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

viTABLE OF CONTENTSPageInstallation .......................................................................................................Section ATechnical Specifications.......................................................................................................A-1General Description..............................................................................................................A-2Recommended Processes and Equipment ..........................................................................A-3Installation of the DH-10 Boom Mount Wire Feeder Components .......................................A-3Mounting the 10-Series Wire Drive Unit........................................................................A-4Mounting Synergic 7F Wire Drive Unit .........................................................................A-4Mounting the DH-10 Control Box .................................................................................A-4Connecting Wire Drive Unit to Control Box ...................................................................A-4Electrode Routing..........................................................................................................A-5Wire Drive Speed Range Selection......................................................................................A-5Control Speed Range Setting .......................................................................................A-510-Series (DH) Wire Drive Ratio Selection ...................................................................A-5Wire Feed Drive Roll Kits .....................................................................................................A-6Procedure to Install Drive Roll and Guide Tubes .................................................................A-6Single Drive 4-Roll Kits ................................................................................................A-6DH Drive Roll Kit Installation ........................................................................................A-6Gun and Cable Assemblies with Standard Connection........................................................A-7GMAW Guns .................................................................................................................A-7Innershield Guns ...........................................................................................................A-7Gun Cable Connection with Standard Connection........................................................A-7Gun and Cable Assemblies with Fast-Mate Connection ......................................................A-7GMAW Guns .................................................................................................................A-7Gun Cable Connection with Fast-Mate Connection ......................................................A-810-Series Double Head Drives Water Connections (For Water Cooled Guns)....................A-810-Series Double Head Drives......................................................................................A-8Synergic 7F Head Drives .............................................................................................A-8GMAW Shielding Gas ...................................................................................................A-8Gas Guard Regulator ....................................................................................................A-8Electrical Installation.............................................................................................................A-9Input Cable: DH-10 Control to Power Source ...............................................................A-9Work Cable ...................................................................................................................A-9Optional Features Installation.............................................................................................A-10Boom and Bench Conversions............................................................................................A-11Operation ............................................................................................................Section BSafety Precautions ..............................................................................................................B-1Duty Cycle ............................................................................................................................B-1DH-10 Control DIP Switch Setup .........................................................................................B-1Keypad and Display Operation.............................................................................................B-5Dual Procedure Remote Control (K1449-1) .........................................................................B-8Wire Reel Loading................................................................................................................B-8Feeding Electrode and Brake Adjustment............................................................................B-9Drive Roll Pressure Setting ..................................................................................................B-9Procedure for Setting Angle of Feedplate ..........................................................................B-10Gas Guard Regulator Setting .............................................................................................B-10Making a Weld....................................................................................................................B-10Wire Reel Changing ...........................................................................................................B-11Loss of Voltage Sense Shutdown ......................................................................................B-11Wire Feed Overload Protection ..........................................................................................B-11Grounding Lead Protector ..................................................................................................B-11Explanation of Prompting and Error Messages..................................................................B-12Accessories .....................................................................................................Section CDrive Roll and Guide Tube Kits............................................................................................C-1Other Optional Features.......................................................................................................C-2Maintenance ....................................................................................................Section DSafety Precautions ...............................................................................................................D-1Routine Maintenance ...........................................................................................................D-1Avoiding Wire Feeding Problems.........................................................................................D-1Periodic Maintenance...........................................................................................................D-1Procedure for Removing Feedplate from Wire Feeder ........................................................D-1Troubleshooting ..............................................................................................Section ESafety Precautions ...............................................................................................................E-1Troubleshooting Procedures ..................................................................................E-2 thru E-9Procedure for Replacing PC Boards ..................................................................................E-14vi