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Lincoln Electric LN-7 User's Manual

1. DC 600 CONNECTION DIAGRAM A WARNING TURN INPUT POWER OFF A WARNING BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER ELECTRIC SHOCK CAN KILL DC 600 POWER SOURCE 717777 e LN 7 GMA 75 76 77 80 81 WIRE FEEDER 4444 is N C LN 7 GMA CONTROL CABLE N C AND N F K291 _ _ ELECTRODE CABLE TO LN 7 GMA CONDUCTOR BLOCK AND N D TO WORK NA WEE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATING WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 9 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED 21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE REMOTE WORK LEAD ACCESSORY ON LN 7 GMA METER KITS WHICH HAVE A DIRECT WORK LEAD JACK AN LN 7 GMA NOT EQUIPPED WITH A METER KIT DOES NOT REQUIRE LEAD 21 TO BE EXTENDED N C CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE POWER SOURCE TERMINAL STRIP OR AN UNPAINTED FRAME SCREW THE POWER SOURCE OF COURSE MUST BE GROUNDED PROPERLY N D DIAGRAM SHOWS ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF AND REVERSE ELECTRODE AND WORK CABLE LEADS AT POWER SOURCE N E IF AN OPTIONAL REMOTE VOLTAGE CON
2. 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 prod ucts 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 5 f LINCOLN equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b 6 j SAFETY 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 WELDING and CUTTING Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used
3. Technical Specifications A 1 Mounting Location A 2 Machine Grounding MP A 2 Input Cable Connections A 2 Work Cables sira i tena iaai dE i raai dee EE cess Q A A 20 Gun and Cable Assemblies A 20 Gun Gable Connections A 20 Water Connections For Water Cooled Guns A 21 Shielding Gas Hookup A 22 enorm Section B Safety Precautions B 1 General Description B 1 Recommended Processes and Equipment B 2 Controls and Settings B 2 Circuit Protection B 3 Avoiding Ground Lead Protector GLP Activation B 3 Drive Roll Installation 2 Roll B 3 Drive Roll Installation 4 Roll B 5 Idle Roll Pressure Setting B 7 Wire LOadling EE B 8 Acceleration Setting B 12 Wire Speed and Voltage Adjustment B 12 Making a Weld B 13 Wire Reel Changing B 13 K4
4. 14 LB INNERSHIELD COILS The K378 small mounting stand for the 14 Ib Innershield coil does not have an adjustable brake It has a fixed drag built into the reel spindle To load 14 Ib coil 1 Remove the snap on lid from the plastic canister 2 Remove the center clamping nut and the cover plate from the wire reel Unpack the 14 Ib coil of wire Be sure not to bend the side tangs of the liner Straighten any tangs that may have been bent 4 Remove the start end of the coil from its holding slot in the coil liner Cut off the bent end Straighten the first six inches and cut off the first inch If the electrode is not properly straightened it may not feed or may not enter the outgoing tube causing a birdnest 5 Thread the end through the canister wire feed liner until about four inches of electrode are exposed 6 Place the coil onto the disc support 7 Replace the front reel cover and center clamping nut Keep the reel from turning and tighten the center clamping nut securely 8 Thread the exposed end of the electrode into the wire feeder until it touches the drive rolls Actuate the gun trigger and feed the electrode through the system LN 7 amp LN 7 GMA LINCOLN B 12 ACCELERATION 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
5. AND jumper from 2 to 4 on the terminal strip or a ELECTRODE CABLE CONNECTIONS power source without a contactor with this wire feeder To do so would defeat the purpose of the grounding lead protector circuit and could result in the overheating of the electrical ground circuit to the wire feeder 2 For constant voltage power sources with an output contactor but no terminal strip or 14 pin control receptacle see Figure 17 For constant voltage power sources without an internal output contactor and requiring a K240 Contactor Kit see Figure A 16 3 If input cables longer than the standard length must be used K292 extension cables 50 ft 15 2 m can be installed These have polarized plugs on each end of the control cable and include a 4 0 107 electrode cable Install the extensions between the standard input cable and the wire feeder Total input cable length should not exceed 400 ft 122 m When using longer lengths of extension cables it may be necessary to add parallel electrode cables to minimize the voltage drop in the cable CONDUCTOR BLOCK CONTROL CABLE ELECTRODE CABLE LN 7 amp LN 7 GMA LINCOLN A 4 INSTALLATION A 4 5 Connect the input control cable polarized clamp Remove the screws holding the clamp to Amphenol plug into the mating 6 pin receptacle the base of the wire reel mounting assembly put on the rear of the control section the input cabl
6. AND CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED 21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE REMOTE WORK LEAD ACCESSORY ON LN 7 GMA METER KITS WHICH HAVE A DIRECT WORK LEAD JACK AN LN 7 GMA NOT EQUIPPED WITH A METER KIT DOES NOT REQUIRE LEAD 21 TO BE EXTENDED N D TAPE UP BOLTED CONNECTION LEADS AND DO NOT APPEAR IN THE LN 7 GMA CONTROL CABLE CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE POWER SOURCE TERMINAL STRIP OR AN UNPAINTED FRAME SCREW THE POWER SOURCE OF COURSE MUST BE GROUNDED PROPERLY N G INSTALL A 5 AMP OR SMALLER FUSE IN LEAD 42 TO PROTECT THE 2 4 CIRCUIT IN WIRE FEEDER N H MAXIMUM RATING OF LN 7 GMA 2 TO 4 CIRCUIT IS 5 AMP 115V AC 5 AMP 28V AC 1 2 AMP 115V AC LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN 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 TABLE A 2 WORK LEAD SPECIFICATIONS Copper Work Cable Size AWG Current 60 Up To 50 Ft 50 Ft 100 Ft Duty Cycle 15 2 m2 15 2 30 4 m2 300 Amps 400 Amps 500 Amps 0 53 mm 00 67 mm 00 67 mm 000 8
7. Motor Armature gas solenoid connected Energizes welder 539 541 circuit is to 7 32A with 115 VAC contactor energized Electrode now hot to ground Wire feed motor starts at low speed and increases speed to welding speed Arc Starts Welding Release Gun Trigger Opens 524 525 De Energizes 1 CR Opens 31 7A circuit Disconnects motor De eneraizes welder 9 armature from SCR control ilot rela ili i P I 1CR normally closed contact Auxlliary equipment anol closes shorting armature de energized De energizes welder Sege Draki contactor ENIM resistor Electrode is cold to work Wire feed motor stops Unit ready for next weld LN 7 amp LN 7 GMA LINCOLN si TROUBLESHOOTING amp REPAIR E HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms th
8. POWER SOURCE TERMINAL STRIP OR AN UNPAINTED FRAME SCREW THE POWER SOURCE OF COURSE MUST BE GROUNDED PROPERLY LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 16 INSTALLATION A 16 FIGURE A 14 LN 7 amp LN 7 GMA TO RANGER 9 CONNECTION DIAGRAM A WARNING DO NOT OPERATE WITH WARNING KEEP GUARDS IN PLACE _ e PANELS OPEN KEEP AWAY FROM MOVING DISCONNECT NEGATIVE PARTS BATTERY LEAD BEFORE SERVICING ONLY QUALIFIED PERSONS SHOULD INSTALL USE OR ELECTRIC DO NOT TOUCH MOVING SERVICE THIS MACHINE SHOCK ELECTRICALLY LIVE PARTS PARTS CAN KILL CAN INJURE TO LN 7 INPUT CABLE PLUG 14 PIN AMPHENOL OPTIONAL K857 REMOTE CONTROL men TO WORK ELECTRODE K584 XX INPUT CABLE ASSEMBLY ELECTRODE CABLE TO WIRE FEED UNIT TO WORK CAUTION s ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION PLACE WELDING TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N B WELDING CABLES MUST BE OF PROPER CAPAC
9. SHINS Belle LSA7IAE HASI Bal 7474214 E amp z7 R AHgSHIAIg i x lu su e cat gal bias Shem si Aasch ail qub w i Qi BAU Al Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig off nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e Ate HE ZLCRU fe STEEL Fe g gt lt F Us e MEARE E Ada pill d ily gst Juill ail e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgehause oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas V J xP 3 7 e SS IR TT BH Pk 2 A edo 93 OM AIS Ah Yi cils UI al UA add y e Aale Get Ai dl Ayan WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO FIR Chinese LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PAR
10. a lugged electrode cable for connection to the wire feeder WELDING GUNS INNERSHIELD GUNS The K126 gun and cable assembly is recommended for most welding with 0 062 in through 3 82 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 LN 7 amp LN 7 GMA LINCOLN C 4 ACCESSORIES C 4 For heavy duty welding at up to 450 amps and with 0 068 in through 3 32 in Innershield electrode use an appropriate K115 or K115 45 gun and cable assembly See Figure C 2 Install the proper insulated nozzle extension and contact tip for the stickout and electrode size being used For welding with 7 64 in Innershield electrode use a K115 3 32 with an M11474 120 nozzle or a K115 45 3 32 with an 11510 120 nozzle Also install a 7 64 in contact tip and install the insulated nozzle extension for the stickout being used NOTE Linconditioner guns are recommended for locations where smoke accumulation is a problem and conventional exhaust systems are ineffective The available smoke removal type Innershield guns and vacuum units can be used in these locations Instructions are shipped with the equipment FIGURE C 2 THE 115 K115 45 GUNS SUBMERGED ARC GUNS The 112 gun and cable assembly is recommended for welding with 1 16 in solid stee
11. coil remove the last of the old electrode from the conductor cable Either pull it out at the nozzle or use the following procedure 1 Cut off the end of the electrode at the gun end Do not break it off by hand Breaking by hand puts a slight bend in the wire making it difficult to pull it back through the nozzle 2 Uncouple the gun conductor cable from the conductor block on the wire feeder drive unit and lay the gun cable out straight 3 Using pliers grip the wire and pull it out of the cable from the connector end 4 After the electrode has been removed connect the gun conductor back to the wire feeder 5 Load a new reel of electrode per the instructions for the specific reel type given previously in this section OPERATION B 13 K417 DIGITAL VOLTMETER KITS Lincoln Specified Procedures give voltmeter readings taken between the work and the gun cable brass connection block inside the LN 7 To match these voltage readings the 21 lead should be extended directly to the work per the instructions on the wire feeder to power source connection diagrams given in the Installation Section To read volts set the Electrode Polarity switch Figure B 9 to the same polarity as the electrode lead connection to the power source The K417 Digital Voltmeter Kit has a hold feature that will freeze the last arc voltage reading at the moment the trigger is released to stop welding This feature allows the welding opera
12. dog points When the guide tubes are properly installed these dog points will lock into the annular grooves in each of the guide tubes LN 7 amp LN 7 GMA LINCOLN B 4 OPERATION 7 Set the idle roll pressure as detailed in the Idle Roll Pressure Setting procedure detailed later in this section FIGURE B 2 INSTALLING DRIVE ROLLS ON A TWO ROLL FEEDER CLAMPING Li COLLAR SPACER IF REQD OUTPUT SHAFT GUIDE TUBE DETAIL OUTGOING GUIDE TUBE OUTGOING GUIDE TUBE INSERT INCOMING GUIDE TUBE SMALL RADIUS LN 7 amp LN 7 GMA LINCOLN B 4 B 5 OPERATION 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 Open both quick release levers by moving the levers outward and pulling them toward you Loosen the thumb screws holding the guide tubes in place Remove the incoming and outgoing guide tubes if installed Remove the hex head screws and clamping collars from the output shafts Remove the drive rolls and middle guide tube if installed The new rolls to be installed are stenciled with the wire size that will be fed An A after the number indicates aluminum wire Remove the rolls from the kit and w
13. reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a friction fit TO MOUNT A 50 OR 60 LB COIL 1 To remove the wire reel from its shaft grasp the spring loaded knob and pull out This straightens the knob so it seats into the shaft when released Remove the reel 2 Lay the reel flat on the floor Loosen the spinner nut and remove the cover plate See Figure B 6 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 placed so the spring loaded arms will not interfere with the later removal of the coil tie wires 5 When loading 0 030 0 035 and 0 045 electrode be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil sides needed for trouble free wire feeding 6 Put the cover plate on the reel so the four arms of the cover plate straddle and are in line with the spring loaded arms of the reel 7 Tighten the cover as much as possible by hand DO NOT hammer on the spinner nut arms OPERATION B 10 CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in ba
14. the life of the reel shaft on the 50 to 60 Ib coils periodically coat it with a thin layer of grease No maintenance to the two position brake is required If the brake shoe wears through to metal replace the brake assembly No routine maintenance is required for Readi Reels and 10 to 30 Ib spools Do not lubricate the 2 in spindles CONTACTOR CIRCUIT FUSE The 2 amp 250 volt fuse F1 on the control P C Board protects the contactor circuit leads 4 and 2 from overloads or shorts which can be caused by a wrong connection at the power source PERIODIC MAINTENANCE WIRE DRIVE MOTOR AND GEARBOX Every year inspect the gearbox and coat the gear teeth with a moly disulfide filled grease Do not use graphite grease Every six months check the motor brushes Replace them if they are less than 1 4 in long GUN AND CABLE MAINTENANCE For instructions on periodic maintenance for the welding gun and cables refer to the manual for your specific model of welding gun Gun Nozzles All 1 Replace worn contact tips as required 2 On Innershield guns remove spatter from tip or extension guide after each ten minutes of arc time or as required 3 Replace worn spring liners in nozzles The life of the liner can be doubled by rotating liner 180 The liner can be pulled out the back end of the nozzle by wedging the blade of a small screwdriver in the I D and pulling 4 Inner parts of nozzles can be removed and replaced by
15. with the LN 7 GMA wire feeder D D D D D D D D A detailed description of each item is given later in this section LN 7 amp LN 7 GMA LINCOLN Innershield gun 350 Amps Innershield welding gun 450 Amps Submerged arc welding gun 500 Amps Submerged arc welding gun 600 Amps Magnum GMA welding gun 200 Amps Magnum GMA welding gun 300 Amps Magnum GMA welding gun 400 Amps Wire Feeder Control Cable Extensions Requires K1818 10 C 2 ACCESSORIES C 2 AUXILIARY 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 32A Additional auxiliary equipment connection is not recommended Install 1 4 quick connect terminals to the leads from the auxiliary equipment Route the leads through the same hole that the motor leads pass through to the inside of the control box and connect the terminals to 32A and 7 on the control PC Board Route the leads so that they are 50 or greater away from the chassis mounted power resistor The current draw must NOT exceed 1 4 ampere CAUTION Do not connect the power source contactor to these terminals NOTE The auxiliary equipment contacts open when the trigger is released When the optional K418 GMA Timer Kit i
16. 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations 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 LINCOLN Oo PRECAUTIONS DE SURETE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes Surete Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et a la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couche pour lesquelles une grande partie du cor
17. 17 Digital Voltmeter Kits B 13 Optional Flux Tank Loading B 14 ACCES SOS a Section E ET E tated pe C 1 Auxiliary Equipment Connection C 2 Options Accessories C 2 Attaching the Wire Reel Stand C 4 Maintenance EE Section D Routine Maintenance D 1 Periodic Maintenance D 1 Sequence of Operation D 4 Troubleshooting Section E Wiring Diagram Section F PAS Ge LEE P 283 Series LN 7 amp LN 7 GMA LINCOLN VI Ai INSTALLATION TECHNICAL SPECIFICATIONS LN 7 and LN 7 GMA INPUT VOLTAGE Supplied by power source 115 VAC 50 60 Hz 2 5 Amps WIRE FEED SPEED 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 WIRE DIAMETERS A 1 0 023 in through 1 16 in lid el NZ GMA 0 6 through 1 6 mm SSES 0 045 in through 5 64 in de 1 2 through 2 0 mm PHYSICAL DIMENSIONS TOTAL WEIGHT LENGTH WIDTH HEIGHT LESS ELECTRODE WITHOUT 9 62 in 9 76 in 10 89 in 24 Ibs TWO WIRE STAND 244 mm 247 m
18. 5 mm 00 67 mm 000 85 mm 000 85 mm 0000 107 mm 600 Amps GUN AND CABLE ASSEMBLIES The LN 7 and LN 7 GMA can be used with several guns In most cases Lincoln guns and cables are shipped assembled ready to weld Use the gun and cable assembly for the electrode type solid Outershield or Innershield and electrode size to be used Refer to the Accessories Section for different gun types GUN CABLE CONNECTIONS Lay the cable out straight Insert the connector on the welding conductor cable through the large hole in the front panel of the LN 7 and into the brass conductor block on the front of the gearbox Refer to Figure A 18 Make sure it is all the way in and tighten the hand wheel Keep this connection clean and bright Connect INSTALLATION AMPHENOL CONNECTOR A 20 the control cable amphenol plug into the mating 5 cavity receptacle on the front of the control section below the nameplate If using the K489 1 Fast Mate Adapter install per the 519389 instructions included with the kit FIGURE A 18 GUN CABLE CONNECTIONS CONDUCTOR BLOCK GUN CABLE ASSEMBLY LN 7 amp LN 7 GMA LINCOLN 21 INSTALLATION A 21 WATER CONNECTIONS 1 Using male 5 8 18 UNF left hand thread fittings connect appropriate water hoses to the coolant FOR WATER COOLED GUNS inlet and outlet on the back of the LN 7 Connect the other ends of these hoses to the appropriate The LN 7 or LN 7 G
19. A K856 POWER SOURCE REMOTE KIT IN THE POWER SOURCE EARLY CV3000 POWER SOURCES CLEVELAND OHIO U S A LINCOLN ELECTRIC LN 7 amp LN 7 GMA LINCOLN A 8 INSTALLATION A 8 FIGURE A 6 LN 7 amp LN 7 GMA TO CV CVI POWER SOURCES WITH TWIST MATE CONNECTOR AND 14 PIN AMPHENOL REMOTE CONTROL CONNECTION DIAGRAM WARNING TURN OFF INPUT POWER WARNING TO THE WELDING POWER __ SOURCE USING THE DISCONNECT SWITCH AT THE FUSE BOX BEFORE CONNECTING THE WIRE FEEDER ELECTRIC ONLY QUALIFIED PERSONS SHOCK SHOULD INSTALL USE OR CAN KILL SERVICE THIS MACHINE CV CV POWER SOURCE OPTIONAL K857 14 PIN REMOTE CONTROL AMPHENOL LN 7 GMA OPTIONAL K864 REMOTE WIRE FEEDER CONTROL ADAPTER TO WORK K480 INPUT CABLE ASSEMBLY ELECTRODE CABLE 80 INPUT C Ss N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B DIAGRAM SHOWS ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF N C USE OF K857 REMOTE CONTROL REQUIRES THE INSTALLATION OF A K864 REMOTE CONTROL ADAPTER TO THE 14 PIN AMPHENOL OF THE POWER SOURCE THE K480 INPUT CABLE CAN BE CONNECTED DIRECTLY TO THE POWER SOURCE IF A REMOTE CONTROL IS NOT REQUIRED LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 9 INSTALLATION A 9 FIGURE A 7 LN 7 amp LN 7 GMA TO CV CVI POWER SOURCE K867 K775 CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNE
20. AR ez 712 Sol Tears H oe e di y due Adi y asa y ci gai Sg deua 9 READ AND UNDERSTAND THE MANUFACTURER 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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera de los humos Utilice ventilacion o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a e Use ventilac o e exhaust o para remover fumo da zona respirat ria ORAV HELCTIHELTFEL e Z IP UR E s FB X8 aK BE SR ER Secr
21. BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER ELECTRIC POWER SOURCE LN 7 GMA CONTROL CABLE LN 7 GMA K291 OR K404 WIRE FEEDER PORTABLE FIELD CONTROL AUTO CABLE FOR REMOTE CONTROL EQUIP STICK WORK OF ARC VOLTAGE Q TO WORK iac ELECTRODE CABLE TO LN 7 GMA CONDUCTOR BLOCK N A N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATING WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED 21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE REMOTE WORK LEAD ACCESSORY ON LN 7 GMA METER KITS WHICH HAVE A DIRECT WORK LEAD JACK AN LN 7 GMA NOT EQUIPPED WITH A METER KIT DOES NOT REQUIRE LEAD 21 TO BE EXTENDED N C CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE POWER SOURCE TERMINAL STRIP OR AN UNPAINTED FRAME SCREW THE POWER SOURCE OF COURSE MUST BE GROUNDED PROPERLY N D TAPE UP BOLTED CONNECTION IF LEAD 21 IS EXTENDED LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 12 INSTALLATION A 12 FIGURE A 10 LN 7 amp LN 7
22. CTING THE LN 7 GMA WIRE FEEDER ELECTRIC SHOCK CAN KILL CV CV I POWER SOURCE SC SPARE AMPHENOL 02 0 81 o V NC LN 7 GMA 42 o WIRE FEEDER K867 UNIVERSAL 41 ADAPTER PLUG 31 o 31 Le 32 o 3 a o 4 91 o 2 NS GREEN f9 9 75 16 16 291 OR K404 INPUT CABLE TO WORK ELECTRODE CABLE OPTIONAL K775 NA AND N D REMOTE CONTROL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B DIAGRAM SHOWS ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF AND REVERSE ELECTRODE AND WORK CABLE LEADS AT POWER SOURCE N C INSULATE EACH UNUSED LEAD INDIVIDUALLY N D SPLICE LEADS AND INSULATE N E USE OF K775 REMOTE CONTROL REQUIRES THE INSTALLATION OF A K856 POWER SOURCE REMOTE KIT IN THE POWER SOURCE LINCOLN E ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 10 INSTALLATION A 10 FIGURE A 8 LN 7 amp LN 7 GMA TO R3S 250 OR R3S 325 CONNECTION DIAGRAM A WARNING TURN INPUT POWER OFF e BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER N A ELECTRIC SHOCK CAN KILL POWER SOURCE AND 21 LN 7 GMA WIRE FEEDER Se ak NC LN 7 GMA CONTROL CABLE i K291 OR K404 N E O N D ELECTRODE CABLE TO LN 7 GMA CONDUCTOR BLOCK AND TO WORK N D N A WELDIN
23. Cold Inch Switch Momentary Up position energizes the gas solenoid but not the wire feeder or welding power source Momentary down position energizes the wire feeder but not the welding power source or the gas solenoid valve Installation and operation instructions M15059 are included with the kit K417 DIGITAL VOLTMETER KIT Includes a three digit LED display and a polarity switch Also includes a hold feature that freezes the display for approximately six seconds at the reading just prior to stopping welding This feature allows the operator to easily check his procedure at the end of the weld and make adjustments if required Installation instructions M15080 are included with the kit K320 FLUX TANK The K320 flux tank is available to permit the LN 7 or LN 7 GMA to be used for submerged arc welding Install per the instructions shipped with the kit WIRE REEL DUST SHIELD DOOR FOR K303 In extremely dusty and dirty locations this door kit can be added to those units having the dust shield kit S 14543 This door kit includes a hinged door and sliding bottom seal When these parts are attached to the reel support per the instructions included the unit becomes a completely enclosed housing Order part no 11514 POWER INPUT CABLES A variety of power input cable assemblies are avail able for various current ratings and power source con nection types All provide a polarized control cable plug MS 3106A 18 12S and
24. ECTRIC AND E MAGNETIC FIELDS Sak may be dangerous 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz ing 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 1 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 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 1 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 N 1 9 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 LINCOLN localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult th
25. ED N C CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE POWER SOURCE TERMINAL STRIP OR AN UNPAINTED FRAME SCREW THE POWER SOURCE OF COURSE MUST BE GROUNDED PROPERLY N D DIAGRAM SHOWS ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF AND REVERSE ELECTRODE AND WORK CABLE LEADS AT POWER SOURCE N E IF AN OPTIONAL REMOTE VOLTAGE CONTROL IS USED CONNECT IT TO THIS TERMINAL STRIP TAPE UP BOLTED CONNECTION IF LEAD 21 IS EXTENDED NG ON EARLIER R3 400 600 AND 800 MACHINES 1 TERMINAL WAS ALSO ON THE TERMINAL STRIP LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 14 INSTALLATION A 14 FIGURE A 12 LN 7 amp LN 7 GMA TO MOST LINCOLN MOTOR GENERATORS CONNECTION DIAGRAM A WARNING TURN INPUT POWER OFF BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER ELECTRIC SHOCK CAN KILL POWER SOURCE 68 OR 73 70 OR 74 LN 7 GMA 22 9 e 67 e AND WIRE FEEDER 21 LN 7 GMA CONTROL CABLE K291 CONNECT TO INNERSHIELD TERMINAL TO WORK ELECTRODE CABLE TO LN 7 GMA CONDUCTOR BLOCK N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATING WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 9 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WOR
26. G CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATING WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED 21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE REMOTE WORK LEAD ACCESSORY ON LN 7 GMA METER KITS WHICH HAVE A DIRECT WORK LEAD JACK AN LN 7 GMA NOT EQUIPPED WITH A METER KIT DOES NOT REQUIRE LEAD 21 TO BE EXTENDED N C CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE POWER SOURCE TERMINAL STRIP OR AN UNPAINTED FRAME SCREW THE POWER SOURCE OF COURSE MUST BE GROUNDED PROPERLY N D DIAGRAM SHOWS ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF AND REVERSE ELECTRODE AND WORK CABLE LEADS AT POWER SOURCE N E IF AN OPTIONAL REMOTE VOLTAGE CONTROL IS USED CONNECT IT TO THIS TERMINAL STRIP N F TAPE UP BOLTED CONNECTION IF LEAD 21 IS EXTENDED LINCOLN amp ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN 11 INSTALLATION A 11 FIGURE A 9 LN 7 amp LN 7 GMA SAM MOTOR GENERATOR OR ENGINE WELDER CONNECTION DIAGRAM A WARNING TURN INPUT POWER OFF e
27. H SWITCH 5 OPTIONAL BS BURNBACK CONTROL OPTIONAL WIRE FEED Ne SPEED CONTROL SS CONTROLS AND SETTINGS Operator controls are illustrated in Figure B 1 Refer to the figure and the following explanations of the controls WIRE FEED SPEED CONTROL This control sets the feed speed of the wire feeder Turn the knob to the left for slower speeds and to the right for higher speeds The control is calibrated The nameplate shows the wire speed for the given setting of the control BURNBACK CONTROL OPTIONAL This control located on the optional K419 Burnback Timer and K418 GMA Timer Kits provides a precise time delay that allows the wire to be burned off at the end of the weld This is useful for those applications where higher speed fine wire feeding is used and there is a tendency for the electrode to overrun at the end of the POLARITY SWITCH OPTIONAL weld and cause sticking in the crater The delay is adjustable for optimum burnback depending on wire size process procedure etc PREFLOW CONTROL OPTIONAL This control located on the optional K418 GMA Timer Kit provides flow of shielding gas to the work before the arc is established The gas solenoid valve is energized immediately when the gun trigger is closed but the time delay before the wire feeder is energized is adjustable from 0 to 1 5 seconds Turn the knob to the left for shorter delays and to the right for longer delays POS
28. ITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL 22 REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION PLACE IDLER SWITCH IN HIGH IDLE POSITION LINCOLN ELECTRIC _ CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 17 INSTALLATION A 17 FIGURE A 15 LN 7 amp LN 7 GMA TO RANGER 10 LX CONNECTION DIAGRAM A WARNING DO NOT OPERATE WITH A WARNING KEEP GUARDS IN PLACE _ e PANELS OPEN KEEP AWAY FROM MOVING DISCONNECT NEGATIVE x PARTS BATTERY LEAD BEFORE SERVICING ONLY QUALIFIED PERSONS SHOULD INSTALL USE OR ELECTRIC NOT TOUCH MOVING SERVICE THIS MACHINE SHOCK ELECTRICALLY LIVE PARTS PARTS CAN KILL CAN INJURE TO LN 7 INPUT CABLE PLUG K584 CONTROL CABLE 14 PIN AMPHENOL gt OPTIONAL K857 REMOTE CONTROL 6 PIN AMPHENOL TO WORK ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION
29. K PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED 21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE REMOTE WORK LEAD ACCESSORY ON LN 7 GMA METER KITS WHICH HAVE A DIRECT WORK LEAD JACK AN LN 7 GMA NOT EQUIPPED WITH A METER KIT DOES NOT REQUIRE LEAD 21 TO BE EXTENDED N C REMOVE LEAD JUMPER BETWEEN 4 AND 244 NO EXTERNAL LEAD IS CONNECTED TO 244 N D USE WELDANPOWER POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH ON THE WELDANPOWER TO A CV POSITION N E TAPE UP BOLTED CONNECTIONS CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE POWER SOURCE TERMINAL STRIP OR AN UNPAINTED FRAME SCREW THE POWER SOURCE OF COURSE MUST BE GROUNDED PROPERLY LINCOLN ELECTRIC CLEVELAND U S A LN 7 amp LN 7 GMA LINCOLN A 15 INSTALLATION A 15 FIGURE A 13 LN 7 amp LN 7 GMA TO WP250 OR G9 PRO CONNECTION DIAGRAM WARNING TURN INPUT POWER OFF CAUTION LN 7 GMA TO WP250 G9 ER CAUTION PRO ANY INCREASE OF THE BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE ELECTRIC WILL CAUSE AN INCREASE SHOCK IN THE AC AUXILIARY CAN KILL VOLTAGE IF THIS VOLTAGE GOES ABOVE 140 VOLTS THE LN 7 GMA CONTROL CIRCUIT WI
30. LL DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE EE FACTORY DO NOT ADJUST VOLTAGE MUST ABOVE RPM SPECIFICATIONS LISTED IN ENGINE WELDER OPERATING MANUAL POWER SOURCE e on LN 7 GMA CONTROL CABLE 31 22 2 4 244 NE K404 WIRE FEEDER N D Ki WORK ELECTRODE AND NE ELECTRODE CABLE TO LN 7 GMA CONDUCTOR BLOCK NA TO WORK N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATING WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 9 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED 21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE REMOTE WORK LEAD ACCESSORY ON LN 7 GMA METER KITS WHICH HAVE 7 LEAD JACK AN LN 7 GMA NOT EQUIPPED WITH A METER KIT DOES NOT REQUIRE LEAD 21 TO BE N C REMOVE LEAD JUMPER BETWEEN 4 AND 244 NO EXTERNAL LEAD IS CONNECTED TO 244 N D USE WELDANPOWER POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH ON THE WELDANPOWER TO A CV POSITION N E TAPE UP BOLTED CONNECTIONS N F CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE
31. LY N C TO 115V AC 500 V A PLUS 250 V A ADDITIONAL IF LINCOLN TRAVEL CARRIAGE IS USED N D LEADS 75 76 77 A B AND C DO NOT APPEAR ON LN 7 GMAS WITH CODES ABOVE 7026 N E Nicene MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS IF USING AN OLDER CONTROL CABLE CONNECT LEAD 75 TO 75 ON TERMINAL STRIP CONNECT LEAD 76 TO 76 ON TERMINAL STRIP CONNECT LEAD 77 TO 77 ON TERMINAL STRIP N G EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATING WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 9 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED 21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE REMOTE WORK LEAD ACCESSORY ON LN 7 GMA METER KITS WHICH HAVE A DIRECT WORK LEAD JACK AN LN 7 GMA NOT EQUIPPED WITH A METER KIT DOES NOT REQUIRE LEAD 21 TO BE EXTENDED N H TAPE UP BOLTED CONNECTION CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE POWER SOURCE TERMINAL STRIP OR AN UNPAINTED FRAME SCREW THE POWER SOURCE OF COURSE MUST BE GROUNDED PROPERLY LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 19 INSTALLATION A 19 FIGURE A 17 LN 7 amp LN 7 GMA TO
32. MA LINCOLN B 6 OPERATION B 6 FIGURE INSTALLING DRIVE ROLLS ON A FOUR ROLL FEEDER 42 CLAMPING COLLAR Kg DRIVE ROLL ON HALVES SPACER IF REQUIRED Wu iS 1 7 LES Be KEY T OUTPUT Pa Jr gt E GUIDE TUBE DETAIL RADIUS OUTGOING GUIDE TUBE OUTGOING GUIDE TUBE INSERT MIDDLE GUIDE TUBE SMALL RADIUS LN 7 amp LN 7 GMA LINCOLN B 7 OPERATION B 7 IDLE ROLL PRESSURE SETTING 2 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 varies After outgoing pressure is set determine how many turns away from full pressure the setting is Set both idle roll tensions to this setting Engage both idle rolls before welding For most applications best wire feeding will occur when both idle roll pressures are set the same with type of wire surface condition lubrication and FIGURE B 4 IDLE ROLL PRESSURE SETTING hardness The optimum idle roll setting can be determined as follows Two roll wire feeders 1 Press the end of the gun against a solid object that is electrically isolated from the welder output
33. MA must have a K527 Water ports on your water cooling units Solenoid Kit installed see the Accessories Section The K440 1 LN 7 GMA model already has a water 2 In the event the water line fittings on your water solenoid installed Refer to Figure A 19 and perform cooled gun are incompatible with the female quick the following steps connects on the front of the LN 7 male quick connects are provided for installation on 3 16 in NOTE If not using a Lincoln water cooler and if your LD hose customer to provide appropriate water cooling device is not designed for use with a clamps The feeder connectors self seal when waterline solenoid valve you may remove the solenoid disconnected and screw the male fitting after applying sealant directly into the brass manifold block FIGURE A 19 WATER CONNECTIONS BACK LN 7 amp LN 7 GMA LINCOLN A 22 SHIELDING GAS HOOKUP LN 7 GMA or LN 7 with Optional K494 Gas Solenoid Installed WARNING 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 the American Welding Society Customer must provide a cylinder of shielding gas a pressure regulator a flow control valve and a hose INSTALLATION A 22 from the
34. N JHL NI LOLS SAOL TT Sc LNTNO ON 1VISO3HH 9334 auiM leg Ve JE GATIVLSNI SI RCI H3HLI3 Q3AOW3H SI Vee MSZ 419V141934 LIM MOvaNung ep HO H3IALL VAD IVNOILdO O N ves 625 J19V1d393H YALAW ON ONILV8H dlAV 400 OWA SEE JATIA GION31OS VNOI LdO OL Vc Z S IVNIINH3 L LO3NNOO MOIND LASSY 4019310Hd aval GNNOYS 43V344 LINDYIO S G F 1 ddl NHOJSNVU d399lu L ADVLIOA v HOLOVINOO OL n ONE p 7 lt lt lt lt 8n gt d IOHLNOO ze de V OLIMS i gt 25 Le 8 N ger 929 Ege EI 22 609 809 ia gt Aus s s OfYld UN 4313W YALAW TV1ISIG IWNOILdO TWNOILdO AINO SNN9 031000 H31VM VND Z N1 GION310S H31VM A NO WD 1 GION310S SVO YOLOW anas DNIGNNOYSD ASVO LN 7 amp LN 7 GMA LINCOLN amp NOTES LN 7 amp LN 7 GMA LINCOLN NOTES LN 7 amp LN 7 GMA LINCOLN NOTES LN 7 amp LN 7 GMA LINCOLN Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground WARNING Spanish No toque las partes o los electrodos AVISO D bajo carga con la piel o ropa moja P H ECA U C
35. N KILL POWER SOURCE 7177777 LN 7 GMA 21 21 2 4 31 32 WIRE FEEDER 4 4 Ss p LU ce EM X O OO N B 11 LN 7 GMA CONTROL CABLE K291 N D N E ELECTRODE CABLE NA TO WIRE FEED UNIT N G TO WORK N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B IF LEAD 21 IS EXTENDED TO THE WORK PIECE DO NOT CONNECT LEADS TO TERMINAL 21 ON TERMINAL STRIP IF LN 7 GMA IS EQUIPPED WITH A METER KIT EXTEND LN 7 GMA CONTROL CABLE LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD MAY BE ORDERED FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE INDEPENDENT OF THE WELDING WORK CABLE CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD IF THE LENGTH OF WELDING WORK CABLE IS SHORT LESS THAN 20 FEET 7 6 M AND CONNECTIONS CAN BE EXPECTED TO BE RELIABLE THEN CONTROL CABLE LEAD 21 DOES NOT NEED TO BE EXTENDED AND CAN BE DIRECTLY CONNECTED TO TERMINAL 21 ON THE TERMINAL STRIP NOTE THAT THIS IS NOT THE PREFERRED CONNECTION BECAUSE IT ADDS ERROR TO THE LN 7 GMA VOLTMETER N C TAPE UP BOLTED CONNECTION IF LEAD 21 IS EXTENDED ND CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 7 NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE GROUNDING TERMINAL MARKED AND LOCATED NEAR THE POWER S
36. NGTH OF WELDING WORK CABLE IS SHORT LESS THAN 25 FEET 7 6 M AND CONNECTIONS CAN BE EXPECTED TO BE RELIABLE THEN CONTROL CABLE LEAD 21 DOES NOT NEED TO BE EXTENDED AND CAN BE DIRECTLY CONNECTED TO TERMINAL 21 ON THE TERMINAL STRIP NOTE THAT THIS IS NOT THE PREFERRED CONNECTION BECAUSE IT ADDS ERROR TO THE LN 7 GMA VOLTMETER N C TAPE UP BOLTED CONNECTION IF LEAD 21 IS EXTENDED N D CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 777 NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE GROUNDING TERMINAL MARKED AND LOCATED NEAR THE POWER SOURCE INPUT POWER CONNECTIONS MUST BE PROPERLY CONNECTED TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL N E IF AN OPTIONAL REMOTE VOLTAGE CONTROL IS USED CONNECT IT TO THIS TERMINAL STRIP DC 400 CODE 9200 AND LATER IF LEAD 21 OF THE CONTROL CABLE IS TO BE CONNECTED TO THE TERMINAL STRIP CONNECT IT TO THE 21 TERMINAL THAT MATCHES THE WORK POLARITY THIS CONNECTION MUST BE CHANGED WHENEVER THE ELECTRODE POLARITY IS CHANGED N G DIAGRAMS SHOW ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF AND REVERSE ELECTRODE AND WORK CABLE LEADS AT POWER SOURCE LINCOLN ELECTRIC _ CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN INSTALLATION A 6 FIGURE AA LN 7 amp LN 7 TO PULSED POWER 500 CONNECTION DIAGRAM WARNING TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER ELECTRIC SHOCK CA
37. NT 1 Turn the Readi Reel or spool 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 6 first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a birdnest Insert the free end through the incoming guide tube Press the gun trigger and push the electrode into the drive roll WARNING ELECTRIC SHOCK e can kill e Do not touch electrically live parts such as output terminals or internal wiring e When inching with the gun trigger electrode and drive mechanism are hot to work and ground Inch the electrode through the gun Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped Do not overtighten LN 7 amp LN 7 GMA LINCOLN B 10 WIRE REEL LOADING 50 AND 60 LB COILS K303 OR K376 WIRE REEL STAND 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 It should be at the outer position for the faster wire speeds often used when feeding smaller diameter electrode To adjust the brake position remove the wire
38. OURCE INPUT POWER CONNECTIONS MUST BE PROPERLY CONNECTED TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL N E IF AN OPTIONAL REMOTE VOLTAGE CONTROL IS USED CONNECT IT TO THIS TERMINAL STRIP N F IF LEAD 21 OF THE CONTROL CABLE IS TO BE CONNECTED TO THE TERMINAL STRIP CONNECT IT TO THE 21 TERMINAL THAT MATCHES THE WORK POLARITY THIS CONNECTION MUST BE CHANGED WHENEVER THE ELECTRODE POLARITY IS CHANGED N G DIAGRAMS SHOW ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF AND REVERSE ELECTRODE AND WORK CABLE LEADS AT POWER SOURCE LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 7 INSTALLATION A 7 FIGURE A 5 LN 7 amp LN 7 GMA TO CV CVI POWER SOURCES WITH 14 PIN AMPHENOL CONNECTOR CONNECTION DIAGRAM WARNING TURN INPUT POWER OFF e BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER ELECTRIC SHOCK CAN KILL CV CV I POWER SOURCE OPTIONAL K857 14 PIN REMOTE CONTROL AMPHENOL N C 6 PIN pe AMPHENOL i 5 LN 7 GMA WIRE FEEDER NA AND TO WORK N B K480 INPUT CABLE TWIST MATE CONNECTOR ELECTRODE CABLE K854 OR K594 STUD TYPE OUTPUT TERMINALS N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B DIAGRAM SHOWS ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF AND REVERSE ELECTRODE AND WORK CABLE LEADS AT POWER SOURCE N C USE OF K857 REMOTE CONTROL MAY REQUIRE THE INSTALLATION OF
39. POWER SOURCES WITH CONTACTOR AND NO TERMINAL STRIP CONNECTION DIAGRAM warning TURN INPUT POWER OFF A BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER ELECTRIC SHOCK N B POWER SOURCE CAN KILL POWER SOURCE N INTERNALLY POWERED EXTERNALLY POWERED CONTACTOR COIL OUTPUT WORK CONTACTOR COIL WORK FOR POWER TO 115V AC OPERATE CONTACTOR NH NC AND ND NE NC AND N D TO TO TO WORK u WORK TO WORK li WORK NA N G li o NA N G e E o Ki NS Ki NS TO 115V AC TO 115V AC 350 VOLT lt 31 350 VOLT AMP lt 31 CAPACITY 14 32 CAPACITY 14 29 lt lt TAPE UP EE TAPE UP EACH LEAD EACH LEAD LN 7 GMA WIRE FEEDER E LN 7 GMA WIRE FEEDER LN 7 GMA CIRCUIT INPUT TO LN 7 GMA CIRCUIT INPUT CONTROL CONTROL Kass SCH A CABLE 115V AC WILL NOT TURNED OFF WHEN POWER SOURCE IS TURNED OFF KIT AND SEMIAUTOMATIC OR AUTOMATIC EQUIPMENT WILL STILL HAVE 115V CONTROL POWER SUPPLIED UNTIL POWER SUPPLIED TO TERMINALS 31 AND 32 15 TURNED FF N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N C EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATING WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT
40. RETURN TO MAIN MENU LN 7 and LN 7 GMA Wire Feeders s gt 2 and 4 Roll Models For machines with code numbers 9100 and above Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful LN 7 GMA shown with optional K417 digital meter kit and K418 GMA timer kit E OPERATOR S MANUAL ISO 9001 wa gt ENIM 7 ams 2 k in E p ni Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 Copyright O Lincoln Global Inc LINCOLN ELECTRIC World s Leader in Welding and Cutting Products e 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 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of Cal
41. TES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR f gt MM CBHOA A OIRBEEK MA C F uv CL THHORSRMELTES TRE S Pt 88 BB BUH 38 AROS R R BAL R ER OREN LARP R J t 5 BB 55 S RERE 0 lol SxS AID FAS EPEAT aad sl Catia Al Sud Aale Sall v i y aat L LINCOLN LINCOLN E e World s Leader in Welding and Cutting Products 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
42. TFLOW CONTROL OPTIONAL This control located on the optional K418 GMA Timer Kit provides flow of shielding gas to the work after welding has stopped Delay for the gas solenoid valve shutoff is adjustable from 0 to 1 5 seconds Turn the knob to the left for shorter delays and to the right for longer delays LN 7 amp LN 7 GMA LINCOLN B 3 OPERATION 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 wire feeder but not the gas solenoid or the welding power source ELECTRODE POLARITY SWITCH OPTIONAL This switch located on the optional K416 Digital and K417 Analog Meter Kits controls the polarity of the meter Set this switch to the same polarity as the electrode lead to allow correct operation of the meter CIRCUIT PROTECTION A manual reset circuit breaker protects the AC supply line and the wire feeder from overloads usually caused by excessive wire drag or other wire feed problems To reset the circuit breaker raise the cover of the wire drive compartment and push the white button on the side of the control box above the drive rolls The LN 7 and LN 7 GMA also include a Ground Lead Protector GLP circuit and fuse in the 2 4 contactor c
43. THE OUTPUT SELECTOR SWITCH TO A CV POSITION PLACE WIRE FEEDER SWITCH TO WIRE FEEDER WITH CONTROL CABLE POSITION N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION CLEVELAND OHIO U S A LINCOLN ELECTRIC LN 7 amp LN 7 GMA LINCOLN A 18 INSTALLATION A 18 FIGURE A 16 LN 7 amp LN 7 GMA TO POWER SOURCES WITH NO OUTPUT CONTACTOR CONNECTION DIAGRAM A WARNING TURN INPUT POWER OFF BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER TO SEMIAUTOMATIC 3 OR AUTOMATIC CONTROL BOX ELECTRIC SHOCK CAN KILL N F CONTROL CABLE N D N B A K 240 CONTACTOR KIT N C 115V 60 HZ TO RECONNECT FOR 50 HZ SEE INSTRUCTIONS ON INSIDE COVER NOTE 600 AMP CAPACITY m ML L ELECTRODE CABLE TO SEMIAUTOMATIC OR AUTOMATIC AUTO POWER SHUNT POWER EQUIP SOURCE SOURCE EENE work 115V AC WILL NOT BE TURNED OFF WHEN POWER SOURCE IS TURNED OFF KIT AND SEMIAUTOMATIC OR AUTOMATIC EQUIPMENT WILL STILL HAVE 115V CONTROL POWER SUPPLIED UNTIL POWER SUPPLIED TO TERMINALS 31 AND 32 IS TURNED OFF N B ON LINCOLN POWER SOURCES WITHOUT A REMOTE CONTROL TERMINAL STRIP HAVING THESE NUMBERS OR WHEN USING NON LINCOLN POWER SOURCES TAPE UP THESE LEADS SEPARATE
44. TROL IS USED CONNECT IT TO THIS TERMINAL STRIP N F TAPE UP BOLTED CONNECTION IF LEAD 21 IS EXTENDED NG FOR DC 600 CODES BELOW 8200 CONNECT A JUMPER FROM N TO S THERE IS NO N P S TERMINAL STRIP ON CODES ABOVE 8200 LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 7 amp LN 7 GMA LINCOLN A 13 INSTALLATION A 13 FIGURE A 11 LN 7 amp LN 7 GMA TO R3S 400 600 OR 800 CONNECTION DIAGRAM WARNING TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER ELECTRIC SHOCK CAN KILL POWER SOURCE 1 LN 7 GMA LN 7 GMA CONTROL CABLE 4 2 WIRE FEEDER AND 21 ELECTRODE CABLE TO LN 7 GMA CONDUCTOR BLOCK TO WORK N A AND N D N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATING WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 9 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED 21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE REMOTE WORK LEAD ACCESSORY ON LN 7 GMA METER KITS WHICH HAVE A DIRECT WORK LEAD JACK AN LN 7 GMA NOT EQUIPPED WITH A METER KIT DOES NOT REQUIRE LEAD 21 TO BE EXTEND
45. 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 Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see i
46. able for the LN 7 GMA wire feeder Refer to the Accessories section for complete descriptions TABLE A 1 LN 7 GMA CONNECTION DIAGRAMS meer o remm EN LN 7 GMA To DC 400 DC 250 and CV CVI Power Sources With Terminal Strip Connection Diagram LN 7 GMA To Pulsed Power 500 Connection Diagram LN 7 GMA To CV CVI Power Sources With 14 Pin Amphenol Connector Connection Diagram A 6 LN 7 GMA To CV CVI Power Sources With Twist Mate Connector and 14 Pin Amphenol Remote Control Connection Diagram LN 7 amp LN 7 GMA LINCOLN A 3 INSTALLATION A 3 1 For K291 and K404 cables connect the end of the 4 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 called for on the connection diagram Do not add any other jumpers or connections WARNING Referring to Figure A 1 route the end of the electrode cable through the large hole in the back panel of the LN 7 case Connect the electrode cable to the brass conductor block on the front of the gearbox using the 1 2 13 x 75 bolt provided Be sure the cable is placed to allow easy access and clearance for the idle roll arm pressure adjustment and to allow the drive roll section cover to close Never operate a Lincoln power source that has a FIGURE A 1 INPUT CONTROL CABLE
47. accidental contact with the workpiece or ground use the following equipment e Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder e AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 2 ARC RAYS 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 standards 4 6 Use suitable clothing made from durable flame resistan
48. act your Local Authorized Field Service Facility LN 7 amp LN 7 GMA LINCOLN F 1 luowyed9q 21199 3 O 1921U09 pue opoo eui jioeds p p u si Sopoo UE JOeX9 JOU S 1nq pun siy e91d SI siy 69 91008 9 464 SIOEGWAS 1V91419113 quvoa IDHINO9 Z N1 N3349 9 JOYLNOD 3LIHM M ep J gt ONIGOO QV31 0 gt Bess quvog JO ACIS ININOdWOD y gt JONANODAS SNIH3SIAQN 26 ALIAVO HOLOANNOO ES 9 L Z EN e 390319373 39018 YHOLONGNOO WIRING DIAGRAM ld 7 9 gt c LOH D gt weg El Les lt 9 LE lt VCE lt 804 601 0 609 A d lt zz H 9 29 4 d LOLHO 176 6 S m J18VO 3 NND ON voir G a xXovaNung Ge LOIS 2 TWNOILdO STT 318VO NND HANIL 1 3 ON TWNOILdO KI ECK ITT LA ava L 5 ONIGNNOYD NI 9NIMO 1H cd YyYYY IYITYITI IN3HHfIO GALVALLOV TN cR T 9214 18 F NOILISOd 24 lt 6 Ee v ew d FHL NI LOIS o Sch 2 I N1 NO e lt lt eed vvS 2 lt es NOIL VH31399V MOTS pp c 228 929 NOLLISOd zy M V
49. and press the trigger for several seconds 2 Ifthe wire birdnests jams or breaks at the drive roll the idle roll pressure is set too high Back the pressure adjustment knob Figure B 4 out 1 2 turn Run new wire through the gun and repeat step 1 3 If the only result is drive roll slippage loosen the gun cable clamping screw on the conductor block and pull the gun cable forward about six inches There should be a slight waviness in the exposed wire If there is no waviness the pressure is too low Increase the pressure setting 1 4 turn Lock the gun cable in place and repeat steps 1 and 2 AT ay PRESSURE Four roll wire feeders ADJUSTMENT 1 Release the incoming idle roll and perform the pressure setting procedure for two roll feeders to set outgoing idle roll pressure KNOB LN 7 amp LN 7 GMA LINCOLN B 8 OPERATION 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 o clock position 3 Position the Readi Reel so that it will rotate in a clockwise direction when feeding wire is to be de reeled from the bottom of the coil 4 Set one of the Readi Reel inside cage wires on the slot in the
50. at the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom 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 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 7 amp LN 7 GMA LINCOLN I TROUBLESHOOTING amp REPAIR 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Rough wire feeding or wire not feed 1 Gun cable kinked and or twisted 1 Inspect gun cable and replace if ing but drive rolls are turning necessary Wire jammed in gun and cable Remove wire from gun and cable feed in new wire Note any obstructions in gun and cable Replace gun and cable if neces Sary Incorrect size or installation of Refer to Operation Section for
51. be pee connected to the LN 7 GMA and LN 7 078 5 64 2 0 mm Drill ein FIGURE D 1 LN 7 CONNECTORS 055 1 4 mm 54 Drill All dimensions in inches and millimeters 749 19 0 747 18 9 62 15 7 dia 03 x 45 76 x 45 062R 1 5R A Dia Hole FIGURE D 2 SWITCH REQUIREMENTS 295 7 49 Em _ 290 7 36 nector must insulated in this area k 1 00 26650 2 00 25 4 1 2 Amp AC 24 Volts Inductive 51 0 8 n 1 2 Amp DC 24 Volts Inductive LN 7 CONNECTOR FOR 1 16 7 64 1 6 2 0 MM WIRE To Gun Switch Connect Leads to Pins A amp 12024 1 L E Part No Amphenol AN3057 10 or equiv 12020 6 L E Part No Amphenol MS 3106A 18 11P or equiv 180 4 5 COMIN 03 x 45 76 x 45 LN 7 CABLE CONNECTOR FOR 023 052 0 6 1 3 mm WIRE FOR ALL OTHER DIMENSIONS SEE ABOVE Dia Hole 495 12 5 Max Dia NOTE Connector part with 7459 747 19 0 18 9 diameter should be made from brass if it is to be part of the welding current carrying circuit LN 7 amp LN 7 GMA LINCOLN D 4 MAINTENANCE D 4 LN 7 SEQUENCE OF OPERATION Optional Timer Kit not Installed Turn on Power Source Press Gun Trigger Closes 524 525 Energizes 1 CR Closes 2 4 Circuit Closes 31 7A circuit 115V AC input power Energizes welder is applied to SCR pilot relay control circuit and Energizes aux equipment and or
52. ck lashing of the coil which may tangle the wire A tangled coil will not feed It must be untangled or discarded 8 Cut and remove only the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires 9 Replace the reel on the wire feeder Grasp the shaft knob pull it out and swing it across the reel hub locking the reel in place FIGURE B 6 LOADING A 50 OR 60 LB COIL SPINNER NUT e COVER SS PLATE SLOTS CARDBOARD COIL LINER TIE WIRE SPRING LN 7 amp LN 7 GMA LINCOLN 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 birdnest 3 Insert the free end through the incoming guide tube 4 Press the gun trigger and push the electrode into the drive roll WARNING ELECTRIC SHOCK can kill e e Do not touch electrically live parts such as output terminals or internal wiring e When inching with the gun trigger electrode and drive mechanism are hot to work and ground 5 Inch the electrode through the gun OPERATION B 11 WIRE LOADING 13
53. d features are the same as other LN 7 GMA models The K521 LN 7 semiautomatic constant speed wire feeder is recommended for self shielded flux cored Innershield electrodes submerged arc welding and other open arc welding lt has the following features e Wire feed dial 50 to 500 in min 1 27 to 12 7 m min Wire drive uses a permanent magnet motor and includes tool less quick release idle roll pressure arm outgoing guide tube and gun cable fastening Optional factory installed water solenoid and fittings for use with water cooled welding guns LN 7 amp LN 7 GMA LINCOLN B 2 OPERATION 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 feeding wires ranging from 0 023 in through 1 16 in 0 6 through 1 6 mm solid 0 045 in through 5 64 in 1 2 through 2 0 mm Innershield and 0 062 in through 5 64 in 1 6 through 2 0 mm Outershield electrodes The LN 7 is capable of feeding wires ranging from 0 023 in through 3 82 in 0 6 through 2 4 mm solid and 0 045 in through 7 64 in 1 2 through 2 8 mm cored FIGURE B 1 WIRE FEEDER CONTROLS PREFLOW POSTFLOW CONTROL CONTROL OPTIONAL OPTIONAL PURGE COLD INC
54. del trabajo de la tierra French ATTENTION German WARNUNG ATENCAO Japanese SI Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e lsolez vous du travail et de la terre Tele oder Elektroden mit Ihrem K rper oder feuchter Kleidung isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec da e Isole se da pe a e terra e REPORT SH J bnfdcfRihzuvcc T 1932 7 APSSAMMEBS NTWSRILTFAUY 345 tiri CHa 3645 Korean Jet WA ll al gaali YO Aral n ag ON d hl eich aal DA dua Ber hren Sie keine stromf hrenden trodos com a pele ou roupa molha Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos EGA PA m 35 B T 1F1 FPF o Se Aal nig Ji ALAN 3 gl e e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use prote o para a vista ouvido e corpo HRUSHICRBARELTE 84 ORR HRERSHRR
55. drive rolls and guide tubes proper installation of drive rolls and guide tubes Drive roll loose Remove clean install and tighten Gun cable dirty Clean cable or replace liner Worn drive rolls Replace Electrode rusty and or dirty Replace Worn nozzle or cable liner Replace Partially flashed or melted contact 19 Replace contact tip tip 10 Incorrect idle roll pressure 10 Set idle roll pressure see Operation Section of manual 11 Wire reel brake tension set too 11 Tension should be just high high enough to prevent overrun Variable or hunting arc 1 Worn and or melted contact tip 1 Replace tip remove any spatter on end of tip 2 Worn work cable or poor work connection 2 Inspect repair or replace as nec essary 3 Loose electrode connections 3 Be sure electrode lead is tight gun cable tight in wire feeder contact block gun nozzle and gun tip tight 4 Wrong polarity 4 Check connection at output studs for polarity required by welding process CAUTION lf 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 LN 7 amp LN 7 GMA LINCOLN E 3 TROUBLESHOOTING amp REPAIR E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Weld porosity narrow and ropey bead or electrode st
56. e assembly under the clamp and reinstall the screws 6 Referring to Figure A 2 install the input cable under the wire reel mounting stand strain relief FIGURE 2 STRAIN RELIEF CLAMP CONTROL CABLE STRAIN LI RELIEF CLAMP ELECTRODE CABLE LN 7 amp LN 7 GMA LINCOLN 5 INSTALLATION 5 FIGURE LN 7 amp LN 7 GMA DC 400 DC 250 AND CV CVI POWER SOURCES WITH TERMINAL STRIP CONNECTION DIAGRAM WARNING TURN INPUT POWER OFF BEFORE CONNECTING THE LN 7 GMA WIRE FEEDER ELECTRIC SHOCK CAN KILL POWER SOURCE K775 OPTIONAL N E REMOTE CONTROL LN 7 GMA WIRE FEEDER CV OUTPUT TERMINALS ON DC250 LN 7 GMA CONTROL CABLE K291 OR K404 N A e BEEN ELECTRODE CABLE TO WIRE FEED UNIT N A AND WORK WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B IF LEAD 21 IS EXTENDED TO THE WORK PIECE DO NOT CONNECT LEADS TO TERMINAL 21 ON TERMINAL STRIP IF LN 7 GMA IS EQUIPPED WITH A METER KIT EXTEND LN 7 GMA CONTROL CABLE LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD MAY BE ORDERED FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE INDEPENDENT OF THE WELDING WORK CABLE CONNECTION FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD IF THE LE
57. e will always be a small amount of air and possible drops of water coming out of the end of the tube coiled under the tank This is an automatic disposal system in case the plant air has water and dirt in it OPERATION B 14 K310 FLUX SCREEN OPTIONAL The unit was designed to fit the top of either the standard fill funnel or a K58 magnetic separator The unit has a steel screen with 0 065 to 0 075 in openings and an air vibrator attached to the frame The vibrator can be used with air line pressures ranging from 20 through 100 psi For ease of handling the user should connect the incoming air line to the 1 8 in pipe elbow with the aid of a quick disconnect type air coupling It is very important that reclaimed flux to be used in the continuous flux feeding system be passed through the K310 screen or its equivalent K58 MAGNETIC SEPARATOR OPTIONAL The K58 is a permanent magnet type separator designed to fit the top of the standard fill funnel of the continuous flux feeding system The purpose of the separator is to remove magnetic materials such as mill scale and any other extraneous magnetic materials which may have been recovered along with the flux to be processed It is important to remove these magnetic particles from the flux which is to be used in the continuous flux feeding systems If the magnetic material is not removed it will gather around the nozzle of the gun and impede or shut off the flux flow when making re
58. eding 0 023 in to 0 045 in wire sizes where there is a tendency for the electrode to overrun at the end of the weld causing sticking in the crater The kit provides a precise time delay that allows the wire to be burned off at the end of the weld The delay is adjustable for optimum burnback depending on wire size process procedure etc This kit also includes a cold inch switch The K419 Burnback Kit is also useful for those installations where the gun is clamped in a fixture and cannot be lifted from the work at the end of the weld Installation and operation instructions M15060 are included with the kit LN 7 amp LN 7 GMA LINCOLN C 3 ACCESSORIES C 3 K418 GMA TIMER KIT This kit is available to provide the following functions 1 Preflow Control Provides flow of shielding gas to the work before the arc is established The solenoid valve is energized immediately when the gun trigger is closed but the time delay before the wire feeder is energized is adjustable to between 0 and 1 5 seconds 2 Postflow Control Provides flow of shielding gas to the work after welding is stopped Solenoid valve shutoff delay after the trigger is released is adjustable from 0 5 to 4 5 seconds 3 Burnback Control Provides a precise time delay that allows the wire to be burned off at the end of the weld The delay is adjustable for optimum burnback depending on the wire size process procedure etc 4 Purge
59. eir physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 2 4 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source 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 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
60. flow valve to the gas inlet fitting of the LN 7 GMA or the K494 Gas Solenoid Valve Kit installed on the LN 7 Install per Figure A 20 and the following 1 Connect the supply hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the LN 7 2 Install the barbed fitting and union nut to the 5 8 18 female inert gas fitting on the front of the LN 7 Connect 3 16 in 4 8 mm 1 0 gas hose from the gun to the barbed fitting When the gun is to be removed this fitting can be easily detached by loosening the union nut FIGURE A 20 SHIELDING GAS HOOKUP E INERT A GAS S gt FITTING s 2 GAS HOSE GAS SUPPLY HOSE LN 7 amp LN 7 GMA LINCOLN B 1 OPERATION B 1 Read and understand this entire section before operating your machine SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground e Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING CUTTING and GOUGING SPARKS can cause fire or explosion Keep flammable material away Do not weld cut or g
61. gmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 du corps PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES A SOUDER A SH TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de et des projections quand on soude ou quand on regarde Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans ap
62. henever air no longer escapes from the coiled tube under the flux tank TO CLEAN Turn off the incoming air and release the tank pres sure Remove the coiled aluminum tubing from the bottom of the filter unit Remove the pinched copper end piece from the end of the aluminum tube Wash all the material out of the aluminum tube Clean out the short pinched section this should have a gap of between 005 to 050 in to allow a small amount of air to escape when the equipment is being used If this end piece is badly corroded replace it with a new piece Loosen the collar on the 2 1 8 inch steel filter tube and take the filter tube off the machine Wash out com pletely Fit steel tube back into its bottom Fill the steel tube to within two inches of the top with any clean Lincoln submerged arc welding flux Raise the steel tube into place and tighten the collar When the air pressure is turned on again part of the flux in the steel tube will be forced into the coiled tube Be certain a small amount of air is escaping from the pinched end of the copper tube LN 7 amp LN 7 GMA LINCOLN 0 3 MAINTENANCE D 3 GUN CABLE CONNECTOR REQUIRE MENTS TO PERMIT PROPER CONNEC A Diameter Hole TION TO LINCOLN LN 7 GMA AND LN 7 7 0 size s WIRE FEEDER in mm Diameter Within 008 20 F I M The following Figures D 1 and D 2 should serve as a 152 24 Drill guide to determine if a particular gun or switch can
63. identification information below for future reference This information can be found on your machine nameplate Product Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below 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 TABLE OF CONTENTS Page SEI EE TAS CU AMON Section A
64. ifornia to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines 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 amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 h To avoid scalding do not remove the AN dicio aan dat hen the engine i powered equipment GER pressure cap when the engine is 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 6 Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 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 amp EL
65. ional remote voltage control if used Set the open circuit voltage to approximately 2 volts higher than the desired procedure voltage The final setting must be made according to the arc voltage while welding The wire speed control on the front of the wire feeder Figure B 8 has a dial that is calibrated directly in inches per minute Set the control for the desired procedure wire speed FIGURE B 8 SETTING WIRE SPEED SPEED LN 7 amp LN 7 GMA LINCOLN 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 contact with the work The work must also be grounded WARNING When using an open arc process it is necessary to use correct eye head and body protection 3 Position the electrode over the joint The end of the electrode may be lightly touching the work 4 Lower your welding helmet Close the gun trigger and begin welding Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used 5 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out WIRE REEL CHANGING At the end of a
66. ipe them clean Wipe the output shafts and locating shoulders clean Install one roll onto either output shaft using the drive key clamping collar and hex head screw Certain size drive rolls consist of two roll halves and may contain a spacer If the drive roll you are installing contains a spacer the spacer fits between the two halves of the drive roll Tighten the hex head screw 7 5 Install the middle guide tube but do not tighten at this time When installing a 0 035 middle guide tube the larger radius should be aligned towards the drive roll Slide the guide tube up against the drive roll Install the second drive roll on the remaining shaft the same way as the first Center the middle guide tube between the rolls and tighten the thumbscrews holding it in place Close and latch both quick release levers Slide the incoming guide tube into the rear hole of the gearbox until it almost touches the drive roll and guide tube Tighten the thumbscrew to hold it in place Install the outgoing guide tube into the front hole of the gearbox through the conductor block and tighten the thumb screw The 0 035 in outgoing guide tube should have the larger radius oriented toward the drive roll For proper installation of the outgoing guide tube insert refer to Figure B 3 Be certain that the guide tubes do not touch the drive rolls or idle rolls If they do touch readjust them and tighten in place LN 7 amp LN 7 G
67. ircuit The frame of the LN 7 wire feed unit is grounded to the frame of the power source by a lead in the control cable The GLP circuit prevents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the gun trigger is pressed When the protector circuit is tripped the wire feed rolls will not turn and the welding contactor in the power source will not close when the gun trigger is pressed To reset the protector circuit press the red button above the drive rolls and to the left of the circuit breaker There is no visual indication when the protector circuit is tripped AVOIDING GROUND LEAD PROTECTOR GLP ACTIVATION DO NOT allow the electrode to contact the case of the wire feeder or the uninsulated part of the wire reel stand when the gun trigger is activated Be sure that all work lead connections to the work make tight metal to metal contact DO NOT allow excess input cable or work cable to be placed closer than three feet from the wire feeder DO NOT coil excess input cable assembly or use a coiled assembly as shipped from the factory Instead loop the excess cable length back and forth in three to six foot straight lengths Coiling the input cable results a transformer action between the electrode conductor cable and the ground lead in the multiconductor control cable This transformer action can cause a current to flow in the ground lead which will falsely activate the GLP c
68. ircuit To reset the GLP circuit press the red button above the drive rolls and to the left of the circuit breaker DRIVE ROLL INSTALLATION CHANGING DRIVE ROLLS FOR TWO ROLL WIRE FEEDERS To change drive rolls on a two roll wire feeder refer to Figure B 2 and perform the following steps 1 Rotate the latch knob on the quick release arm 2 Remove the hex head screw and clamping collar Remove the drive roll from the shaft The new roll to be installed is stamped for the size to be fed An A after the size indicates aluminum wire Remove the rolls from the kit and wipe them clean Wipe the output shaft and locating shoulder clean 4 Use the drive key clamping collar and hex head screw to install the roll on the output shaft Certain size drive rolls consist of two roll halves and may contain a spacer If the drive roll you are installing contains a spacer the spacer fits between the two halves of the drive roll Tighten the hex head screw 5 Back out the guide tube clamping screws Remove the old guide tubes if installed 6 Insert the outgoing guide tube the one with the plastic insert into the front hole If the guide tube has a non symmetrical chisel end the larger radius must face the drive roll See Figure B 2 Push the guide tube back as far as it will go and tighten the clamping screw Insert the incoming guide tube as far back as it will go and tighten the clamping screw The clamping screws are
69. l electrode at up to 500 amps The K113 gun and cable is recommended for 5 64 in and 3 82 in 2 0 and 2 4 mm solid steel electrodes types L50 L60 L61 and 170 for use up to 600 amps GMAW GUNS An expanding line of Magnum GMA gun and cable assemblies are available to allow welding with solid and cored electrodes using the GMAW process See the appropriate Magnum literature for descriptions of the 100 500 ampere air cooled gun and cables that are available Gun cable lengths range from 10 to 25 ft 3 0 to 7 5 m and feed electrode sizes 0 023 in to 3 32 in 0 6 to 2 4 mm NOTE Magnum GMA welding guns require a K466 1 connector for use with an LN 7 GMA wire feeder K527 WATER SOLENOID KIT Install and connect per the instructions M16261 shipped with the kit This kit is factory installed on the K440 1 LN 7 GMA K494 LN 7 GAS SOLENOID KIT Standard on LN 7 GMA Install per the instructions M16057 shipped with the kit K303 50 TO60 LB WIRE REEL MOUNTING STAND The K303 60 Ib Wire Reel Mounting Stand includes a dust shield The assembly includes a framework to which is attached the 50 to 60 Ib wire reel a mounting spindle a lift bale and a cable clamp for fastening the input cable assembly It is easily mounted to the basic wire feed unit by following the Attaching the Wire Reel Stand procedure at the end of this section ATTACHING THE WIRE REEL STAND The mounting hardware for mounting the stands is incl
70. latively long welds or welding continuously The magnetic particles can also cause porosity in the weld LN 7 amp LN 7 GMA LINCOLN 1 ACCESSORIES GENERAL The following is a list of the accessories that can be used with the LN 7 GMA wire feeder TABLE C 1 LN 7 GMA ACCESSORIES Product Number K162 1 K163 419 K418 Spindle Kit Two inch Hub Undercarriage Burnback timer kit GMA Timer Kit 417 K320 K303 M 11514 Digital voltmeter kit Flux tank 50 60 Ib Wire reel mounting stand Wire reel dust shield door for K303 Weld Power Cables K1840 10 Twist Mate to Lug 1 0 350A 6096 Duty Cycle 25 ft K1841 25 Twist Mate toTwist Mate 1 0 350A 6096 Duty Cycle 25 ft K1841 50 Twist Mate toTwist Mate 2 0 350A 60 Duty Cycle 25 ft K1842 10 Lug to Lug 3 0 600A 6096 Duty Cycle 10 ft K1842 35 Lug to Lug 3 0 600A 6096 Duty Cycle 35 ft K1842 60 Lug to Lug 3 0 600A 6096 Duty Cycle 60 ft K1842 110 Lug to Lug 4 0 600A 6096 Duty Cycle 110 ft Welding Guns K126 115 112 113 497 470 471 527 Water solenoid kit K494 Gas solenoid valve kit Included on LN 7 GMA K1818 10 Wire Feeder Control Cable 10 ft K1797 25 Wire Feeder Control Cable Extensions Requires K1818 10 K1797 50 K1798 Adapter Cable for Control Cable to Terminal Strip Power Source K1803 1 Work and Wire Feeder Power Cables Package Magnum GMA welding guns require a K466 1 connector for use
71. m 277 mm 10 9 kg GE WITH WIRE 20 68 in 9 76 in 17 00 in 36 Ibs STAND K377 525 mm 247 mm 432 mm 16 3 kg WITHOUT 9 70 in 11 60 in 11 11 in 30 5 Ibs WIRE STAND 246 mm 295 mm 282 mm 13 8 kg WITH WIRE 20 76 in 11 60 in 17 00 in 42 5 lbs STAND K377 527 mm 295 mm 432 mm 19 3 kg DUTY CYCLE The amount of welding performed in a 10 minute period expressed as a percentage 0 023 in through 3 32 in lid el LN 7 0 6 through 2 4 mm SES 0 045 in through 7 64 in 1 2 through 2 8 mm i LN 7 amp LN 7 GMA LINCOLN A 2 INSTALLATION A 2 WARNING MOUNTING LOCATION The LN 7 and LN 7 GMA wire feeder can be mounted directly on top of the power source providing that itis Turn input power off before connecting the LN 7 secure and level It can also be mounted to an GMA wire feeder undercarriage when portability is required For connecting an LN 7 GMA to a specific Lincoln MACHINE GROUNDING power source follow steps 1 through 6 and refer to the connection diagrams in Figure A 3 through A 17 for the specific power source Table A 1 lists each figure The LN 7 and LN 7 GMA wire feeders are ground to number with its corresponding power source the power source through the input cable The power source grounding terminal must be properly connected to electrical ground per the power source operating manual INPUT CABLE CONNECTIONS Various input cable assemblies are avail
72. me Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 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 Please record your equipment
73. models are set for fast acceleration Fast acceleration is typically the best for most smaller wire procedures Slow acceleration may be more desirable for long stickout applications or if a larger diameter electrode is being used Acceleration is set on the control PC board To gain access to the control PC board make certain the input power is off and remove the side cover on the control side of the LN 7 or LN 7 GMA To change the acceleration on earlier control PC boards reconnect the jumper to F Fast or S Slow Later control PC boards use a DIP switch S101 S101 has 8 circuits switches only circuit 1 is used Set circuit 1 in the F position for fast acceleration or in the S position for slow acceleration See Figure B 7 FIGURE 7 ACCELERATION SETTING LATER CONTROL PC BOARDS UNUSED CIRCUITS OPERATION CONTROL CIRCUIT 1 B 12 WIRE SPEED AND VOLTAGE ADJUSTMENT Use only constant voltage power type sources If using a multiple process power source be sure it is set for constant voltage output per instructions in the manual for the power source Set the power source polarity switch or properly connect the electrodes and work leads for the correct electrode polarity If the wire feeder is equipped with an optional meter kit set the meter polarity switch to the proper working polarity Set the voltage using the control on the power source or the opt
74. ouge on containers that have held com bustibles ARC RAYS can burn Wear eye ear and body protection Only qualified personnel should operate this equip ment Observe all safety information throughout this manual 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 and other open arc welding It has been factory assembled with the following features e Wire feed dial 75 to 700 in min 1 9 to 17 8 m min e Factory installed gas solenoid valve and gas fittings Wire drive uses a permanent magnet motor and includes tool less quick release idle roll pressure arm outgoing guide tube and gun cable fastening Optional factory installed water solenoid and fittings for use with water cooled welding guns The K567 1 LN 7 GMA 4 Roll is designed to provide the additional feeding force required when using gun cables over 15 ft 4 6 m long or when the wire is pulled long distances such as when bulk packages are used Because the four roll feeder has twice the contact surface it can also help when feeding softer wires by delivering the same or more feeding force as the two roll with less overall wire deformation Wire size range speed an
75. propri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you T hank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that ti
76. ps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on au
77. removing the internal hollow lock set screw from the contact tip end of the nozzle with a 5 32 or 3 32 Allen wrench The insert and retainer will normally fall out the end of the nozzle but if they do not gently drive the spring liner towards the outgoing end of the nozzle When re assembling nozzle make certain the ceramic nozzle insert if used is placed next to the spring liner The hollow lock set screw is to be tightened to give the dimension specified below as measured from the end of the nozzle to the hollow lock set screw DIMENSION K289 5 64 K289 3 32 amp 120 K309 LN 7 amp LN 7 GMA LINCOLN 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 feeder Lay it out straight on the floor Remove the contact nozzle tip from the gun Using an air hose and only partial pres sure gently blow out the cable Work the full length of the cable by bending it back and forth and then blow it out again Repeat this procedure until no more dirt comes out AUTOMATIC FLUX FEEDING SYSTEM K320 The only maintenance required on the flux feeding system is cleaning the water and sludge trap sump Do this every six months or w
78. retaining spring tab 5 Lower the Head Heel to depress the retaining spring and align the other inside cage wires with the grooves in the adapter 6 Slide the cage all the way onto the adapter until the retaining spring pops up fully WARNING Check to be sure the retaining spring has been fully returned to the locking position and has SECURELY locked the Readi Reel cage in place Retaining spring must rest on the cage not the welding electrode 7 To remove the Head Heel from the adapter depress the retaining spring with thumb while pulling the Readi Reel cage from the adapter with both hands Do not remove the adapter from the spindle FIGURE B 5 INSTALLING A 30 LB READI REEL PACKAGE 2 IN O D SPINDLE GROOVES READI REEL ADAPTER RETAINING SPRING THREADED LOCKING COLLAR INSIDE CAGE WIRES LN 7 amp LN 7 GMA LINCOLN B 9 OPERATION B 9 TO MOUNT 10 TO 30 LB SPOOL 12 DIAMETER 3 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 of the spool Be certain the wire comes off the reel in a clockwise direction when de reeled form the bottom of the coil 3 Replace and tighten the locking collar ELECTRODE FEEDING AND BRAKE ADJUSTME
79. s installed the auxiliary contacts open after the postflow time delay K162 1 SPINDLE The K162 1 spindle is used for mounting Readi Reels and 2 in 1 0 spools with a 60 capacity on a K303 Wire Reel Stand When used with Read Reels a Read Reel Adapter is required For 8 in O D spools a K468 Spindle Adapter is available The K162 1 is a high capacity design which replaces the original K162 30 lb spindle The K162 1 spindle has a white spacer and has part no M 14587 1 molded on The original K162 spindle has a black spacer and the part 14587 Parts may not be exchanged from one design to the other WARNING Do not use coils or spools heavier than 30 Ibs the original K162 spindle To mount the 2 in spindle kit for Readi Reels and 10 through 60 spools remove the shaft for the standard 50 60 pound wire coils from the mounting framework Install the spindle per the instructions M15241 shipped with the spindle kit K163 UNDERCARRIAGE The undercarriage includes casters wheels a handle and related hardware Casters are mounted at the front and wheels at the rear of the platform The handle is bolted to the front of the platform so the wire feeder can be tilted back and wheeled like a two wheel truck Installation sheet M13424 is provided with the undercarriage K419 BURNBACK TIMER KIT The kit is available for those applications where the LN 7 or LN 7 GMA is used for higher speed fine wire fe
80. t material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 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 with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 6 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 spe cific 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
81. tem 1 Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing a k a Use only compressed gas cylinders Sel CYLINDER may explode If damaged 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located e Away from areas where they be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association
82. tor to easily check the arc voltage and make adjustments if necessary to match procedures For accuracy it is important to release the gun trigger and the lift the gun away from the work The hold circuit automatically releases about six seconds after the gun trigger is released It is also released when the trigger is closed again to begin welding FIGURE B 9 ELECTRODE POLARITY SWITCH LX POLARITY SWITCH LN 7 amp LN 7 GMA LINCOLN B 14 FLUX TANK LOADING K320 FLUX TANK 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 provided put 100 pounds of flux in the tank It is very important that only new or properly reclaimed flux be put in the tank Coarse particles and or magnetic particles will stop the flux feeding process New Lincoln flux is properly screened at the factory All reclaimed flux must be separately screened through a vibrating screen with 0 065 in to 0 075 in openings and be put through a magnetic separator The K310 vibrated screen and K58 magnetic separator are available for this purpose The screen in the funnel supplied with the tank has much larger openings and its only purpose is to keep paper and slag out of the tank Ther
83. ubbing into plate when welding LN 7 circuit breaker trips while weld ing LN 7 or power source electrical problems such as Power source fuse blowing LN 7 circuit breaker tripping e No control of wire feed motor Wire feed motor not running Auxiliary equipment connected to 32A and 7 not working Power source contactor not working but LN 7 feeds wire PROBLEMS Contaminated weld joint or improper procedures Lack of shielding gas See problem 1 High ambient temperature caus ing circuit breaker to trip Electrical problems in power source or LN 7 Loose connections or broken lead Grounding lead protector tripped Electrical component has failed Contactor circuit fuse on motor control P C board blown Clean welded joint Check that controls are set correctly for pro cedure Obtain proper gas flow Correct problems Provide better ventilation for LN 7 Make sure ventilation louvers and clean and un obstructed See problem 5 Turn power source and LN 7 off and check leads and connections Push reset button Replace blown fuses or reset cir cuit breaker and try to weld If trouble reoccurs contact your local authorized field service shop Correct problem and replace fuse 2A 250V CAUTION lf for any reason you do not understand the test procedures or are unable to perform the tests repairs safely cont
84. uded with the LN 7 and LN 7 GMA Screws and washers are inserted in their respective mounting holes To connect 1 Remove the three 3 8 in hex head bolts from the back of the wire feed unit 2 Place the wire reel mounting stand mounting bracket in position against the back of the wire feed unit 3 Replace and tighten the hex head bolts The long screw and plain washer go into the top hole LN 7 amp LN 7 GMA LINCOLN 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 If a wire size other than that stamped on the rolls is to be used the rolls and guide tubes must be changed The drive rolls for 0 045 and 0 052 cored electrode and 1 16 0 068 5 64 3 32 and 7 64 electrode have a double set of teeth so they can be reversed for additional life Between the two knurled rolls except 1 16 and smaller rolls is a shim washer which limits the damage to the electrode if wire feeding problems occur Drive rolls for 0 023 through 0 052 solid electrodes have no teeth Refer to the instructions included with the drive roll kit for installation and replacement of the drive rolls on the wire feeder WIRE REEL MOUNTING To prolong

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