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LN-742 & LN-742H Wire Feeders

OPERATOR’S MANUAL

IM476-A

August, 2005

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part.

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.

For use with machines having Code Numbers:

10027
10028
10048
10049
10238
10239
10240
10241

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Содержание LN-742

Страница 1: ...RATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10027 10028 10048 10049 10238 10239 10240 10241 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 li...

Страница 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 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 availa...

Страница 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders ...

Страница 4: ...event the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Страница 5: ...propriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6...

Страница 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Страница 7: ...1 Controls and Settings B 2 Acceleration Setting B 3 English or Metric Speed Display Units B 3 Circuit Protection B 3 Drive Roll Installation B 3 Idle Roll Pressure Setting B 7 Wire Loading B 8 Making a Weld B 12 Wire Reel Changing B 12 Accessories Section C General C 1 Flux System Components C 2 Power Input Cables C 3 Welding Guns C 3 Spindles Stands and Adapters C 4 Attaching the Wire Reel Stand...

Страница 8: ...5 mm 10 89 in 277 mm 17 00 in 432 mm 11 11 in 282 mm 17 00 in 432 mm SYSTEM LN 742 LN 742H DIAMETER 0 025 in through 1 16 in 0 6 through 1 6 mm 0 025 in through 0 045 in 0 6 through 1 2 mm 0 045 in through 3 32 in 1 2 through 2 4 mm 0 035 in 0 9 mm TECHNICAL SPECIFICATIONS LN 742 INPUT VOLTAGE WIRE FEED SPEED WIRE DIAMETERS 40 to 42V 10 50 60 Hz 4 0 Amps WIRE SPEED RANGE 50 in to 770 in per minute...

Страница 9: ...a specific Lincoln power source follow steps 1 through 5 and refer to the connection diagram in Figure A 3 The welding cable used must be sized according to the current and the duty cycle of the application With input power disconnected at the source install the input cable per connection diagram A 3 and complete the following instructions 1 Connect the end of the control cable with the 14 pin cab...

Страница 10: ...clamp and reinstall the screws The connection diagram Figure A 3 shows the electrode as positive To change polarity turn the power source off Reverse the electrode and work cables at the power source and set the wire feeder voltmeter polarity switch on the power source to the proper polarity Pins not listed in the table in Figure A 3 are not connected on the cable If using the K589 1 remote contro...

Страница 11: ...LE PLUG REAR VIEW FUNCTIONS ARE LISTED FOR REFERENCE ONLY AND EACH MAY OR MAY NOT BE PRESENT IN YOUR EQUIPMENT 14 SOCKET BOX RECEPTACLE REAR VIEW AND 14 PIN CABLE PLUG FRONT VIEW 14 PIN AMPHENOL K 42 K 42 I 41 I 41 H 21 H 21 C 2 C 2 G 75 G 75 D 4 D 4 F 76 PIN C 2 TRIGGER CIRCUIT TRIGGER CIRCUIT OUTPUT CONTROL OUTPUT CONTROL OUTPUT CONTROL WORK 42V AC 42V AC 4 77 76 75 21 41 42 LEAD FUNCTION F 76 E...

Страница 12: ...oln 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 Section C Accessories 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 742 and into the br...

Страница 13: ...id and screw the male fitting after applying sealant directly into the brass manifold block 1 Using male 5 8 18 UNF left hand thread fittings connect appropriate water hoses to the coolant inlet and outlet on the back of the LN 742 Connect the other ends of these hoses to the appropriate ports on your water cooling units 2 In the event the water line fittings on your water cooled gun are incompati...

Страница 14: ... hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the LN 742 2 Install the barbed fitting and union nut to the 5 8 18 female inert gas fitting on the front of the LN 742 Connect 3 16 in 4 8 mm I D 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 The LN 742...

Страница 15: ...0 in min 1 25 to 19 5 m min for the LN 742 80 to 1200 in min 2 00 to 30 5 m min for the LN 742H 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 LN 742 ...

Страница 16: ... energized after preflow time when the trigger is released Closing the trigger a second time turns off the wire feeder and then the power source after burnback time Releasing the trigger a second time turns off the solenoid after Burnback time The bottom light indicates spot weld trigger mode Closing the trigger allows a single timed weld cycle The duration of the weld cycle is set with the time s...

Страница 17: ...from 1 slowest to 5 fastest This number is adjusted using the setting adjustment arrow keys To exit the acceleration setting function press both keys a second time or press any other key except for the setting adjustment arrow keys ENGLISH OR METRIC SPEED DISPLAY UNITS Pressing both the Gas Purge key and Timer Selection key causes the speed display units to toggle between inches per minute no deci...

Страница 18: ...E DETAIL OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE LARGE RADIUS DRIVE ROLL INCOMING GUIDE TUBE SMALL RADIUS IDLE ROLL CLAMPING COLLAR SPACER IF REQUIRED OUTPUT SHAFT DRIVE ROLL HALVES FIGURE B 2 INSTALLING DRIVE ROLLS ON A TWO ROLL FEEDER ...

Страница 19: ...ers by moving the levers outward and pulling them toward you 4 Loosen the thumb screws holding the guide tubes in place Remove the incoming and outgoing guide tubes if installed 5 Remove the hex head screws and clamping collars from the output shafts Remove the drive rolls and middle guide tube 6 The new rolls to be installed are stenciled with the wire size that will be fed An A after the number ...

Страница 20: ...URE B 3 INSTALLING DRIVE ROLLS ON A FOUR ROLL FEEDER GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE MIDDLE GUIDE TUBE SMALL RADIUS IDLE ROLL LARGE RADIUS CLAMPING COLLAR OUTPUT SHAFT SPACER IF REQUIRED DRIVE ROLL HALVES ...

Страница 21: ...sure 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 cab...

Страница 22: ...e bottom of the coil 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 7 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 8 Slide the cage all the way onto the adapter until the retaining spring pops up fully Check to be sure the Retaining Spring has fully returned to the locking po...

Страница 23: ...ly engage the retaining groove on the spindle ELECTRODE FEEDING AND BRAKE ADJUSTMENT 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 first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a b...

Страница 24: ...loaded arms will not interfere with the later removal of the coil tie wires 5 When loading 0 030 to 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...

Страница 25: ...ge DO NOT hammer on the spinner nut arms 4 Cut and remove only the tie wire holding the free end of the coil Hook the free end around the rim of the reel cover and wrap it around to secure Cut and remove the retaining tie wires FIGURE B 7 K1504 1 COIL REEL 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 roll...

Страница 26: ...ded The work cable must make good electrical contact with the work The work must also be grounded When using an open arc process it is necessary to use correct eye head and body protection 9 Position the electrode over the joint The end of the electrode may be lightly touching the work 10 Lower your welding helmet Close the gun trigger and begin welding Hold the gun so the contact tip to work dist...

Страница 27: ...el Adapter K376 and 303 50 to 60 lb Wire Reel Mounting Stands K1524 1 Universal Wire Reel Stand 2 Spindle K1504 1 60 lb Coil Adapter for K1524 1 Stand K1551 1 Insulated Lift Bail for K1524 1 Stand K1556 1 Caster Kit for K1524 1 Stand K1557 1 Swivel Platform for K1524 1 Stand K1819 25 Control Cable Assembly 25 Ft K1819 50 Control Cable Assembly 50 Ft K1819 75 Control Cable Assembly 75 Ft K1819 100 ...

Страница 28: ...57 can be installed on the LN 742 when it is used with newer Lincoln power sources that are equipped with a 6 socket ms type receptacle or K864 14 pin connector adapter for connection of the plug on the 28 ft 8 5 m control cable of the K857 See the instructions S19103 included with the kit FLUX SYSTEM COMPONENTS The flux system is available to permit the LN 742 to be used for submerged arc welding...

Страница 29: ...er end is an 8 pin anphe nol and the power source end is a 14 pin amphenol The control cable supplies 42VAC from the welding power source to the feeder It also carries a lead for the work voltage and sends signals for the gun trigger and remote voltage potentiometer See connection diagram of wire feeder to power source in the Installation Section K1817 CONTROL CABLE EXTENSIONS The control cable ex...

Страница 30: ... shield The assembly includes a framework to which is attached the 50 to 60 lb 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 UNIVERSAL WIRE REEL STAND K1524 1 Includes a 2 51mm O D Spindle with adjustable brake and ...

Страница 31: ...h adjustable brake and 50 to 60 lb 22 7 to 27 7 kg K438 Readi Reel adapter Includes a lift bail and cable clamp for fastening the input cable assembly Does not include a dust shield A dust shield that covers the wire reel and protects the wire from falling dirt and dust is available for this unit Order part number S14543 This unit will accept the M11514 door kit see K303 but only if already equipp...

Страница 32: ... 16 0 045 0 052 in 1 2 1 3 mm Solid KP653 052S KP655 052S 0 045 0 052 in 1 2 1 3 mm Cored KP653 052C KP655 052C 0 035 in 0 9 mm Solid KP653 035S KP655 035S 0 035 in 0 9 mm Cored KP653 035C KP655 035C 0 030 in 0 8 mm Solid KP653 030S KP655 030S 0 023 0 025 in 0 6 mm Solid KP653 025S KP655 025S Aluminum Wire Sizes 1 16 in 1 6 mm KP654 1 16A KP656 1 16A 3 64 in 1 2 mm KP654 3 64A KP656 3 64A 0 035 in...

Страница 33: ...s have no teeth Refer to the instructions in Section B Operation for installation of drive rolls WIRE REEL MOUNTING To prolong the life of the reel shaft on the 50 to 60 lb 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 ...

Страница 34: ...at 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...

Страница 35: ...ted No wire feed when the gun trigger is activated The solenoid does not function No arc voltage present The display board indicates the LN 742 has input power applied 1 Make sure the control cable is connected to the welding power source correctly 2 Make sure the welding power source is turned on and func tioning properly 3 Check the 42 VAC fuse or cir cuit breaker in the welding power source 1 C...

Страница 36: ...trol cable from the Lincoln power source Place a jumper across sockets C and D of the 14 pin amphenol plug at the power source Open circuit voltage should be pre sent at the welder output termi nals If no voltage is present at the output terminals the power source is faulty 2 The control cable may be faulty Check leads 2 and 4 pins C and D for continuity zero ohms 3 The welding cables may me fault...

Страница 37: ...e arrow or select keys are pressed The arrow keys do not change the welding wire feed speed 1 Make sure the polarity switch on the Lincoln welding power source is in the correct position for the welding process 2 Check or replace the control cable Check the continuity zero ohms of leads 21 and 67 1 Check for mechanical restric tions in the wire feed path 1 Make sure the control cable is connected ...

Страница 38: ... XX is some number from 1 to 10 The EP symbol appears on the display The uP symbol appears on the dis play Microprocessor RAM error 1 Contact your local Lincoln Authorized Field Service Facility 1 Check plug J6 located on the control board for loose or faulty connections 1 Contact your local Lincoln Authorized Field Service Facility 1 If the arc voltage is greater than 44 VDC this is a normal cond...

Страница 39: ...h or not feeding The drive rolls are turn ing The drive rolls do not turn when the gun trigger is pressed The gas solenoid activates and arc voltage is present 1 Check for mechanical restric tions in the wire feeding path Check the gun and gun compo nents 2 Check the drive roll position and idle roll pressure 3 The electrode may be dirty or rusty 4 Check for the correct gun liner tip and guide tub...

Страница 40: ...for loose or faulty connections 2 Make sure the wire feed speed voltage polarity and shielding gas are correct for the process being used 3 Check for mechanical restric tions in the wire feed path 4 Make sure the welding power source is functioning properly 1 Make sure the wire feed speed voltage polarity and shielding gas are correct for the process being used 2 Make sure the welding power source...

Страница 41: ...It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Страница 42: ...NOTES LN 742 LN 742H ...

Страница 43: ...NOTES LN 742 LN 742H ...

Страница 44: ...F 4 NOTES LN 742 LN 742H F 4 ...

Страница 45: ...F 5 NOTES LN 742 LN 742H F 5 ...

Страница 46: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Страница 47: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Страница 48: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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