DH-10 Heads & Controls OPERATOR'S MANUAL ... - Lincoln Electric

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A-2GENERAL DESCRIPTIONINSTALLATIONAVAILABLE MODELS:A-2The DH-10 is a modular line of 42VAC input dual head 4-rollwire feeders. A single control with dual procedure presettabilityof wire feed speed (in IPM or M/min) and arc voltagefor each head is used with a single DC welding powersource.The DH-10 models have controls providing keypad orremote selectability of wire drive head, and either of two procedurespreset independently for each head.The units offer 4 independently selectable gun triggermodes for each head procedure; cold feed, 2 step and 4-step trigger and spot weld mode.Also, 4 selectable, presettable timers for each head procedure;preflow, postflow, burnback and spot weld time.Arc starting can be optimized for each head procedure with5 selectable wire feed acceleration rates, and independentcontrol of slower run-in procedure.A gas purge key is provided, as well as cold feed forwardand reverse keys with independently adjustable forwardfeed speed setting.All of these features are selected with a tactile-feel keypad,and are set independently for each head using one of tworotating knob encoders, setting levels are displayed on oneof two digital LED displays.The DH Wire Drive assemblies include two heavy dutyheads with externally changeable gear ratio and 4 driven rolldrives housed together in a single combination mountingand connection box. Gun adapters are available to permituse with a variety of standard welding guns.The DH-10 Wire Feeder system is available configured inboth Bench and Boom models.Bench Models consists of a DH-10 control and a DHdouble header wire drive assembly premounted on aplatform with a dual 2" (50.8mm) O.D. spindle mounting.Boom Models consist of a DH-10 control and a choice ofwire drives designed to be mounted separately and joinedby available head to control cable assemblies.The head to control cable assemblies are available intwo types; one control cable is required for each head:K1785-”L”Includes a control cable with a 14-pinms style connection on each end, anda 3/0 weld cable. Available in lengths“L” of 12, 16 or 25 ft. (3.6, 4.9 or 7.6m) for recommended boom lengths of8-9 ft, 10-12 ft or 16-18 ft. respectively.(2.4-2.7m, 3.0-3.7m or 4.9-5.5m).The DH-10 boom packages are available in standardpackages as follows:K1521 -1 includes:DH-10 Control (Sames as K1496-1)DH-10 Std. Wire Drive Head (Same as K1497-1)16 ft. (4.9m) Control Cable (Same as K681-16)16 ft. (4.9m) Control and Weld Cable (Same as K1498-16)K1521 -4 includes:DH-10 Control (Sames as K1496-1)DH-10 Std.(Left)/Hi-Speed (Right) Heads (Same as K1497-2)16 ft. (4.9m) Control Cable (Same as K681-16)16 ft. (4.9m) Control and Weld Cable (Same as K1498-16)K1521 -7 includes:DH-10 Control (Sames as K1496-2)DH-10 Standard Wire Drive Heads (Same as K1497-3)16 ft. (4.9m) Control Cable (Same as K681-16)16 ft. (4.9m) Control and Weld Cable (Same as K1498-16)10 ft. (3.5m) Control CableAlso there are four additional Zipline Boom Packages(K1521-2,-3,-5,&-6). For specifications see IM596-4.DH-10
A-3RECOMMENDEDAND EQUIPMENTPROCESSESThe DH-10 Wire Feeder system is recommended foruse with solid wire gas-metal-arc or CV Submergedarc processes, as well as cored wire for Outershield,GMAW or Innershield processes.The wire type and size range for the wire drive used,and gear ratio change selected, are given in theSpecifications.Recommended power sources are Lincoln ElectricCompany constant voltage power sources with 42VAC auxiliary power and a 14-pin connector receptacle.At the time of printing these include: CV 250,CV300-I, CV-300, CV400-I, CV-400, CV500-I, DC-400, CV-655, Invertec V300-PRO, +V300-I, V350-PRO, DC-600, DC-650 PRO and DC-655.The DC-250, DC-600(Below Code 10500), DC-1000and the Pulse Power 500 (Non-Pulsed CV mode only)may also be used with the DH-10 if the optionalK1520-1 115V / 42V Transformer Kit is used.INSTALLATIONSAFETY PRECAUTIONSA-3ELECTRIC SHOCK cankill.• Turn the input power off at the power sourcedisconnect switch before attempting to connectthe input power to the DH-10 Control.• Only qualified personnel should perform this installation.----------------------------------------------------------------------------------------INSTALLATION OF THE DH-10BOOM MOUNT WIRE FEEDERCOMPONENTSMounting the 10-Series Wire Drive Unit(K1497-1, -2, -3,-4, K1563-1,-2,-3,-4)Mount the 10-series wire drive unit to the boom orstructure using the four 5/16-18 threaded mountingholes located on the bottom of the DH drive connectionbox. See Figure A.1 for the size and location ofthe mounting holes. The feed plate assembly is electrically"hot" when the gun trigger is pressed.Therefore, make certain the feed plate does not comein contact with the structure on which the unit ismounted.The wire drive unit should be mounted so that thedrive rolls are in a vertical plane so dirt will not collectin the drive roll area. Pivot the feed plate so it willpoint down at an angle so the wire feed gun cable willnot be bent sharply as it comes from the unit. See“Procedure for setting angle of Feed Plate” in theOPERATION section of this manual.DH-10
Page 4 and 5: iiiSAFETYiiiWELDING SPARKS cancause
Page 6 and 7: vThank Youfor selecting a QUALITY p
Page 8 and 9: viiTABLE OF CONTENTSPage ......Diag
Page 12 and 13: A-4INSTALLATIONA-45/16-18 THREAD 2.
Page 14 and 15: A-6WIRE FEED DRIVE ROLL KITSNOTE: T
Page 17 and 18: A-9INSTALLATIONELECTRICAL INSTALLAT
Page 19 and 20: A-11Configuration 2K489-7 Dual Sche
Page 21 and 22: B-2OPERATIONB-2SINGLE HEADS:For K15
Page 23 and 24: B-4Metric/English Wire Feed Speed D
Page 25 and 26: B-6Trigger Mode SelectionOPERATIOND
Page 27 and 28: B-8DUAL PROCEDURE REMOTECONTROL (K1
Page 29 and 30: B-101) Press end of gun against a s
Page 31 and 32: B-12EXPLANATION OF PROMPTINGAND ERR
Page 33 and 34: C-2INPUT CABLE ASSEMBLIES: (One req
Page 35 and 36: D-1MAINTENANCEMAINTENANCEAvoiding W
Page 37 and 38: E-2PROBLEMS(SYMPTOMS)Rough wire fee
Page 39 and 40: E-4PROBLEMS(SYMPTOMS)Neither side
Page 41 and 42: E-6PROBLEMS(SYMPTOMS)Feeder key doe
Page 43 and 44: E-8PROBLEMS(SYMPTOMS)Displays & LED
Page 45 and 46: E-10Procedure for Replacing PC Boar
Page 47 and 48: AF-2DIAGRAMSF-2N.A. REVERSING PLUG
Page 49 and 50: F-4DIAGRAMSDIMENSION PRINTF-4(18.61
Page 51 and 52: 4-7-95F-6DIAGRAMS10.92F-6R .141(3 S
Page 53 and 54: NOTESDH-10
Page 55 and 56: ● Keep your head out of fumes.●

DH-10 Heads & Controls OPERATOR'S MANUAL ... - Lincoln Electric

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