TION LN-7 & LN-7 GMA A-15 FIGURE A.13 – LN-7 & LN-7 GMA TO WP250 OR G9 PRO - CONNECTION DIAGRAM. CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING LN-7 GMA TO WP250 G9 PRO: ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERR[...]

A-16 INST ALLA TION LN-7 & LN-7 GMA A-16 FIGURE A.14 – LN-7 & LN-7 GMA TO RANGER 9 – CONNECTION DIAGRAM. ELECTRIC SHOCK CAN KILL DO NOT OPERA TE WITH P ANELS OPEN. DISCONNECT NEGA TIVE (-) BA TTERY LEAD BEFORE SERVICING. DO NOT TOUCH ELECTRICALL Y LIVE P ARTS. W ARNING MOVING P ARTS CAN INJURE KEEP GUARDS IN PLACE. KEEP A W A Y FROM MOV[...]

A-17 INST ALLA TION LN-7 & LN-7 GMA A-17 FIGURE A.15 – LN-7 & LN-7 GMA TO RANGER 10-LX – CONNECTION DIAGRAM. ELECTRIC SHOCK CAN KILL DO NOT OPERA TE WITH P ANELS OPEN. DISCONNECT NEGA TIVE (-) BA TTERY LEAD BEFORE SERVICING. DO NOT TOUCH ELECTRICALL Y LIVE P ARTS. W ARNING MOVING P ARTS CAN INJURE KEEP GUARDS IN PLACE. KEEP A W A Y FROM[...]

A-18 INST ALLA TION LN-7 & LN-7 GMA A-18 FIGURE A.16 – LN-7 & LN-7 GMA TO POWER SOURCES WITH NO OUTPUT CONTACTOR - CONNECTION DIAGRAM. CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-19 INST ALLA TION LN-7 & LN-7 GMA A-19 FIGURE A.17 – LN-7 & LN-7 GMA TO POWER SOURCES WITH CONTACTOR AND NO TERMINAL STRIP - CONNECTION DIAGRAM. CLEVELAND, OHIO U.S.A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. W ARNING[...]

A-20 INST ALLA TION LN-7 & LN-7 GMA A-20 WORK CABLE Connect a work lead of sufficient size and length (Table A.2) between the proper output stud on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. Poor work lead connections can result in the grounding lead protector being activated[...]

A-21 INST ALLA TION LN-7 & LN-7 GMA A-21 W A TER CONNECTIONS (FOR W A TER COOLED GUNS) The LN-7 or LN-7 GMA must have a K527 Water Solenoid Kit installed (see the Accessories Section). The K440-1 LN-7 GMA model already has a water solenoid installed. Refer to Figure A.19 and perform the following steps: NOTE: If not using a Lincoln water cooler[...]

A-22 INST ALLA TION LN-7 & LN-7 GMA A-22 SHIELDING GAS HOOKUP (LN-7 GMA or LN-7 with Optional K494 Gas Solenoid Installed) Gas under pressure is explosive. Always keep gas cylinders in an upright position and to the undercarriage or a stationary support. See American National Standard Z-49.1, “ Safety In Welding And Cutting ” , published by[...]

B-1 OPERA TION B-1 GENERAL DESCRIPTION The K440 LN-7 GMA semiautomatic constant speed wire feeder is specifically equipped for gas metal arc welding using flux-cored Outershield electrodes and solid wire. The LN-7 GMA is also suitable for self- shielded flux-cored Innershield electrodes, submerged arc welding (if constant voltage is satisfactory), [...]

B-2 OPERA TION B-2 RECOMMENDED PROCESSES AND EQUIPMENT The LN-7 GMA is recommended for use in MIG and Innershield welding applications, the LN-7 is recommended for Innershield welding applications. Both are recommended for use with constant voltage power sources such as the Idealarc DC-250, 400, or 600, or CV types. The LN-7 GMA is capable of feedi[...]

B-3 OPERA TION B-3 PURGE - COLD INCH SWITCH (OPTIONAL). This control, located on the optional K418 GMA Timer Kit, provides control of some wire feeder functions without energizing the welding power source. The momentary up position energizes the gas solenoid but not the wire feeder or welding power source. The momentary down position energizes the [...]

B-4 OPERA TION B-4 LN-7 & LN-7 GMA FIGURE B.2 – INSTALLING DRIVE ROLLS ON A TWO-ROLL FEEDER. 7. Set the idle roll pressure as detailed in the Idle Roll Pressure Setting procedure detailed later in this section.[...]

B-5 OPERA TION B-5 CHANGING DRIVE ROLLS FOR FOUR- ROLL WIRE FEEDERS: To change drive rolls on a four-roll wire feeder, refer to Figure B.3 and perform the following steps: 1. Remove the gun and cable from the conductor block on the feeder by loosening the hand screw and pulling the gun straight out of the block. 2. Open both quick release levers by[...]

B-6 OPERA TION B-6 LN-7 & LN-7 GMA FIGURE B.3 – INSTALLING DRIVE ROLLS ON A FOUR-ROLL FEEDER. CLAMPING COLLAR SP ACER (IF REQUIRED) DRIVE ROLL HAL VES KEY OUTPUT SHAFT OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE IDLE ROLL SMALL RADIUS MIDDLE GUIDE TUBE DRIVE ROLL LARGE RADIUS GUIDE TUBE DET AIL[...]

B-7 OPERA TION B-7 IDLE ROLL PRESSURE SETTING The idle roll pressure is set at the factory. Two-roll feeders are set with the pressure adjustment knob backed out two turns from full pressure, and four-roll feeders are set backed out three turns. This is an approximate setting. For small wire sizes and aluminum wire the optimum idle roll pressure va[...]

B-8 OPERA TION B-8 WIRE LOADING WIRE REEL LOADING – READI-REELS AND SPOOLS TO MOUNT A 30 LB READI-REEL PACKAGE USING THE MOLDED PLASTIC K363-P TYPE ADAPTER: 1. Make certain that the threaded locking collar is tight and securely locks the adapter on the spindle. See Figure B.5. 2. Rotate the spindle and adapter so the retaining spring is at the 12[...]

B-9 OPERA TION B-9 TO MOUNT 10 TO 30 LB SPOOL (12 ” DIAMETER): (For 8 in. spools a K468 spindle adapter must be used.) 1. Remove the locking collar and Read-Reel adapter shipped on the 2 in. diameter spindle (adapter is not required). 2. Place the spool on the spindle making certain the brake holding pin enters one of the holes in the back side o[...]

B-10 OPERA TION B-10 WIRE REEL LOADING – 50 AND 60 LB COILS (K303 OR K376 WIRE REEL ST AND) ADJUSTABLE WIRE REEL BRAKE The mount for standard 50 and 60 pound electrode coils includes a two-position brake assembly. Generally the brake should be at the inner position (nearest to the wire reel shaft) for wire feed speeds below 400 in./min (10 m/min)[...]

B-11 OPERA TION B-11 FEEDING ELECTRODE 1. Turn the reel until the free end of the electrode is accessible. 2. While tightly holding the electrode, cut off the bent end and straighten the first six inches. Cut off the first inch. (If the electrode is not properly straightened, it may not feed or may not go into the outgoing guide tube causing a “ [...]

B-12 OPERA TION B-12 ACCELERA TION SETTING The LN-7 and LN-7 GMA can be configured for optimum starting for different procedures by selecting between two speeds of controlled wire acceleration. As shipped from the factory, the LN-7 and LN-7 GMA models are set for fast acceleration. Fast acceleration is typically the best for most smaller wire proce[...]

B-13 OPERA TION B-13 MAKING A WELD 1. Inch the electrode through the gun and cable. For solid wire, cut the electrode within approximately 3/8 in. of the end of the contact tip. If using cored wire, cut the electrode within 3/4 in. of the extension guide. 2. Connect the work cable to the metal to be welded. The work cable must make good electrical [...]

B-14 OPERA TION B-14 FLUX T ANK LOADING K320 FLUX T ANK (OPTIONAL) Either turn off the incoming air line or remove the quick disconnect if one has been installed. Slightly loosen the tank cap and let the air in the tank escape in the holes in the side of the cap. After pressure has been released, remove the cap from the tank. Using the funnel provi[...]

C-1 ACCESSORIES C-1 GENERAL The following is a list of the accessories that can be used with the LN-7 GMA wire feeder. LN-7 & LN-7 GMA Product Number Name K162-1** Spindle Kit-Two inch Hub K163** Undercarriage K419** Burnback timer kit K418** GMA Timer Kit K417** Digital voltmeter kit K320** Flux tank K303** 50-60 lb Wire reel mounting stand M-[...]

C-2 ACCESSORIES C-2 AUXILIAR Y EQUIPMENT CONNECTION The power for 115 volt AC auxiliary equipment can be obtained from the 7 and 32A terminals inside the control box. The 7 and 32A circuit is energized when the gun trigger circuit is closed. NOTE: The LN-7 GMA already has the factory installed gas solenoid valve leads attached to terminals 7 and 32[...]

WELDING GUNS INNERSHIELD GUNS The K126 gun and cable assembly is recommended for most welding with 0.062 in. through 3/32 in. Innershield electrodes at up to 350 amps. Install the insulated nozzle extension (or thread protector) and the nozzle contact tip for the stickout and electrode size being used. (See Figure C.1.) FIGURE C.1 – THE K126 GUN.[...]

SUBMERGED ARC GUNS The K112 gun and cable assembly is recommended for welding with 1/16 in. solid steel electrode at up to 500 amps. The K113 gun and cable is recommended for 5/64 in. and 3/32 in. (2.0 and 2.4 mm) solid steel electrodes (types L50, L60, L61, and L70) for use up to 600 amps. GMA W GUNS An expanding line of Magnum GMA gun and cable a[...]

D-1 MAINTENANCE D-1 ROUTINE MAINTENANCE DRIVE ROLLS AND GUIDE TUBES After feeding every coil of wire, inspect the drive roll section. Clean the assembly as necessary. Do not use solvent to clean the drive roll assembly as it may wash the lubricant out of the bearings. The drive rolls and guide tubes are stamped with the wire sizes they will feed. I[...]

D-2 MAINTENANCE D-2 Gun Cables (All) A dirty gun cable can cause rough and erratic wire feeding. Therefore, the cable liner must be cleaned periodically. Clean Innershield gun cables after using approximately 300 pounds of electrode; clean sub- merged arc gun cables after using approximately 600 pounds of electrode. Remove the cable from the wire f[...]

D-3 MAINTENANCE D-3 LN-7 & LN-7 GMA The following Figures D.1 and D.2 should serve as a guide to determine if a particular gun or switch can be connected to the LN-7 GMA and LN-7. “ A ” Diameter Hole to be Concentric to Wire Size .749/.747 (19.0/18.9) in. (mm) Diameter Within .008 (.20) F.I.M. 7/64 .152 [#24 Drill] 0.68-5/64 (1.7-2.0) .125 [...]

D-4 MAINTENANCE LN-7 & LN-7 GMA D-4 LN-7 SEQUENCE OF OPERA TION (Optional T imer Kit not Installed) Turn on Power Source Closes 524-525 Closes 31-7A circuit 115V AC input power is applied to SCR control circuit and Motor Armature (539-541 circuit) is energized Energizes 1 CR Press Gun Trigger Closes 2-4 Circuit Energizes welder pilot relay and/[...]

LN-7 & LN-7 GMA E-1 TROUBLESHOOTING & REP AIR E-1 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 [...]

E-2 TROUBLESHOOTING & REP AIR E-2 LN-7 & LN-7 GMA 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 Authorized Field Service Facility . CAUTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED [...]

E-3 TROUBLESHOOTING & REP AIR E-3 LN-7 & LN-7 GMA 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 Authorized Field Service Facility . CAUTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED [...]

F-1 WIRING DIAGRAM F-1 LN-7 & LN-7 GMA 1 3 2 4 6 5 567 21 508 509 526 525 567 21 OPTIONAL ANALOG METER KIT PLUG OPTIONAL DIGITAL METER KIT PLUG P5 J5 D C F B A E . CR2 526 527 21 GLP REED SWITCH N.E. GND 2 4 INPUT CONTROL CABLE TO CONTACTOR CIRCUIT 115 V.A.C. WORK 4 2 1 6 } * 31 32A 531 4 2 3 P1 1 6 } * 4 2 3 P3 322 523 509 508 31 32A 5 B B Y Y[...]

NOTES LN-7 & LN-7 GMA[...]

NOTES LN-7 & LN-7 GMA[...]

NOTES LN-7 & LN-7 GMA[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O 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 E[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

• 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 •[...]