Lincoln Electric Ln 10 Heads And Controls Im587 B Users Manual

IM587-B to the manual 46ecbe3e-4065-4eda-af14-c9aea12592cc

2015-02-09

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IM587-B
LN-10 Heads & Controls

August, 2007

Boom Mount or Bench Models
For use with: LN-10 Control - Boom Mount Code 10442, 10831
10 Series Wire Drive - Boom Mount Code 10443, 10444, 10763, 10764, 10818, 10819
LN-10 Boom Package Code 10445, 10765, 10820
Synergic 7F Drive Code 10190, 10191
LN-10 - Bench Model Code 10440, 10441, 10761, 10762, 10816, 10817
LN-10 - Zipline Boom Package Code 10497, 10498 , 10771, 10772, 10824

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 thoughtful 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.

OPERATOR’S MANUAL

• 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

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
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 & 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 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.

FOR ENGINE
powered equipment.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________
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
refueling to prevent spilled fuel from vaporizing 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.
____________________________________________________
1.e. 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.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. 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.d.2. Never coil the electrode lead around your body.
2.d.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.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

___________________________________________________
1.g. 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.

2.d.5. Do not work next to welding power source.

Mar ʻ95

SAFETY
ARC RAYS can burn.

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.
3.b. 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
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and 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 below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. 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 specific 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.
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 products.
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 manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.

AUG 06

iii

SAFETY
WELDING and CUTTING
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.

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 Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. 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.
6.d. 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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

6.f. 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 a
welding area.
6.g. 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 circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
6.I. 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.
6.j. Do not use a welding power source for pipe thawing.

FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.

Jan, 07

SAFETY

Mar. ʻ93

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!

CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. 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 possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs 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 identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
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
Installation .......................................................................................................Section A
Technical Specifications .......................................................................................................A-1
General Description..............................................................................................................A-1
Recommended Processes and Equipment ..........................................................................A-2
Installation of the LN-10 Boom Mount Wire Feeder Components ........................................A-2
Mounting the LN-10 Wire Drive Unit .............................................................................A-2
Mounting Synergic 7F Wire Drive Unit (K679-1 or -2)...................................................A-3
Mounting the LN-10 Control Box ..................................................................................A-3
Connecting Wire Drive Unit to Control Box ...................................................................A-3
Electrode Routing..........................................................................................................A-4
Wire Drive Speed Range Selection ......................................................................................A-4
Control Speed Range Setting .......................................................................................A-4
10 Series Wire Drive Ratio Selection ............................................................................A-4
Wire Feed Drive Roll Kits .....................................................................................................A-5
Procedure to Install Drive Roll and Guide Tubes .................................................................A-5
Synergic 7F 4-Roll Kits (KP655 and KP656).................................................................A-5
10 Series Wire Drive Roll Kit Installation ......................................................................A-5
Gun and Cable Assemblies with Standard Connection........................................................A-6
GMAW Guns .................................................................................................................A-6
Innershield Guns ...........................................................................................................A-6
Gun Cable Connection with Standard Connection........................................................A-6
Gun and Cable Assemblies with Fast-Mate Connection ......................................................A-6
GMAW Guns .................................................................................................................A-6
Gun Cable Connection with Fast-Mate Connection ......................................................A-7
Water Connections (For Water Cooled Guns) .....................................................................A-7
10 Series Wire Drives ...................................................................................................A-7
Synergic 7F Drives (K679) ............................................................................................A-7
GMAW Shielding Gas ...................................................................................................A-7
Gas Guard Regulator ....................................................................................................A-7
Electrical Installation.............................................................................................................A-8
Input Cable: LN-10 Control to Power Source ................................................................A-8
Work Cable ...................................................................................................................A-8
Optional Features Installation...............................................................................................A-9
Boom and Bench Conversions.............................................................................................A-9

Operation ............................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
Duty Cycle ............................................................................................................................B-1
LN-10 Control DIP Switch Setup ............................................................................B-1 thru B-5
Keypad and Display Operation ...............................................................................B-6 thru B-9
Dual Procedure Remote Control (K1449-1) ...........................................................................10
Wire Reel Loading ..............................................................................................................B-10
Feeding Electrode and Brake Adjustment ..........................................................................B-11
Drive Roll Pressure Setting ................................................................................................B-11
Procedure for Setting Angle of Feedplate ..........................................................................B-12
Gas Guard Regulator Setting .............................................................................................B-12
Making a Weld....................................................................................................................B-12
Wire Reel Changing ...........................................................................................................B-13
Loss of Voltage Sense Shutdown ......................................................................................B-13
Wire Feed Overload Protection ..........................................................................................B-13
Grounding Lead Protector ..................................................................................................B-13
Explanation of Prompting and Error Messages ..................................................................B-14

Accessories .....................................................................................................Section C
Drive Roll and Guide Tube Kits ............................................................................................C-1
Other Optional Features.........................................................................................C-2 thru C-4

Maintenance ....................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Avoiding Wire Feeding Problems .........................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Procedure for Removing Feedplate from Wire Feeder ........................................................D-1

Troubleshooting ..............................................................................................Section E
Safety Precautions ...............................................................................................................E-1
Troubleshooting Procedures .................................................................................E-2 Thru E-8
Procedure for Replacing PC Boards ....................................................................................E-9

vii

TABLE OF CONTENTS
Page ......
Diagrams ..........................................................................................................Section F
Wiring (LN-10 Control) ...........................................................................................F-1
Wiring (10 Series Wire Drive) ................................................................................F-2
Dimension Print......................................................................................................F-3
Parts List ......................................................................................................P311 Series

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – LN-10 Heads & Controls
SPEC.#

WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER
LOW SPEED RATIO
HIGH SPEED RATIO

TYPE

Speed
K1563-1,-3 10 Series
35-500 IPM
Std Drive
Boom Mount (0.89-12.7 M/M)

Wire Size
Solid
Cored
.025 - 3/32 in.
.035 - .120 in
(0.6 - 2.4 mm)
(0.9 - 3.0 mm)

.50 - 750 IPM
(1.25 - 19.0 M/M)

Wire Size
Solid
Cored
.025 - 1/16 in.
.035 - 5/64 in.
(0.6 - 1.6 mm)
(0.9 - 2.0 mm)

K1563-2,-4 10 Series
55 - 825 IPM
Hi-Speed
Boom Mount (1.40 - 21.0 M/M)

.025 - 1/16 in.
(0.6 - 1.6 mm)

.035 - 5/64 in.
(0.9 - 2.0 mm)

80 - 1250 IPM
(2.00 - 31.8 M/M)

.025 - .045 in.
(0.6 - 1.2 mm)

.035 - .045 in.
(0.9 - 1.2 mm)

K679-1
Std Drive

Synergic 7F* 50 - 770 IPM
Boom Mount (1.27 - 19.5 M/M)

.025 - 1/16 in.
(0.6 - 1.6 mm)

.035 - 5/64 in.
(0.9 - 2.0 mm)

---

K679-2
Hi-Speed

Synergic 7F*
Boom Mount

80 - 1200 IPM
(2.00 - 30.5 M/M)

.025 - .045 in.
(0.6 - 1.2 mm)

.035 - .045 in.
(0.9 - 1.2 mm)

---

Speed

K1559-1,-3 LN-10
35-500 IPM
Std Drive
Bench Model (0.89-12.7 M/M)

.025 - 3/32 in.
(0.6 - 2.4 mm)

.035 - .120 in.
(0.9 - 3.0 mm)

50 - 750 IPM
(1.25 - 19.0 M/M)

.025 - 1/16 in.
(0.6 - 1.6 mm)

.035 - 5/64 in.
(0.9 - 2.0 mm)

K1559-2,-4 LN-10
55 - 825 IPM
Hi-Speed
Bench Model (1.40 - 21.0 M/M)

.025 - 1/16 in.
(0.6 - 1.6 mm)

.035 - 5/64 in.
(0.9 - 2.0 mm)

80 - 1250 IPM
(2.00 - 31.8 M/M)

.025 - .045 in.
(0.6 - 1.2 mm)

.035 - .045 in.
(0.9 - 1.2 mm)

SPEC.#

TYPE

K1562-1Δ,-2Δ LN-10
Control
Controls

CONTROLS, HEADS AND COMPLETE UNITS
INPUT POWER
PHYSICAL SIZE•
40-42 Vac + 10%
4.0 Amps 50/60 Hz (K1562-1)
6.0 Amps 50/60 Hz (K1562-2)

K1563-1Δ,-3Δ 10 Series
Std Drive
Boom Mount

Dimensions
Height
14.80 “
(375.9 mm)

Width
Depth
Weight
14.20 “
4.20 “
18.0 Lbs
( 360.7mm) (106.7 mm) (8.2 Kg)

7.81 “
(198.4 mm)

14.71 “
11.00“
25.0 Lbs
(373.6 mm) (27.94 mm) (11.3 Kg)
30.0 Lbs
(13.6 Kg)

K1563-2,-4
Hi-Speed
K679-1
Std Drive

Synergic 7F*
Boom Mount

K679-2
Hi-Speed

Synergic 7F*
Boom Mount

K1559-1,-3
Std Drive

LN-10
40-42 Vac + 10%
20.46 “
Bench Model 4.0 Amps 50/60 Hz (K1559-1,-2) (519.7 mm)
6.0 Amps 50/60 Hz (K1559-3,-4)

TEMPERATURE RATING

11.5“
( 285.8mm)

7.16“
8.06“
(181.9 mm) (204.7mm)

Storage

K-1563-1,-2

K-1563-3,-4

+40°C +40°C
to
to
-20°C -40°C

16.5 Lbs
(7.5 Kg.)

14.73 “
30.35 “
65.0 Lbs
(366.5 mm) (770.9 mm) (29.5 Kg)
70.0 Lbs
(31.8 Kg)

K1559-2,-4
Hi-Speed

Operating

K-1559-1,-2
K-1559-3,-4

• Excluding Wire Reel
Δ Included with K1561-Series, LN-10 Boom Packages
*Synergic 7F wire drives use 4-roll drives with 2 driven rolls(Drive roll kits not common with 10 Series heads)

GENERAL DESCRIPTION
The LN-10 is a modular line of 42VAC input 4-roll wire feeders. A single control with dual procedure presettability of
wire feed speed (in IPM or M/min) and arc voltage is used
with a single DC welding power source.
The LN-10 models have controls providing keypad or
remote selectability of either of two procedures.
The units offer 4 independently selectable gun trigger
modes for each procedure; cold feed, 2 step and 4-step trigger and spot weld mode.

Also, 4 selectable, presettable timers for each procedure;
preflow, postflow, burnback and spot weld time.
Arc starting can be optimized for each procedure with 5
selectable wire feed acceleration rates, and independent
control of slower run-in procedure.
A gas purge key is provided, as well as cold feed forward
and reverse keys with independently adjustable forward
feed speed setting.

LN-10

A-2

INSTALLATION

All of these features are selected with a tactile-feel keypad,
and are set independently using one of two rotating knob
encoders, setting levels are displayed on one of two digital
LED displays.

The wire type and size range for the wire drive used,
and gear ratio change selected, are given in the
Specifications.

The 10 Series Wire Drive assemblies include a heavy duty
head with externally changeable gear ratio and 4 driven roll
drives housed together in a single combination mounting
and connection box. Gun adapters are available to permit
use with a variety of standard welding guns.

Recommended power sources are Lincoln Electric
Company constant voltage power sources with 42
VAC 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, DC400, DC-600, CV-655, Invertec V300-PRO, V350PRO DC-650 PRO and DC- 655.

Available Models:
The LN-10 Wire Feeder system is available configured in
both Bench and Boom models.
Bench Models consists of an LN-10 control and a 10
Series wire drive assembly premounted on a platform
with a dual 2" O.D. spindle mounting.

The DC-250, DC-1000 and the Pulse Power 500 (CV
mode only) may also be used with the LN-10 if the
optional K1520-1 115V / 42V Transformer Kit is used.

SAFETY PRECAUTIONS
ELECTRIC SHOCK can
kill.

Boom Models consist of an LN-10 control and a choice of
wire drives designed to be mounted separately and joined
by available head to control cable assemblies.
The head to control cable assemblies are available in
two types; one control cable is required for each head:

• Turn the input power off at the power source
disconnect switch before attempting to connect
the input power to the LN-10 Control.
• Only qualified personnel should perform this installation.
----------------------------------------------------------------------------------------

K1498-”L”

Includes a control cable with a 14-pin
ms style connection on each end, and
a 3/0 weld cable. Available in lengths
“L” of 16, 20 or 25 ft. (4.9, 6.1 or 7.6 m)

INSTALLATION OF THE LN-10
BOOM MOUNT WIRE FEEDER
COMPONENTS

K681-”L”

Same as above but does not include
weld cable available in lengths “L” of
12, 16 or 25 ft. (3.6, 4.9 or 7.6 m).

Mounting the 10 Series Double Header
Wire Drive

LN-10 Boom Packages (K1564-Series) are also available which include:
• LN-10 Control Box
• 10 Series Wire Drive
• Appropriate length Control and Weld Cables to
connect Control to Wire Drive
• Accessories specific to the Boom package
ordered

RECOMMENDED PROCESSES AND
EQUIPMENT
The LN-10 Wire Feeder system is recommended for
use with solid wire gas-metal-arc or CV Submerged
arc processes, as well as cored wire for Outershield
GMA or Innershield processes.

Mount the 10 Series wire drive to the boom or structure using the four 5/16-18 threaded mounting holes
located on the bottom of the drive connection box.
See Figure A.1 for the size and location of the mounting holes. The feed plate assembly is electrically "hot"
when the gun trigger is pressed. Therefore, make certain the feed plate does not come in contact with the
structure on which the unit is mounted.
The wire drive unit should be mounted so that the
drive rolls are in a vertical plane so dirt will not collect
in the drive roll area. Pivot the feed plate so it will
point down at an angle so the wire feed gun cable will
not be bent sharply as it comes from the unit. See
“Procedure for setting angle of Feed Plate” in the
OPERATION section of this manual.

LN-10

A-3
5/16-18 THREAD

11.00

A-3

INSTALLATION
2.25

10.50

CLEARANCE
FOR 1/4 BOLT

6.00

.50

13.75
14.00
12.75
10.00

3.00

FEED PLATE
DOOR OPEN

CLEARANCE
FOR 1/4 BOLT

BOTTOM FRONT

10.50
14.50

5.00

2.63
14.50

Mounting Synergic 7F Wire Drive Unit
(K679-1 or -2)
Mount the wire feed unit by means of the insulated
mounting bracket attached to the bottom of the gearbox.
Reference L9777 (included with Drive unit) to find the
size and location of the mounting holes. The gearbox
assembly is electrically “hot” when the gun trigger is
pressed. Therefore, make certain the gearbox does not
come in contact with the structure on which the unit is
mounted.
The wire feed unit should be mounted so that the drive
rolls are in a vertical plane so dirt will not collect in the
drive roll area. Position the mechanism so it will point
down at about a 45° angle so the wire feed gun cable will
not be bent sharply as it comes from the unit.
Note: The K1562-1 control box must be used with the
K679-1 or -2.

Mounting the LN-10 Control Box
The same control box is used for both a 10 Series drive,
or a Synergic 7F drive. The back plate of the control box
has two keyhole slots and one bottom slot for mounting.
See Figure A.2 for the size and location of these slots.
Mount the box at some convenient location close to the
wire drive unit which will enable the desired control cable
to reach between the control box and the wire drive unit.
a) Drill the required holes in the mounting surface,
partially install 1/4-20 screws.

c) Tighten the screws.

5.25

FIGURE A.2

FIGURE A.1

b) Mount the box.

2.63

Connecting Wire Drive Unit to Control Box
One head to control cable assembly is required. The
Head to Control cable assemblies are available in two
types:
K1498-"L" -Includes a control cable with 14-pin ms-style
connectors on each end, and a 3/0 weld
cable (rated 600 amps, 60% duty cycle) to
route between the wire drive and the control
box. Available in lengths "" of 16 ft. (4.9 m),
20 ft. (6.1 m) and 25 ft. (7.6 m)
K681-"L" - Same as K1498, but does not include weld
cable. Available in lengths "L" of 12 ft (3.6 m),
16 ft (4.9 m) and 25 ft. (7.6 m).
a) Making certain the cables are protected from any
sharp corners which may damage their jackets,
mount the cable assembly along the boom so the end
with the female amphenol connector pins is at the
wire feed unit.
b) Connect the 14-socket cable connectors to the mating
receptacles on the back of the wire feed unit connection box.
c) At the same end, connect the electrode lead to the
1/2" connection bolt on the front of the left wire drive
head feed plate.
d) At the control box end, connect the 14 pin connectors
of the cable to the mating receptacle on the bottom of
the control box.
e) At the control box current sensor, slip the cover box
up off the sensor and connect the electrode cable(s)
to the top bolt connection.

LN-10

A-4

INSTALLATION

A-4

The electrode supply may be either from reels, ReadiReels, spools, or bulk packaged drums or reels.
Observe the following precautions:

a) Loosen the clamping collar screw using a 3/16"
Allen wrench. The clamping collar screw is
accessed from the bottom of the feedplate. It is
the screw which is perpendicular to the feeding
direction.

a) The electrode must be routed to the wire drive
unit so that the bends in the wire are at a minimum, and also that the force required to pull the
wire from the reel into the wire drive unit is kept
at a minimum.

b) Loosen the retaining screw, which is also
accessed from bottom of feeder, using a 3/16"
Allen wrench. Continue to loosen the screw
until the feedplate can be easily pulled off of the
wire feeder.

b) The electrode is "hot" when the gun trigger is
pressed and must be insulated from the boom
and structure.

3) Loosen, but do not remove, the screw on the lower
right face of the feedplate with a 3/16" Allen
wrench.

c) If more than one wire feed unit shares the same
boom and are not sharing the some power
source output stud, their wire and reels must be
insulated from each other as well as insulated
from their mounting structure.

4) Remove the screw on the left face of the feedplate.
If changing from high speed (larger gear) to low
speed (smaller gear), line the lower hole on the left
face of the feedplate with the threads on the
clamping collar. Line the upper hole with the
threads to install larger gear for high speed feeder.
If feedplate does not rotate to allow holes to line
up, further loosen the screw on right face of feedplate.

Electrode Routing

WIRE DRIVE
SELECTION

SPEED

RANGE

The rated speed and wire size range for each wire
drive head is shown in the SPECIFICATIONS in the
front of this section.

5) Install gear onto output shaft and secure with flat
washer, lock washer, and Phillips head screw
which were previously removed.

Control Speed Range Setting

6) Tighten the screw on lower right face of feedplate.

The speed range is set up to match the wire feed
head connected to the LN-10 control by properly setting the switch (S1) code on the control board inside
the control box. See OPERATION “Setting the DIP
Switches” for setting instructions.

7) Re-attach feedplate to wire feeder if removed in
Step 2.
8) Feedplate will be rotated out-of-position due to the
gear change. To re-adjust angle of feedplate:
a) Loosen the clamping collar using a 3/16" Allen
wrench. The clamping collar screw is accessed
from the bottom of the feedplate. It is the screw
which is perpendicular to the feeding direction.

10 Series Wire Drive Ratio Selection
The 10 Series type drives include two external gear
sizes; a 1" dia. gear and a 1-1/2" dia. gear. The smaller gear provides the low speed range ratio, and the
larger gear provides the high speed range ratio per
the SPECIFICATIONS in the front of this section.
The following procedure is for changing ratio of the 10
Series wire drive:
1) Pull open the Pressure Door.

b) Rotate feedplate to the desired angle and tighten clamping collar screw.
9) Make sure to properly set the switch (S2) code on
the control board inside the control box for the
new gear size installed. See OPERATION “Setting
the DIP Switch” for setting instructions.

2) Remove the Phillips head screw retaining the pinion gear to be changed and remove the gear. If the
gear is not easily accessible or difficult to remove,
remove the feedplate from the gearbox. To remove
feedplate:

LN-10

A-5

INSTALLATION

WIRE FEED DRIVE ROLL KITS
NOTE: The maximum rated solid and cored wire
sizes for each wire drive head and selected
drive ratio is shown on the SPECIFICATIONS
in the front of this section.

The electrode sizes that can be fed with each roll and
guide tube are stenciled on each part. Check the kit
for proper components.
Synergic 7F Wire Drives (K679) use 4-Roll drive roll
kits with 2 driven rolls, per Table C.1 in ACCESSORIES. These kits are common with those used for
the 4-Roll LN-7 GMA and LN-9 GMA Lincoln Wire
Feeders, but are not common with those used with the
10 Series wire drive units. Installation instructions are
included with the kits.
10 Series Wire Drives use 4-Roll drive roll kits with 4
driven rolls, per Table C.1 in ACCESSORIES.

PROCEDURE TO INSTALL DRIVE
ROLL AND WIRE GUIDES
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.

A-5

3) Remove clamping screw & clamping collar from
the drive shaft closest to the incoming side of the
feeder.
4) Install drive roll onto keyed shaft. (Do not exceed
the maximum wire size rating of the wire drive.)
Replace collar and tighten clamping screw.
5) Back out the set screw for the middle guide tube.
Install the middle guide tube and slide it up against
the drive roll. DO NOT TIGHTEN THE MIDDLE
GUIDE AT THIS TIME.
6) Install the outgoing drive roll following the same
procedure as steps 3 & 4.
7) Center the middle guide between the two drive
rolls and tighten in place.
8) Back out the screws for the incoming and outgoing
guide tubes.
9) Install the longer guide tube in the rear hole near
the incoming drive roll. Slide the tube in until it
almost touches the roll. Tighten in place.
10) Install the remaining guide tube in the front hole.
Be certain that the proper plastic insert is used.
Fine wire chisel point tube must have largest
radius next to drive roll. Tighten in place.
11) Re-latch both quick release levers.

• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.

12) To start new electrode, straighten the first 6"
(150mm) and cut off the first 1" (25 mm). Insert
free end through the incoming tube. Press gun
trigger and push wire into the drive roll.
TO SET IDLE ROLL PRESSURE, see “Idle Roll
Pressure Setting” in OPERATION.

10 Series Wire Drive Roll Kit Installation
(KP1505 and KP1507)
1) Turn OFF Welding Power Source.

Observe all additional Safety Guidelines detailed
throughout this manual.

Synergic 7F Wire Drive 4-Roll Kits (KP655
and KP656)
1) Turn OFF welding power source.

2) Pull open Pressure Door to expose rolls and wire
guides.
3) Remove Outer Wire Guide by turning knurled
thumb screws to unscrew from Feedplate.
4) Remove drive rolls, if any are installed, by pulling
straight off shaft. Remove inner guide.

2) Release both quick release levers by sliding the
levers sideways into the open positions.

5) Insert inner Wire Guide, groove side out, over the
two locating pins in the feedplate.

LN-10

A-6

INSTALLATION

6) Install each drive roll by pushing over shaft until it
butts up against locating shoulder on the drive roll
shaft. (Do Not exceed maximum wire size rating of
the wire drive).
7) Install Outer Wire Guide by sliding over locating
pins and tightening in place.
8) Engage upper drive rolls if they are in the “open”
position and close Pressure Door.
TO SET IDLE ROLL PRESSURE, see “Idle Roll
Pressure Setting” in OPERATION.

GUN AND CABLE ASSEMBLIES
WITH STANDARD CONNECTION
The 10 Series Wire Drive Heads each require a
K1500 Gun Adapter installed See “Gun Adapters” in
ACCESSORIES section. The K1500-2 Gun Adapter
and Trigger Cable for Magnum 200-400 guns are factory included with the LN-10.

A-6

Gun Cable Connection with Standard
Connection
1. Check that the drive rolls and guide tubes are
proper for the electrode size and type being used.
If necessary, change them per “Wire Drive Roll
Kits” in this section.
2. Lay the cable out straight. Insert the connector on
the welding conductor cable into the brass conductor block on the front of the wire drive head. Make
sure it is all the way in and tighten the hand clamp.
Keep this connection clean and bright. Connect the
trigger control cable polarized plug into the mating
5 cavity receptacle on the front of the wire drive
unit.
3. For GMA Gun Cables with separate gas fitting (10
Series Wire Drive using K1500-1 Gun Adapter),
connect the 3/16" I.D. gas hose from the wire drive
unit to the gun cable barbed fitting.

GUN AND CABLE ASSEMBLIES
WITH FAST-MATE CONNECTION

GMAW Guns
An expanding line of Magnum 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
200 to 550 ampere air cooled gun and cables that are
available. Gun cable lengths range from 10 ft. (3.0 m)
to 25 ft. (7.6 m) and feed electrode sizes .025" (0.6
mm) to 3/32" (2.4 mm). The entire line of Magnum
Fast-Mate gun and cable assemblies can also be
used by installing a K489-2 Fast-Mate adapter kit.
See “Gun and Cable Assemblies with Fast-Mate
Connection” in this section for details.

Innershield Guns
K126 and K115 gun and cable assemblies are available to allow welding with Innershield electrodes. Gun
cable lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m)
The 350 ampere K126 will feed electrode sizes .062
(1.6 mm) to 3/32" (2.4 mm). The 450 ampere K115
will feed 5/64" (2.0 mm) to 3/32" (2.4 mm) electrode.
Three smoke extraction gun and cable assemblies are
available, 250 ampere K309, 350 ampere K206 and
the 500 ampere K289. All gun cable lengths are 15 ft.
(4.5 m). These guns will feed electrode sizes .062"
(1.6 mm) to 3/32" (2.4 mm) and require the use of the
K184 vacuum unit for use with the LN-10.

(Requires K489-2 Fast Mate™ Adapter Kit used with
the K1500-1 Gun Adapter)

GMAW Guns
An expanding line of Magnum Fast-Mate™ air cooled
and water cooled 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 200 to 400
ampere air cooled gun and cables that are available
as well as the Magnum “Super Cool” 450 ampere
water cooled gun and cable. Gun cable lengths range
from 10 ft. (3.0 m) to 25 ft. (7.6 m) and feed electrode
sizes .025" (0.6 mm) to 5/64" (20 mm).
An expanding line of Magnum X-Tractor gun and
cable assemblies provides fume extraction capability
for welding with solid and cored electrodes using the
GMAW process. See the appropriate Magnum literature for descriptions of the 250 to 400 ampere air
cooled gun and cables that are available. Gun cable
lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m) and
feed electrode sizes .035" (0.9 mm) to 1/16" (1.6 mm).
These guns require the use of either the K173-1 or
K184* vacuum units.
*Requires S14927-8 connector hose and an S20591
hose adapter.

LN-10

A-7

INSTALLATION

Gun Cable Connection with Fast-Mate
Connection
1. Check that the drive rolls, feeder guide tubes and
gun connector guide tube are appropriate for the
electrode size being used. If necessary, change
them per “Wire Drive Roll Kits” in this section.
2. Connect gun to gun connector making sure all pins
and gas tube line up with appropriate holes in connector. Tighten gun by turning large nut on gun
cable clockwise.

10 SERIES WIRE DRIVE WATER
CONNECTIONS (FOR WATER
COOLED GUNS)
10 Series Wire Drive: must have a K590-4 Water
Connection Kit installed for water cooled guns. (See
ACCESSORIES).
Using male quick-connect fittings, connect the water
hoses to the coolant inlet and outlet on the back of the
wire drive. Connect the other ends of these hoses to
the appropriate ports on the water cooling units.
In the event the water line fittings on your water
cooled gun are incompatible with the female quick
connects on the front of the wire drive, male quickconnects (L.E. Part No. S19663) are provided in the
Kit for installation on 3/16" (5 mm) I.D. hose
(Customer to provide appropriate clamps). The feeder
connectors self seal when disconnected.

Synergic 7F Wire Drive (K679) :Must have a
K682-2 Water Connection Kit installed. (See ACCESSORIES).
Using hose clamps provided with the K682-2 kit, connect appropriate water hoses to the coolant inlet and
outlet fittings on the back of the K682-2 Kit. Connect
the other ends of these hoses to the appropriate ports
on the water cooling units.

GMAW Shielding Gas

WARNING
CYLINDER may explode if damaged.
• Keep cylinder upright and chained to
support.
• Keep cylinder away from areas where
it may be damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live electrical circuits.
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply when not
in use.
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
from the flow valve to the gas inlet fitting of the wire
drive unit.
Connect a supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on the
back panel of the wire drive or, if used, on the inlet of
the Gas Guard regulator. (See Below).
Gas Guard Regulator - The Gas Guard Regulator is
an optional accessory (K659-1) on these models.
Install the 5/8-18 male outlet of the regulator to the
5/8-18 female gas inlet on the back panel of the wire
drive. Secure fitting with flow adjuster key at top.
Attach gas supply to 5/8-18 female inlet of regulator
per instructions above.

In the event the water line fittings on your water
cooled gun are incompatible with the female quick
connects on the front of the K682-2 Kit male quickconnects are provided with the kit for installation on
3/16 (5 mm) I.D. hose (Customer to provide appropriate clamps). The feeder connectors self seal when
disconnected.

LN-10

A-8

INSTALLATION

ELECTRICAL INSTALLATION
WARNING

Current
60% Duty
Cycle

Copper Work Cable Size, AWG

400 Amps

00 (67 mm2)

500 Amps

000 (85 mm2)

600 Amps

000 (85 mm2)

Up to 100 ft Length (30m)

ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.

Observe all additional Safety Guidelines detailed throughout this manual.

Input Cable: LN-10 Control to Power
Source
K1501-10 (Control Cable only)
Consists of a 9-conductor control cable with 14-pin
control cable plug, without electrode cable, and is
available in a length of 10 ft. (3 m).
With input power disconnected from the power
source, install the input cable per the following:
1) Connect the end of the control cable with the 14pin cable plug to the mating receptacle on the
power source.
2) Connect the electrode lead to the power source
output terminal of the desired polarity.
3) Connect the 9-socket plug of the control cable to
the mating receptacle on the bottom of the LN-10
control box.
4) Slip the current sensor cover off enough to expose
the input connector stud. Connect the electrode
cable from the power source to this stud with the
nut provided, then reclose the current sensor
cover.
Work Cable
Connect a work lead of sufficient size and length (per
the following table) between the proper output terminal on the power source and the work. Be sure the
connection to the work makes tight metal-to-metal
electrical contact.
LN-10

A-9

INSTALLATION

OPTIONAL FEATURES
INSTALLATION

A-9

When installed and properly configured, the K1561-1
Robotics Interface Module allows complete control of
the welding process from the robot controller.

Dual Procedure Switch Options
K683-1 Dual Procedure Switch (One per gun) Requires K686-2 Adapter for LN-10. Kit includes gun
switch, and mountings for Lincoln Innershield and
Magnum guns, with 15 ft. (4.5 m) control cable and 3pin plug. K686-2 Adapter permits 3-pin plug and 5-pin
gun trigger plug to be connected to LN-10 5-pin
Trigger/Dual Procedure receptacle.
Connect the 5-pin plug of the K686-2 Adapter to the
LN-10 Wire Feeder Trigger/Dual Procedure 5-socket
receptacle.
The 3-pin plug of the K683-1 Dual Procedure switch
connects to the 3-socket receptacle of the Adapter,
and the 5-pin plug of the welding un connects to the 5socket receptacle of the Adapter.
K683-3 Dual Procedure Switch Kit includes gun
switch, and mountings for Lincoln Innershield and
Magnum guns, with 15 ft. (4.5m) control cable and 5pin plug with two leads to connect to gun trigger.
Connect the 5-pin plug of the K683-3 Dual procedure
Switch to the LN-10 Wire Feeder Trigger/Dual
Procedure 5-socket receptacle.
The two lead plug cord extending out of the 5-pin plug
of the Dual Procedure switch is to be connected to the
two trigger leads of the welding gun per the instructions shipped with the kit.
K1449-1 Dual Procedure Remote Control
Provides remote rotating knob encoder control of Wire
Feed Speed and Voltage, along with a dual procedure
selector switch, when the remote control is connected
and REMOTE is selected by the LN-10 Procedure
key. The LN-10 A or B procedure light will also be on
to indicate which procedure is selected by the remote
control.

The Lincoln Electric Companyʼs Automation Center
should be contacted for questions regarding installation or operation of the Robotics Interface Module.
All other options, see ACCESSORIES section, are
shipped with installation instructions.

BOOM AND BENCH CONVERSIONS
The modular design of these feeders allows them to
be converted from bench to boom models or vise
versa. Some additional parts are required to make this
conversion.

Materials Required for bench to boom
conversion:
S13100-197 Plug and Lead assembly, allows a control cable to connect from control box to the wire drive.
G2868 Mounting Bracket, allows reed switch to be
relocated to control box.
K1498-16 AND K1498-25 Control Box to Wire Drive,
Control cable and power cable from control box to
wire drive.

Materials Required for boom to bench
conversion:
L10286-1 Wire Reel Stand, for LN-10 or STT-10,
mount the reed switch onto the reel stand.
S22777 Control Box Support Bracket, to mount the
control box onto the wire drive.
S13100-198 Plug and Lead Assembly, electrical connection between control box and wire drive.

The 4-pin plug of the remote control connects to the
mating receptacle on the bottom of the LN-10 Control
box.
The K1450-”L” Extension cable is used to extend the
16 ft (5m) cable attached to the remote control.
Lengths “L” are available to match the Length of the
control to boom mount wire drive cable being used.
K1561-1 Robotics Interface Module - The module
plugs directly into the LN-10 control board and provides an interface to a properly equipped Fanuc robot.
LN-10

B-1

OPERATION

OPERATING INSTRUCTIONS
Safety Precautions

WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Unless using cold feed feature when inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could
remain energized several seconds after the
gun trigger is released.
• Turn OFF input power at welding power
source before Control switch setup or
changing drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
operate this Equipment.

1. Instead of displaying a preset value in volts, the top
display will show a number from "0.00" to "10.00" in
increments of 0.02. The number can be used for
setting run-in "voltage" as well as "weld preset voltage". When the trigger is closed or while welding,
the top display will display actual arc voltage.
The voltage displayed while welding can be used to
determine the arc voltage to be expected for a given
number setting. Actual arc voltage display will still
flash for 5 seconds after a weld has been completed.
2. If a loss of arc voltage occurs, wire will NOT stop
feeding. The Loss of Voltage Sense Shutdown feature is disabled to permit the use of the LN-10 with
power source connections that do not connect the
work voltage back to the LN-10 through the input
power cable. The actual weld voltage while welding
will NOT be shown on the top display if the work
voltage is not available to the LN-10 through the
input power cable.

Observe all additional Safety Guidelines detailed
throughout this manual.

Setup DIP Switch Access

Duty Cycle
The LN-10 models are rated at 60% duty cycle * for a
maximum current of 600 amps.

1) Shut off the input power to the LN-10 control by
turning off the power at the welding power source it

* Based on a 10 minute time period (6 minutes on, and 4 minutes off).

LN-10 CONTROL DIP SWITCH
SETUP
Initial set up of the LN-10 control for the system components being used and for general operator preferences is done using a pair of 8-pole DIP switches
located inside the LN-10 control box.
"Other: Power Source Independent" power
source selection dip switch setting:
The LN-10 is designed to work with the following
Lincoln Electric power sources: CV250, CV300-I,
CV300, CV400-I, CV400, CV500-I, CV655, DC250,
DC400, DC600, DC650 PRO, DC1000, Pulse Power
500 (non-pulse CV modes only), the V300 PRO,
V350 PRO, and the DC655. To use the LN-10 with
other power sources, the "Other: Power Source
Independent" power source selection dip switch setting (S1 switches 1-4 in the OFF position) may be
used. All LN-10 features operate as described elsewhere in this manual except for the following differences:

WARNING
is connected to.
Have qualified personnel do the set up and
maintenance work. Turn the input power off at
the power source before working inside the wire
feeder.
----------------------------------------------------------------------2) Remove the two screws on the top of the LN-10
control box door and swing the door down to open.
3) Locate the two 8-pole DIP switches, near the top
left corner of the LN-10 Control P.C. board, labeled
S1 and S2.
NOTE: Switch settings are only programmed during
input power-up restoration.

LN-10

B-2

OPERATION

For K679-1 (Single Head Boom) with 50-770 IPM
(1.27-19.5 m/m) Low Speed Ratio set S1 DIP Switch
as follows:

Setting the DIP Switches
The DIP switches are each labeled with an “ON”
arrow showing the on direction for each of the 8 individual switches in each DIP switch (S1 and S2). The
functions of these switches are also labeled and set
as described below:
Head

Pwr Sources
ON

M 4 S R + -

For K679-2 (Single Head Boom) with 80-1200 IPM
(2.00-30.5 m/m) High Speed Ratio set S1 DIP Switch
as follows:

Head

Pwr Sources

Head

Pwr Sources
ON

Wire Drive Head Selection

The LN-10 control is set up for proper presettable wire
feed speed by setting S1 DIP switches (5 to 8) as
appropriate per the following examples for the head
specification and 10 Series wire drive external gear
selection being used:

For K1563-1,-3 or K1564-Series (LN-10 Boom) or
K1559-1 (LN-10 Bench) with 35-500 IPM (0.89-12.7
m/m) Low Speed Ratio set S1 DIP Switch as follows:
Head

Pwr Sources
ON

Note: The K679-1 and -2 require the K1562-1 control box.

Welding Power Source Selection
The LN-10 Control is set up for proper presettable
weld voltage control by setting S1 DIP switches (1 to
4) as appropriate per the following information for the
welding power source being used:

CV-250/CV 300-I:
8

S1
Pwr Sources

For K1563-1,-3 or K1564-Series (LN-10 Boom) or
K1559-1 (LN-10 Bench) with 50-750 IPM (1.25-19.0
m/m) High Speed Ratio set S1 DIP Switch as follows: (initial factory setting)
Head

Pwr Sources
ON

CV-300/CV 400-I:
8

Pwr Sources
ON

For K1563-2,-4 (LN-10 Boom) or K1559-2 (LN-10
Bench) with 55-825 IPM (1.40-21.0 m/m) Low
Speed Ratio set S1 DIP Switch as follows:

Pwr Sources

Head

Pwr Sources
ON

CV-400/CV 500-I:

ON
8

For K1563-2,-4 (LN-10 Boom) or K1559-2 (LN-10
Bench) with 80-1250 IPM (2.00-31.8 m/m) High
Speed Ratio set S1 DIP Switch as follows:

Pwr Sources
ON

Head

Pwr Sources
ON

CV-655: (initial factory setting)

V350-PRO And V450-PRO:
Pwr Sources
ON
S1

LN-10

B-3

OPERATION

DC-250: *

Metric/English Wire Feed Speed Display Selection

Pwr Sources
ON

The LN-10 Control is set up for Wire Feed Speed display in Metric units (m/min.) or English units (IPM) by
setting S2 DIP Switch 1 (Labeled “M”):
S2 switch 1 OFF = IPM (as shipped)

DC-400:
Pwr Sources

M 4 S R + ON

DC-600:

S2 switch 1 ON = m/min
Pwr Sources
ON

M 4 S R + ON

DC-650 PRO:

4-Step Trigger Mode Operation Selection

Pwr Sources
ON

DC-1000: *
Pwr Sources
ON

The LN-10 Control is set up for 4-Step Trigger mode
operation with or without weld current interlock by setting S2 DIP switch 2 (Labeled “4”).
When 4-Step trigger mode is selected on the LN-10
keypad (See Keypad and Display Operation in this
section) S2 DIP switch setting determines the 4-step
trigger operation:

S2 switch 2 OFF = 4-Step with current interlock
operation: (As shipped)

Pulse Power 500: *

M 4 S R + -

Pwr Sources
ON

1) Closing Trigger initiates gas preflow time followed
by Run-in speed and strike voltage until arc strike
initiates welding.

V300 PRO:
Pwr Sources
ON

10.0 TO 45.0 VOLT LINEAR PRESET
(FOR POWER SOURCES WITH LINEAR VOLTAGE
CONTROL PROTOCOL)

2) Opening Trigger after welding arc is established
continues welding with weld current interlock.
(Breaking arc stops the feeder operation).
3) Reclosing Trigger continues welding but shuts off
current interlock function.

Pwr Sources
ON

4) Reopening Trigger stops wire feed and initiates
burnback time, then gas postflow time.

0.0 TO 10.0 LINEAR PRESET:
Pwr Sources
ON

* Requires optional K1520-1 115V/42V Transformer
Kit.

LN-10

B-4

OPERATION

S2 switch 2 ON = 4-Step without current interlock
operation:

The LN-10 control is set up for Robotics Mode by setting the S2 DIP Switch 4 (Labeled “R”). For Robotics
Interface Mode to operate, a K1561-1 Robotics
Interface Module must be installed.

M 4 S R + ON

Robotics Mode Selection

S2 switch 4 ON = Robotics mode ON
1) Closing Trigger initiates gas flow.

M 4 S R + ON

2) Opening Trigger initiates gas preflow timer followed by Run-in speed and strike voltage until arc
strike initiates welding. (Trigger is released before
arc is struck, but once established breaking arc
stops the feeder operation).

S2 switch 4 OFF = Robotics mode OFF (As shipped)

3) Reclosing Trigger stops wire feed and initiates
burnback time, then gas postflow time.

M 4 S R + ON

4) Reopening Trigger stops gas flow if, or when, postflow time is over.

Maximum Limits Setting Mode Selection
Security Mode Selection

The LN-10 control is set up for allowing a maximum
weld WFS and arc voltage setting for each procedure
by setting S2 DIP Switch 5 (Labeled “+”)

The LN-10 Control is set up for Security Mode (See
“Security Mode” in this section) by setting S2 DIP
Switch 3 (Labeled “S”):

S2 switch 5 ON = Max. Limits Setting mode ON
M 4 S R + -

S2 switch 3 ON = Security mode ON

S2 switch 3 OFF = Security mode OFF (as shipped)

M 4 S R + -

M 4 S R + ON

When Maximum Limits Setting mode is selected, all keys
except the procedure key are disabled. Welding is not
allowed while in this mode. The mode is used for maximum limits setup only. See “Limits Setting Mode” in this
section for the correct procedure for setting the WFS and
voltage limits.

S2 switch 5 OFF = Maximum Limits Setting mode
OFF (As shipped)
M 4 S R + ON
S2

LN-10

B-5

OPERATION

Minimum Limits Setting Mode Selection
The LN-10 control is set up for allowing a minimum weld
WFS and arc voltage setting for each procedure by setting S2 DIP Switch 6 (Labeled “-”).
S2 switch 6 ON - Minimum Limits Setting mode ON

M 4 S R + ON

When Minimum Limits Setting mode is selected, all keys
except the procedure key are disabled. Welding is not
allowed while in this mode. The mode is used for minimum limits setup only. See “Limits Setting Mode” in this
section for the correct procedure for setting the WFS and
voltage limits.
S2 switch 6 OFF = Minimum Limits Setting mode OFF
(As shipped)

M 4 S R + ON

LN-10

B-5

B-6

OPERATION

KEYPAD AND DISPLAY OPERATION
LINCOLN

COLD FEED
FORWARD

Power to the LN-10 is supplied and controlled from
the power source. The LN-10 automatically senses
the loss of power when the power source is turned off.
Dual procedure settings, including; trigger mode, cold
feed speed, Run-in and weld speed and voltage,
timers and acceleration are automatically saved for
each feeder when power is removed. This feature
does not require batteries and when power is restored
it will automatically return all settings to the state they
were in when power was removed. The operator may
overwrite any or all of these settings following power
up recall.

COLD FEED
REVERSE

GAS PURGE

WFS
A

REMOTE

PROCEDURE

VOLTS

COLD FEED
2-STEP STD

TRIGGER

4-STEP LOCK

SPOT

PREFLOW

Power-Down Save

RUN-IN
VOLTS / WFS

SPOT
BURNBACK

WIRE FEED SPEED

2 POSTFLOW

Operation Keys
TIMER

CONTROL

A
THE LINCOLN ELECTRIC COMPANY

CLEVELAND, OHIO

U.S.A.

REMOTE

G3161

Keypad and Display Description

PROCEDURE

Keypad - Seven key, membrane type with "snap" tactile feel and embossed domes. Long life design.
Spatter resistant surface.

Displays - Two digital LED displays with .56" (14.2
mm) character height. Top (3-1/2 digit) displays
Preset and Actual (while welding) arc voltage in volts
with (+) or (-) polarity indicators, and also displays all
timers in seconds. Bottom (4 digit) displays preset
wire feed speed in IPM, or m/m, and acceleration
selection.

Indicator Lights - Extra bright red LEDs for viewing
at almost any angle. Always indicate the feeder and
procedure selected, trigger mode being used and
function or timer being displayed.

Procedure Lights - Indicate which
procedure (A or B) is selected for the
selected feeder. The Procedure select
key selects A or B, or if REMOTE Light
is selected, the procedure selection
light is controlled by connection of an
optional Dual Procedure gun switch
(K683-1, -3) or Dual Procedure
Remote Control (K1449-1).

Cold Feed Keys - energize
the wire feeder but not the
power source or gas solenoid valve. Cold Feed
Forward speed is factory
set at 200 IPM, but is adjustable with WFS encoder
knob and displayed on WFS display (with ”Cld” shown
on the Voltage display) only while pressing Cold Feed
Forward, and the last speed set is stored in memory
for the next cold feeding, unless changed in Cold
Feed trigger mode (see following section). Cold Feed
Reverse retracts wire at a fixed 80 IPM speed which is
not adjustable.

Rotating Encoders - Knob controls increase or
decrease settings of volts and wire feed speed. (initially factory set to minimum) Alternately, the top
encoder adjusts timer settings and bottom selects
acceleration settings when selected for these parameters to be displayed.

LN-10

COLD FEED
FORWARD

GAS PURGE

COLD FEED
REVERSE

Gas Purge key - energizes the gas
solenoid valve but not the wire feeder or
power source.

B-7

OPERATION

Trigger Mode Selection

Display Control Keys

Trigger Mode Select key
- enables operator to
choose mode of operation
shown by the indicator
lights. Pressing key causes
mode
lights
to
sequence (top to bottom) starting from the current
indicated selection.
COLD FEED

2-STEP STD

TRIGGER

4-STEP LOCK

SPOT

Top Light - Indicates gun trigger has been selected to
perform the Cold Feed Forward function in exactly the
same manner as Cold Feed Forward key (See
Operation Keys - Cold Feed Keys) with the same
memory stored adjustable speed setting, and “Cld”
shown on the Voltage display.

Timer Select key - enables operator to
choose burnback, spot or gas timers, as
indicated by the appropriate light.
Pressing the key causes lights to
sequence (top to bottom, then all off) starting from the
current indicated selection.
TIMER

When a timer is selected the Voltage display shows
the time setting in seconds, as indicated by “SEC” displayed on the speed display. The times are set using
the Voltage encoder knob.
1

PREFLOW

SPOT

Second Light - indicates 2-step (standard) trigger
mode.

BURNBACK

2 POSTFLOW

Top Light - indicates preflow time
is being displayed, set 0.0 to 2.5
seconds (0.2 sec as shipped). This
is the time the shielding gas flows
before the wire feed and power
source are activated.

1. Trigger closure energizes the solenoid valve,
then the wire feeder and the power source
after Preflow time.

Second Light - indicates spot time is being displayed,
set 0.0 (as shipped) to 199.9 seconds.

2. Releasing the trigger turns off the wire feeder,
then power source after burnback time and
then the gas solenoid valve after Postflow time.

Third Light - indicates burnback time is being displayed, set 0.00 (as shipped) to 0.25 seconds. This is
the time the arc power is delayed at the stop of the
weld, and should be set to the lowest time required to
prevent the wire sticking in the weld.

Third Light - indicates 4-step (lock) trigger mode.
This mode may be selected to include or exclude weld
current interlock. (See “4-Step Trigger Mode
Operation Selection” in this section for 4 step Trigger
Mode operation)

Bottom Light - indicates postflow time is being displayed, set 0.0 to 10.0 seconds (0.5 sec as shipped).

Bottom Light - indicates Spot Weld Mode, which will
only light if a spot time is set (See “Display Control
Keys” in this section). If set to 0.0 seconds, spot
mode light selection will be skipped. Trigger closure
energizes the gas solenoid valve, then wire feeder
and the power source. The spot timer starts when
current flows. The wire feeder and power source then
solenoid valve are all turned off when the spot on
timer times out even though the trigger is opened or is
still closed. Preflow/Postflow and burnback timers are
also functional in spot mode. (See “Display Control
Keys” in this section).

This is the
time the shielding gas flows after the wire feed and
power source are deactivated.
Pressing Timer Select Key again, or closing the gun
trigger, shuts all timer lights off, indicating weld
Voltage and Wire Feed Speed are again being displayed, and set by the appropriate encoder knob.

LN-10

B-8

OPERATION

CONTROL

Control Select key - enables operator to
choose Run-In procedure as indicated by the
light turning on. When light is on, the settings of
Run-In Wire Feed Speed and Voltage are displayed. After Weld procedure is set, Run-in procedure should be set to optimize arc starting.

Speed encoder knob can adjust run-in
speed between min. rated speed and up to
the procedure Weld speed setting. Run-in
speed setting can not exceed Weld speed
setting. Run-in speed setting of 100 IPM or less is recommended for optimum starting. Factory setting is near min. rated
speed.
RUN-IN
VOLTS / WFS

If set below minimum rated speed “- -” will show on the WFS
display, indicating Run-in speed is set to match weld speed setting.
The Run-in (strike) voltage can be set above or below the Weld
voltage setting up to a max of 60 V. If set below a min of 10 V,
the Run-In (strike) voltage display shows “---”, indicating the
Run-In Voltage is set to match the weld voltage setting. Also,
the difference between Run-in voltage and Weld voltage settings is maintained automatically if the Weld voltage setting is
changed, so the run-in voltage encoder knob does not need to
be changed to follow the Weld voltage setting.
When trigger is closed (and preflow time is over) the wire feeds
at Run-In speed and volts until the welding arc strikes, which
causes the feed speed and volts to change to Weld settings.
If the arc does not strike within about 2 seconds, the Run-In
speed automatically changes to Weld speed to permit “Hot”
feeding at higher speed setting for loading wire.

GAS PURGE

CONTROL

Acceleration Selection
To provide optimum starting of various
processes and procedures, the wire feed
acceleration of the LN-10 can be set to five levels; 1 thru 5, for each feeder and procedure. 1
is the slowest acceleration and 5 is the fastest.
(Factory set to 4.)

To change acceleration hold the Gas Purge Key closed, then
press the Control key. The top (Voltage) display shows “Acc”
indicating acceleration setting, 1 thru 5, is displayed on the bottom (Speed) display. Use the speed encoder knob to change
setting from 1 thru 5.
To exit this function, and enter the acceleration setting into the
procedure memory, press both keys again or close the trigger.

Security Mode
Security mode is used to capture timer, acceleration, and control
selections and settings, then to disable these selections until
security mode is deactivated. Encoder knob setting changes of
cold feed, weld speed and weld voltage are not disabled.
Security mode is activated, or deactivated, by shutting off the
input power to the LN-10 with all Timer and Control settings as
desired for both procedures for both Feeders. Then setting S2
DIP switch 3 inside the LN-10 Control Box ON or OFF and restoring input power (See “Setting DIP Switches” in this section).
When activated, the Timer and Control selections no longer light,
but function with the captured settings. All other keys and
encoder knob controls function normally.

Pressing control key again, or closing the gun trigger, shuts off
light indicating knob settings and displays are returned to Weld
Voltage and Wire Feed Speed.

Digital “Memory” Voltmeter
When the welding gun trigger is activated, the top LN-10 display
reads actual welding voltage from 0.0 to 60.0 VDC with automatic polarity indication for positive (+) or negative (-) electrode.
If actual voltage drops below 8.0 volts for over 0.8 sec when the
trigger is closed, Loss of Voltage Sense Shutdown will occur.
See “Loss of Voltage Sense Shutdown” in this section.
The last welding voltage monitored at the end of the weld is displayed for 5 seconds after the weld has stopped, as indicated
by a 5 second “blinking” display. This allows checking actual
weld voltage after weld has stopped.
Any keypad or trigger operation will interrupt the 5 second
memory display.
LN-10

B-9

OPERATION

Maximum and Minimum Limits Setting
Modes
Limits setting modes are available for limiting the
range for setting wire feed speed and voltage. The
limits can be set independently for each procedure.
The following steps should be followed for setting the
maximum and minimum limits:
1. Turn off the power at the power source.
2. Remove the two screws at the top of the LN-10
control box and open the control box door.
3. Put DIP switch S2 switch 5 in the ON position.
4. Close the control box door.
5. Turn on the power at the power source.
6. Set the maximum WFS and voltage limits for procedure A and procedure B using the two encoder
knobs and the procedure key. The maximum WFS
limit can be set for the entire range of the wire
drive that is being used. The maximum voltage
limit can be set over the range of 10.0 to 60.0 volts.
The maximum limits can be turned off independently for each procedure by turning the encoder
knobs clockwise until the appropriate display (WFS
or voltage) reads “OFF” while the correct procedure light is lit. (The limits are set to “OFF” from
the factory.
7. Turn off the power at the power source.

B-9

8. Open the control box door.
9. Put DIP switch S2 switch 5 in the OFF position and
DIP switch S2 switch 6 in the ON position.
10. Close the control box door.
11. Turn on the power at the power source.
12. Set the minimum WFS and voltage limits for procedure A and procedure B using the two encoder
knobs and the procedure key. The minimum WFS
limit can be set from the minimum speed of the
wire drive that is being used to the maximum limit
that has been set for the selected procedure. The
minimum voltage limit can be set over the range of
10.0 to the maximum voltage limit that has been
set for the selected procedure. The minimum limits can be turned off independently for each procedure by turning the encoder knobs counter clockwise until the appropriate display (WFS or voltage
reads “OFF” while the correct procedure light is
lit. (The limits are set to “OFF” from the factory).
13. Turn off the power at the power source.
14. Open the control box door.
15. Put DIP switch S2 switch 6 in the OFF position.
16. Close the control box door.
17. Reinstall the two screws that had previously been
removed in step 2.

LN-10

B-10

DUAL PROCEDURE
CONTROL (K1449-1)

B-10

OPERATION
REMOTE

When this option is connected to the LN-10 Control
Box receptacle, and the Procedure Key selects
“REMOTE” the front panel knob controls and procedure selection is transferred to the knob encoder controls and Procedure Selector Switch of the remote,
which function in the exact same manner. Remote
knob encoders set Weld voltage and wire feed speed,
as well as Trigger Cold Feed Speed, but not Timers or
Run-In.

WARNING
Check to be sure the Retaining Spring has 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.
___________________________________________
9) To remove Readi-Reel from Adapter, depress
retaining spring tab with thumb while pulling the
Readi-Reel cage from the molded adapter with
both hands. Do not remove adapter from spindle.

If using the optional K683-1, -3 Dual Procedure
Switch, for a wire drive, to select A or B along with the
(K1449-1) remote, both the front panel and remote
Procedure selector and switch must be set to
“REMOTE” and “Gun Switch” (center) positions.
The LN-10 Procedure lights indicate whether A or B is
remotely selected.

WIRE REEL LOADING - READI-REELS,
SPOOLS OR COILS
To Mount a 30 Lb. (14 kg) Readi-Reel Package
(Using the Molded Plastic K363-P Readi-Reel
Adapter:)
The Spindle should be located in the LOWER mounting hole.

FIGURE B.1

1) Depress the Release Bar on the Retaining Collar
and remove it from the spindle.

To Mount 10 to 44 Lb. (4.5-20 kg) Spools
(12"/300 mm Diameter) or 14Lb.(6 Kg)
Innershield Coils:

2) Place the Adapter on the spindle.
3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.

The Spindle should be located in the LOWER mounting hole.
(For 8" (200 mm) spools, a K468 spindle adapter must
first be slipped onto spindle.)

4) Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.

(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil
Adapter must be used).

5) Position the Readi-Reel so that it will rotate in a
direction when feeding so as to be de-reeled from
bottom of the coil.

1) Depress the Release Bar on the Retaining Collar
and remove it from the spindle.

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 cage all the way onto the adapter until the
retaining spring "pops up" fully.

2) Place the spool on the spindle making certain the
spindle brake pin enters one of the holes in the
back side of the spool. Be certain the wire comes
off the reel in a direction so as to de-reel from the
bottom of the coil.
3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.

LN-10

B-11

OPERATION

To Mount a 50-60 Lb. (22.7-27.2 kg) Coil:
(Using K1504-1 Coil Reel) (For 50-60 lb ReadiReels a K438 Readi-Reel Adapter must be used).

1) Turn the Reel or spool until the free end of the
electrode is accessible.

The Spindle must be located in the UPPER mounting hole.
1) With the K1504-1 Coil Reel mounted on to the 2"
(51 mm) spindle (or with reel laying flat on the
floor) loosen the spinner nut and remove the reel
cover. (See Figure B.2).
2) Before cutting the tie wires, place the coil of electrode on the reel so it unwinds from the bottom as
the reel rotates.
3) Tighten the spinner nut against the reel cover as
much as possible by hand using the reel cover
spokes for leverage. 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 secure it by wrapping it
around. Cut and remove the remaining tie wires.

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 “backlashing” of the coil, which may tangle
the wire. A tangled coil will not feed so it must either
be untangled or discarded.
___________________________________________
5) Be sure the coil reel is engaged with the spindle
brake pin and the Release Bar on the Retaining
Collar “pops up” and that the collar retainers fully
engage the retaining groove on the spindle.
SPINNER NUT

COVER
PLATE

SLOTS
CARDBOARD
COIL LINER

COIL

FEEDING ELECTRODE AND BRAKE
ADJUSTMENT

2) While tightly holding the electrode, cut off the bent
end and straighten the first 6" (150 mm). Cut off
the first 1" (25 mm). (If the electrode is not properly straightened, it may not feed or may jam causing
a "birdnest".)
3) Insert the free end through the incoming guide
tube.
4) Press the Cold Inch key or the Cold Feed Mode
gun trigger and push the electrode into the drive
roll.

WARNING
When feeding with the gun trigger, unless “COLD
FEED” trigger mode is selected, the electrode and
drive mechanism are always “HOT” to work and
ground and could remain “HOT” several seconds after
the gun trigger is released.
___________________________________________
5) Feed the electrode through the gun.
6) 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.

DRIVE ROLL PRESSURE SETTING
The LN-10 pressure is factory pre-set to about position “2" as shown on the pressure indicator on the
front of the feedplate door. This is an approximate
setting.
The optimum drive roll pressure varies with type of
wire, surface condition, lubrication, and hardness.
Too much pressure could cause “birdnesting”, but too
little pressure could cause wire feed slippage with
load and/or acceleration. The optimum drive roll setting can be determined as follows:

TIE WIRE
SPRING
LOADED ARM

REEL

FIGURE B.2
LN-10

B-12

OPERATION

1) Press end of gun against a solid object that is
electrically isolated from the welder output and
press the gun trigger for several seconds.
2) If the wire "birdnests", jams, or breaks at the drive
roll, the drive roll pressure is too great. Back the
pressure setting out 1/2 turn, run new wire through
gun, and repeat above steps.
3) If the only result is drive roll slippage, disengage
the gun, pull the gun cable forward about 6" (150
mm). There should be a slight waviness in the
exposed wire. If there is no waviness, the pressure is too low. Increase the pressure setting
turn, reconnect the gun, tighten locking clamp and
repeat the above steps.

4) Use Control Select and encoder knobs to set desired
Weld feed speed and voltage then Run-in speed and
voltage to optimize arc starting. (Set for each procedure if using front panel, remote control or optional
dual procedure switch.) (Refer to “Operation Keys”
and “Display Control Keys” in this section)
5) Adjust the wire feed acceleration if desired, for
each feeder and procedure. (Refer to “Acceleration
Selection” in this section)
6) Use Timer Select and Voltage Encoder knob to set
desired timers. (Refer to “Trigger Mode Selection”
in this section)

PROCEDURE FOR SETTING ANGLE
OF FEEDPLATE

7) Feed the electrode through the gun and cable and
then cut the electrode within approximately .38"
(9.5 mm) of the end of the contact tip for solid wire
and within approximately .75" (19mm) of the extension guide for cored wire.

1) Loosen the clamping collar screw using a 3/16"
Allen wrench. The clamping collar screw is
accessed from the bottom of the feedplate. It is
the screw which is perpendicular to the feeding
direction.

8) Connect work cable to metal to be welded. Work
cable must make good electrical contact to the
work. The work must also be grounded as stated in
"Arc Welding Safety Precautions".

WARNING

2) Rotate feedplate to the desired angle and tighten
clamping collar screw.

When using an Open Arc process,
it is necessary to use correct eye,
head, and body protection.

GAS GUARD REGULATOR SETTING
NOTE: Gas supply pressure must be regulated to a
maximum of 80 psi(5.5 bar).
1) With the gas supply shut off, the Gas Guard regulator flow adjusting Key should be set to maximum
(full clockwise) which is rated to be 60 SCFH (28
l/min).
2) Adjust gas supply flow rate for a level higher than
will be required, then adjust Gas Guard flow
adjusting Key counterclockwise to the desired gas
flow rate.

____________________________________
9) If used, be sure shielding gas valve is turned on.
10) Position electrode over joint. End of electrode
may be lightly touching the work.
11) Lower welding helmet, close gun trigger, and start
welding. Hold the gun so the contact tip to work
distance gives the correct electrical stickout as
required for the procedure being used.
12) To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out and Postflow time, if used, is over.

MAKING A WELD
1) Use only a Lincoln Electric recommended constant
voltage DC power source compatible with the LN10 Wire Feeder.
2) Properly connect the electrode and work leads for
the correct electrode polarity.

13) If necessary to optimize arc starting, readjust wire
speed acceleration, (Refer to “Acceleration
Selection” in this section) and/or Run-In speed,
(Refer to “Display Control Keys” in this section).

3) Use the Mode Selection key to set desired trigger
mode for each procedure. (Refer to “Trigger Mode
Selection” in this section)
LN-10

B-13

OPERATION

B-13

WIRE REEL CHANGING

WIRE FEED OVERLOAD PROTECTION

At the end of a coil, remove the last of the old electrode coil from the conductor cable by either pulling it
out at the nozzle end of the gun or by using the following procedure:

The LN-10 has solid-state overload protection of the
wire drive motor. If the wire drive motor becomes
overloaded for an extended period of time, the protection circuitry turns off the power source, wire feed and
gas solenoid, and then displays “H30” on the WFS
display (with blank Voltage display). This indicates
the wire drive motor is overloaded and will remain
shut down for about 30 seconds before the unit will
automatically reset. The “H30” display decrements
every second until it reaches “H00”. At that time, the
unit resets automatically and the previous displays will
return indicating the unit is ready to operate again.
Overloads can result from improper tip size, liner,
drive rolls, or guide tubes, obstructions or bends in the
gun cable, feeding wire that is larger than the rated
capacity of the feeder or any other factors that would
impede normal wire feeding. (See “Avoiding Wire
Feeding Problems” in the MAINTENANCE section).

1) Cut the end of the electrode off at the gun end. Do
not break it off by hand because this puts a slight
bend in the wire making it difficult to pull it back
through the nozzle.
2) Disconnect the gun cable from the gun connector
on the LN-10 wire drive unit and lay the gun and
cable out straight.
3) Using pliers to grip the wire, pull it out of the cable
from the connector end.
4) After the electrode has been removed, reconnect
the gun cable to the drive. Load a new reel of electrode per the instructions in “Wire Reel Loading” in
this section.

LOSS OF VOLTAGE SENSE SHUTDOWN
If the actual displayed voltage, when the trigger is
closed, drops below 8.0 volts for over 0.8 second it is
assumed the voltage feed back sensing circuit to the
LN-10 is opened or faulty, so Loss of Voltage Sense
Shutdown occurs until the trigger is released.
This shutdown stops the motor, shuts off the gas flow
and disables the power source output to prevent the
LN-10 voltage control from driving the power source
output too high due to loss of proper feedback sensing
via #21 (WORK) and #67 (ELECTRODE) sensing
leads.

GROUNDING LEAD PROTECTOR
The frame of the LN-10 Control is grounded to the
frame of the power source by a lead in the control
cable. An overload protector prevents welding current
from damaging this lead if the electrode circuit touches the wire feeder frame while the electrode is electrically hot.
If such a grounding lead fault occurs, the WFS display
will show “GLP,” (with blank Voltage display) and the
trigger circuit will be disabled. To reset the circuit,
release the trigger, make sure that the electrode is not
touching the wire feeder frame, and then either press
any key on the keypad or close the trigger. When the
GLP circuit is reset, the “GLP” display is removed and
the wire feeder is returned to normal operating mode.

LN-10

B-14

OPERATION

EXPLANATION OF PROMPTING
AND ERROR MESSAGES
Display

Prompt or Error

Acc

Displayed on Voltage display, indicates WFS
display is showing acceleration setting, “1" to
“5" (See “Acceleration Selection” in this section).

OFF

Displayed on WFS and voltage displays; indicates limits for WFS or voltage are off for the
displayed procedure. (See “Maximum and
Minimum Limits Setting Modes” in this section).

SEC

Displayed on WFS display, indicates Voltage
display is showing a Timer setting in seconds. (See “Display Control Keys” in this
section)

GLP

Displayed on WFS display, indicates that the
Grounding Lead Protector circuit was activated due to excessive current flow into the
wire feeder frame. When the GLP circuit is
activated the wire feeder is disabled (the trigger output to the power source is opened up,
the motor is stopped, and the gas solenoid is
turned off). To resume normal operation,
release the trigger, make sure that the electrode is not touching the wire feeder frame,
and then either press a key on the keypad or
close the trigger. (See “Grounding Lead
Protector” in this section)

Cld

Displayed on Voltage display when Cold
Feed Forward or Cold Feed Reverse Key is
pressed, or Cold Feed Trigger mode is
selected. Indicates wire is fed “cold” (no
weld voltage) at the speed indicated on the
WFS display. (See “Operation Keys” and
“Trigger Mode Selection” in this section).

---

Displayed on Voltage or WFS displays with
RUN-IN selected, indicates setting will match
those set for Weld Voltage and Wire Feed
Speed (See “Display Control Keys” in this
section).

HXX

Displayed on WFS display, indicates wire feed overload. XX indicates time remaining in seconds before
unit resets automatically. (See “Wire Feed Overload
Protection” in this section and “Avoiding Wire
Feeding Problems” in the MAINTENANCE section).

LN-10

B-14
EEPROM error. Usually occurs at power-up.
Indicates one or more of the recalled settings is out
of acceptable limits. Press any key to return to normal operation. Be sure to check all voltage, wire feed
speed, acceleration and timer settings before you
proceed.

C-1

ACCESSORIES
TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS
Wire Size

4-Roll
DH Drive
(4-Driven)

4-Roll
Single Drive
(2-Driven)

Solid Steel Electrode
0.025”

(0.6 mm)

KP1505 - 030S

KP655 - 025S

0.030”

(0.8 mm)

KP1505 - 030S

KP655 - 030S

0.035”

(0.9 mm)

KP1505 - 035S

KP655 - 035S

0.040”

(1.0 mm)

KP1505 - 040S

KP655 - 035S

0.040”

(1.0 mm)

KP1505 - 045S

KP655 - 035S

0.045”

(1.2 mm)

KP1505 - 045S

KP655 - 052S

0.052”

(1.4 mm)

KP1505 - 052S

KP655 - 052S

1/16”

(1.6 mm)

KP1505 - 1/16S

KP655 - 1/16

5/64”

(2.0 mm)

KP1505-5/64

KP655 - 3/32

3/32”

(2.4 mm)

KP1505-3/32

---------------

Cored Electrode
0.030

(0.8 mm)

KP1505 - 035C

---------------

0.035”

(0.9 mm)

KP1505 - 035C

KP655 - 035C

0.040”

(1.0 mm)

KP1505 - 045C

KP655 - 035C

0.045”

(1.2 mm)

KP1505 - 045C

KP655 - 052C

0.052”

(1.4 mm)

KP1505 - 052C

KP655 - 052C

1/16”

(1.6 mm)

KP1505 - 1/16C

KP655 - 1/16

0.068” - 0.072”

(1.7 - 1.8 mm)

KP1505 - 068

KP655 - 3/32

5/64”

(2.0 mm)

KP1505 - 5/64

KP655 - 3/32

3/32”

(2.4 mm)

KP1505 - 3/32

---------------

7/64” Lincore Hard Facing (2.8mm)

KP1505 - 7/64H

---------------

7/64”

(2.8mm)

KP1505 - 7/64

---------------

.120”

(3.0mm)

KP1505 - 120

---------------

Aluminum Electrode
0.035”

(0.9 mm)

KP1507 - 035A

KP656 - 035A

0.040”

(1.0 mm)

KP1507 - 040A

---------------

3/64”

(1.2 mm)

KP1507 - 3/64A

KP656 - 3/64A

1/16”

(1.6 mm)

KP1507 - 1/16A

KP656 - 1/16A

Aluminum Electrode
(For use with Binzel Guns Only)
0.040”

(1.0 mm)

---------------

KP647 - 040A

3/64”

(1.2 mm)

---------------

KP647 - 3/64A

1/16”

(1.6 mm)

---------------

KP647 - 1/16A

LN-10

C-2

ACCESSORIES

INPUT CABLE ASSEMBLIES:

C-2

K683-3 DUAL PROCEDURE SWITCH

K1797-25
Consists of a 14-conductor control cable extension 25ʼ
in length.

K1797-50
Consists of a 14-conductor control cable extension 50ʼ
in length.
Note: Extensions can only be connected up to 100ʼ Maximum
length.

K1520-1 115V/42V TRANSFORMER KIT
Required to use LN-10 with Lincoln Power Sources
without 42VAC auxiliary and a 14-pin connector receptacle. These power sources include the DC-250, DC600 (Below Code 10500), DC-1000 and Pulse Power
500. Also can be used with older DC-400 models.

Kit includes gun switch, and mountings for Lincoln
Innershield and Magnum guns, with 15 ft. (4.5m) control cable and 5-pin plug with two leads to connect to
gun trigger.

SPINDLE ADAPTERS:
K162H (Not required for LN-10 Bench Models)
Spindle for boom mounting Readi-Reels and 2" (51
mm) I.D. spools with 60 lb. (27.2 kg) capacity. User
mounted to appropriately prepared boom framework.
Includes an easily adjustable friction brake for control
of overrun.
When a 2" (51 mm) spindle is used with Readi-Reels
or coils not on 12" (305 mm) O.D. spools, an adapter
is required:

K590-4 WATER CONNECTION KIT Coil Adapter:
Includes water cooled gun tube fittings and self-sealing
outlet and inlet quick-connectors for mounting into the
DH wire drive connection box.

K1504-1 Permits 50 lb to 60 lb (22.7-27.2 Kg.) Coils
to be mounted on 2” (51 mm) O.D. spindles.

K659-1 GAS GUARD REGULATOR K435
Adjustable flow regulator with removable adjustor key
for CO2 and Argon blend gases. Mounts onto wire drive
gas inlet, and reduces gas waste and arc start "blow" by
reducing surge caused by excess pressure in supply
hose.

K1449-1
DUAL
REMOTE CONTROL

PROCEDURE

Permits 14 lb. (6 kg) Innershield coils to be
mounted on 2" (51 mm) O.D. spindles.

K468 Permits 8" (203 mm) O.D. spools to be mounted on 2" (51 mm) O.D. spindles.

Readi-Reel Adapters:
K363P Adapts Lincoln Readi-Reel coils of electrode

Includes a remote control box with a 16 ft. (5 m) length
control cable with 4-pin plug for the mating receptacle
on the bottom of the LN-10 control box. The remote control box contains a procedure selector switch and 2
rotating knob encoders, one controls arc voltage and the
other controls wire feed speed, which function the same
as comparable controls on the LN-10 front panel, when
the remote is connected and selected by the LN-10
Procedure Key.

K1450-”L” - Extension cables are available in lengths
“L” of 12, 16 or 25 ft. (3.6, 4.9 or 7.6) to match the control to Feeder cable length used.

K683-1 DUAL PROCEDURE SWITCH
Requires K686-2 Adapter for LN-10. Kit includes gun
switch, and mountings for Lincoln Innershield and
Magnum guns, with 15 ft. (4.5 m) control cable and 3pin plug. K686-2 Adapter permits 3-pin plug and 5-pin
gun trigger plug to be connected to LN-10 5-pin
Trigger/Dual Procedure receptacle.

30 lb. (14 kg) and 22 lb. (10 kg) to a 2" (51 mm) spindle. Durable molded plastic one piece construction.
Designed for easy loading; adapter remains on spindle for quick changeover.

K438 Adapts Lincoln Readi-Reel coils of electrode
50-60 lb. (22.7-27.2 kg) to a 2" (51 mm) spindle.

GUN ADAPTERS (FOR 10 SERIES
WIRE DRIVE)
The LN-10 wire feeder is equipped with a factory
installed K1500-2 gun connection kit. This kit is for
guns having a Tweco #2-#4 type connector. The LN10 has been designed to make connecting a variety of
guns easy and inexpensive with the K1500 series of
gun connection kits. Gun trigger and dual procedure
lead connections connect to the single 5 pin receptacle on the front of the feed head box.

LN-10

C-3

ACCESSORIES

Magnum 200/300/400 Guns
The easiest and least expensive way to use Magnum
200/300/400 guns with the LN-10 wire feeder is to
order them with the K466-2 connector kit, or to buy a
completely assembled Magnum gun having the K4662 connector (such as the K497-21,-22,-23 dedicated
Magnum 400 guns and the K497-20,-21 dedicated
Magnum 200 guns).
Magnum 550 Guns
The easiest and least expensive way to use the
Magnum 550 guns with LN-10 wire feeders is to order
the gun with the K613-2 connector kit, and install a
K1500-3 gun connection kit to the wire feeder.

C-3

GUN RECEIVER BUSHINGS AND GUN ADAPTERS
K489-7 (Dual Schedule Fast-Mate Adapter)
This adapter installs directly into the wire drive feedplate, to provide for use of guns with Fast-Mate or
European style gun connections. This K489-7 will
handle both standard Fast-Mate and Dual Schedule
Fast-Mate guns.

GUN AND CABLE ASSEMBLIES
The following Lincoln gun and cable assemblies are
compatible with 10 Series Wire Feed heads with
appropriate K1500 Gun Adapter:

Lincoln Innershield and Sub Arc Guns
All of these guns can be connected to the LN-10 by
using the K1500-1 Adapter Kit.

K126 (Requires K1500-1) Innershield gun and cable
assemblies are rated at 350 amps, 60% duty cycle.
(Consult sales specifications for appropriate models)

Lincoln Fume Extraction Guns
The K556 (250XA) and K566 (400XA) guns require
that a K489-7 Fast-Mate adapter kit be installed.

K115 (Requires K1500-1) Innershield gun and cable
assemblies are rated at 450 amps, 60% duty cycle.
(Consult sales specifications for appropriate models)

The K206, K289, and K309
require only the installation of a K1500-1 connector in
the LN-10 wire feeder.

K470 (With K466-9 requires K1500-2) Magnum 300

Non-Lincoln Guns
Most competitive guns can be connected to the LN-10
by using one of the K1500 series adapter kits.

K1500-1 (Lincoln Innershield gun standard connection)
Use this kit to connect the following guns: Guns having a
Lincoln standard innershield gun connector, Magnum
200/300/400 with K466-1 connector kit, and Magnum 550
guns with the K613-1 gun connection kit.

K1500-2 (Tweco #2-#4 type connection)
The K1500-2 gun adapter comes factory installed on the
LN-10 wire feeder. Use this adapter for guns that have a
Tweco #2-#4 connector. Such guns include Magnum
200/300/400 guns with K466-2 connector kit, and completely factory assembled Magnum guns that are factory
equipped with the K466-2 connector (such as the K471-21, 22, and -23 dedicated Magnum 400 guns and the K497-20
and -21 Magnum 200 guns).
K1500-3 (Tweco #5 connection)
For Magnum 550 gun with K613-2 Connection Kit,
and any other gun having a Tweco #5 connector .
K1500-4 (Miller connection)
For any gun having a newer style Miller connector.

GMAW gun and cable assemblies are rated 300
amps, 60% duty cycle. (Consult sales specifications
for appropriate models)

K471 (With K466-9 requires K1500-2) Magnum 400
GMAW gun and cable assemblies are rated 400
amps, 60% duty cycle. (Consult sales specifications
for appropriate models)

K497 (With K466-9 requires K1500-2) Magnum 200
GMAW gun and cable assemblies are rated 200
amps, 60% duty cycle. (Consult sales specifications
for appropriate models)

K541 (With K466-9 requires K1500-2) Magnum 400
Short Neck GMAW gun and cable assemblies are
rated 400 amps, 60% duty cycle. (Consult sales
specifications for appropriate models)

K598 (With K613-7 requires K1500-3) Magnum 550
GMAW gun and cable assemblies are rated 550
amps, 60% duty cycle. (Consult sales specifications
for appropriate models) The following Lincoln gun and
cable assemblies are equipped with a Fast-Mate™
connector. They can be used with 10 Series wire feed
models by installing a K489-2 Fast-Mate™ adapter kit
and a K1500-1 Lincoln Gun adapter.

K684 Magnum "Super Cool" FM water cooled
GMAW gun and cable assemblies are rated 450
amps, 100% duty cycle (CO2). (Consult sales specifications for appropriate models)
LN-10

C-4

ACCESSORIES

K498 Magnum 200 FM GMAW gun and cable
assemblies are rated for 200 amps 60% duty cycle.
(Consult sales specifications for appropriate models)

K534 Magnum 250L FM GMAW gun and cable
assemblies are rated for 250 amps, 30% duty cycle.
(Consult sales specifications for appropriate models)
K478 Magnum 300 FM GMAW gun and cable
assemblies are rated for 300 amps, 60% duty cycle.
(Consult sales specifications for appropriate models)
K479 Magnum 400 FM GMAW gun and cable
assemblies are rated for 400 amps, 60% duty cycle.
(Consult sales specifications for appropriate models)
USING DUAL PROCEDURE WITH FAST-MATE
GUNS
There are a number of different options available for
using dual procedure with Fast-Mate guns. These
configurations are outlined below along with any additional required equipment.

Using Dual Schedule with Fast-Mate Guns
on -10 Series Feeders
Configuration 1
K489-7 Dual Schedule Fast-Mate adapter
K575-Magnum 400 DS/FM gun (or competitive
DS/FM gun)
Configuration 2
K489-7-Dual Schedule Fast-Mate adapter
K683-1-Dual Procedure Switch (3 pin)
K686-2-"Y" adapter (3pin + 5 pin to 5 pin)
K*-Non-DS Fast-Mate gun (Magnum 450WC,
Magnum 200, Magnum 300, Magnum 400, and
others)

K1558-1 REMOTE SWITCH INTERFACE
MODULE
The Module provides for user interface connection of
an external switch (flow switch, etc.) which must be
closed to enable the feeder welding operation. Also,
the Module provides for interface connection of external equipment (fume extractor, etc.) to the Moduleʼs
isolated relay contacts which actuate when the feeder
welding gas solenoid is activated (representing welding operation in process).

C-4

K1561-1 ROBOTICS INTERFACE
MODULE
The module plugs directly into the LN-10 control board
and provides an interface to a properly equipped
Fanuc robot. When installed and properly configured,
the K1561-1 Robotics Interface Module allows complete control of the welding process from the robot
controller.
The Lincoln Electric Companyʼs Automation Center
should be contacted for questions regarding installation or operation of the Robotics Interface Module.

K1557-1 SWIVEL MOUNT
The K1557-1 Swivel mount attaches to the power
source. This kit includes a feeder adapter plate that
allows the feeder to rotate on top of the power source.
The feeder can be easily separated from the swivel
mount at any time. This option is compatible with the
K1556-1 Light Duty Caster Kit.

K1556-1 LIGHT DUTY CASTER KIT
This option provides 4 casters and all required hardware to mount it to the Power Feed 10. This option is
compatible with the K1557-1 Swivel Mount.

K1555-1 INSULATED LIFT HOOK
For applications where an insulated lift hook is
required. This kit provides an easily installed, heavy
duty insulated lift eye that mounts to the wire reel
stand mast. See the instructions provided with the kit
for installation.

K1634-1 WIRE REEL ENCLOSURE KIT
The K1634-1 Wire Reel Enclosure Kit provides the
necessary parts to cover the wire and protect it from
excessive dirt and contamination. The kit is not for use
with 60lb coils (most 30 lb, 15kg, 44 lb fiber spools,
and smaller coils will work). The kit includes a 2 part
plastic reel cover, a Magnum conduit adapter for the
incoming end of the wire feeder feed plate, and a
short length of Magnum conduit to go between the
reel cover and the feedplate.

LN-10

D-1

MAINTENANCE

D-1

MAINTENANCE

Avoiding Wire Feeding Problems

Safety Precautions

Wire feeding problems can be avoided by observing
the following gun handling and feeder set up procedures:
• Do not kink or pull cable around sharp corners.

WARNING
ELECTRIC SHOCK can kill.

• Keep the electrode cable as straight as possible
when welding or loading electrode through cable.

• Do not touch electrically live parts such
as output terminals or internal wiring.
• When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.

• Do not allow dolly wheels or trucks to run over
cables.

• Keep cable clean by following maintenance
instructions.
• Use only clean, rust-free electrode. The Lincoln
electrodes have proper surface lubrication.
• Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or
deformed.

Observe all additional Safety Guidelines detailed
throughout this manual.

• Do not use excessive wire spindle brake settings.
• Use proper drive rolls, guide tubes and drive roll
pressure settings.

Routine Maintenance
Drive Rolls and Guide Tubes

Periodic Maintenance

After feeding every coil of wire, inspect the drive roll
section. Clean it as necessary. Do not use a solvent
for cleaning the idle roll because it may wash the
lubricant out of the bearing. The driver roll and guide
tubes are stamped with the wire sizes they will feed.
If a wire size other than that stamped on the roll(s) is
to be used, the roll(s) and guide tubes must be
changed.
The drive rolls for .035” (0.9mm) through .052”
(1.3mm) cored electrode and 1/16” (1.6mm) through
3/32” (2.4mm) electrode have a double set of teeth so
they can be reversed for additional life. Drive rolls for
.023" (0.6 mm) through .052" (1.3 mm) solid electrodes and aluminum sizes have no teeth, but use two
grooves so they also can be reversed for additional
life.
See “Procedure to Install Drive Roll and Guide Tubes”
in the INSTALLATION section for roll changing
instructions.

Wire Reel Mounting - Readi-Reels and
10lb through 30lb (4.5-14kg) Spools
No routine maintenance required. Do not lubricate 2”
(51mm) spindle.

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” long.
Gun and Cable Maintenance
See appropriate Operatorʼs Manual.

Procedure for Removing Feedplate from
Wire Feeder
1) Loosen the clamping collar screw using a 3/16"
Allen wrench. The clamping collar screw is
accessed from the bottom of the feedplate. It is
the screw which is perpendicular to the feeding
direction.
2) Loosen the retaining screw, which is also
accessed from bottom of feeder, using a 3/16"
Allen wrench. Continue to loosen the screw until
the feedplate can be easily pulled off of the wire
feeder.

LN-10

E-1

TROUBLESHOOTING

E-1

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 (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

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.

Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

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-10

E-2

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE
CAUSE

RECOMMENDED
COURSE OF ACTION

Rough wire feeding or wire not feed- 1. Gun cable kinked and/or twisted.
ing, but drive rolls are turning.
2. Wire jammed in gun and cable.
3. Check for current position of
drive rolls relative to split wire
guide groove.
4. Drive rolls may not be seated
properly.
5. Gun cable dirty.
6. Worn drive roll.
7. Worn nozzle or cable liner.
9. Partially flashed or melted contact
tip
10. Incorrect drive roll pressure.
11. Improper liner, contact tip, or
inner/outer wire guides.
12. Incorrect wire drive or gear ratio
selection on the control p.c.
board.
Variable or “hunting” arc.

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

1. Wrong size, worn and/or melted
contact tip.
2. Worn work cable or poor work
connection.
3. Loose electrode or work cable
connections.
4. Wrong polarity.
5. Gas nozzle extended beyond gun
tip or wire stickout too long while
welding.
6. Poor gas shielding on processes
requiring gas.
7. Improper power source selection
on the control p.c. board.

E-3

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE
CAUSE

RECOMMENDED
COURSE OF ACTION

1. Improper procedures or techniques.
Poor arc striking with sticking or
“blast-offs”, weld porosity, narrow
and ropy looking bead, or electrode 2. Improper gas shielding.
stubbing into the plate while welding.
Tip seizes in the diffuser.

1. Tip overheating because of prolonged
or excessive high current and/or duty
cycle welding.

Motor does not turn when trigger is 1. The wire drive motor may be overloaded. “Hxx” will be displayed on the
pulled.
WFS display, where “xx” is the number of seconds until the wire drive
attempts to run again.
2. A jumper plug or K1558-1 Remote
Switch Interface Module must be
properly installed into connector J5.
3. Damaged wiring in the trigger circuit.
4. Control p.c. board failure.
The drive motor does not turn
although arc voltage is present
and the gas solenoid is on.

1. Damaged leads to the drive motor.

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

2. Damaged wire drive motor.
3. Damaged control p.c. board.

1. Damaged leads to the motor
No control of wire feed speed.
tachometer.
Motor turns. Gas solenoid operates
properly and arc voltage is present.
Wire feed speed can be set on the
2. Damaged tachometer.
display, but has no control of the
wire feed speed.
3. Damaged control p.c. board

Wire feed motor turns and gas sole- 1. Power source is unable to provide arc
voltage because of thermal shutdown
noid operates, but no arc voltage is
or other failure.
present.

E-4

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE
CAUSE

RECOMMENDED
COURSE OF ACTION

Speed does not change when weld 1. Run-in and weld speeds are set
current flows.
to the same value.
2. Current sensing reed switch is not
operating properly.
3. The wiring from the control p.c.
board to the weld current sensing
reed switch is damaged.
4. Damaged control p.c. board.

Voltmeter does not function proper- 1. The work sense lead (#21) or the
ly. Welding may or may not vary
electrode sense lead (#67) may
from normal procedure. Wire feeds
have intermittent or poor connecproperly.
tions.
2. Improper power source selection
on the control p.c. board.
3. Control p.c. board failure.

Cold feed forward or cold feed
reverse buttons on keypad do not
work, but motor control otherwise
functions properly.

1. The connector from the control
p.c. board to the display p.c.
board or the connector from the
display p.c. board to the keypad
are loose or improperly inserted.

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

2. Damaged keypad
3. Damaged display p.c. board.
4. Damaged control p.c. board.

Gas purge key does not operate
1. The connector from the control
the gas solenoid, but gas flow does
p.c. board to the display p.c.
occur while welding.
board or the connector from the
display p.c. board to the keypad
are loose or improperly inserted.
2. Damaged keypad
3. Damaged display p.c. board.
3. Damaged control p.c. board.

E-5

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE
CAUSE

RECOMMENDED
COURSE OF ACTION

1. The connector from the control
Pressing the procedure key does
p.c. board to the display p.c.
not select between A - Remote - B.
board or the connector from the
display p.c. board to the keypad
are loose or improperly inserted.
2. Damaged keypad
3. Damaged display p.c. board.
4. Damaged control p.c. board.

Pressing the timer or control key has 1. Make sure that the DIP switches
on the control p.c. board are not
no effect while not welding.
set for security mode.
2. The connector from the control
p.c. board to the display p.c.
board or the connector from the
display p.c. board to the keypad
are loose or improperly inserted.
3. Damaged keypad
4. Damaged display p.c. board.
5. Damaged control p.c. board.

Pressing the trigger key has no
effect while not welding.

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

1. The connector from the control
p.c. board to the display p.c.
board or the connector from the
display p.c. board to the keypad
are loose or improperly inserted.
2. Damaged keypad
3. Damaged display p.c. board.
4. Damaged control p.c. board.

E-6

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE
CAUSE

RECOMMENDED
COURSE OF ACTION

One of the knobs changes the dis- 1. The display is in a mode that can
only use one encoder.
play, but the other doesnʼt.
2. The connector from the control
p.c. board to the encoder p.c.
boards may be loose or improperly inserted.
3. Damaged encoder p.c. board.
4. Damaged control p.c. board.

Neither knob changes the display.

1. The connector from the control
p.c. board to the encoder p.c.
boards may be loose or improperly inserted.
2. Damaged control p.c. board.
3. Damaged encoder p.c. boards.

Displays & LEDʼs on keypad are off. 1. Power source is off.
The green and red LEDʼs on the
2. Power source supply is not supcontrol p.c. board are off.
plying 42 VAC to the wire feeder
control box.

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

3. Damaged input power wiring in
the LN-10 control box.
4. Damaged control p.c. board.

Displays & LEDʼs on keypad are off. 1. The connectors from the control
p.c. board to the display p.c.
The green and red LEDʼs on the conboard are loose or improperly
trol p.c. board are both blinking at
inserted.
about one second intervals.
2. Damaged display p.c. board.
3. Damaged control p.c. board.

Displays & LEDʼs on keypad are off. 1. Damaged control p.c. board.
The green or red LED on the control
p.c. board is blinking at a very fast
or erratic rate.

E-7

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)
The K1449-1 remote control is not
functioning when the Procedure
LED is in the REMOTE position.

POSSIBLE
CAUSE

RECOMMENDED
COURSE OF ACTION

1. The remote control Amphenol
connection is not securely
attached.
2. Faulty wiring from the Amphenol
connector to the control p.c.
board.
3. Damaged remote control.
4. Damaged control p.c. board.

Dual procedure switch is not functioning at the gun.

1. Machine and remote control not
properly set for using a dual procedure switch at the gun
2. Disconnected or damaged wiring
between the wire drive and control box.
3. Damaged wiring in the LN-10 wire
drive.
If all recommended possible areas
4. Damaged wiring in the LN-10 con- of misadjustment have been
checked and the problem persists,
trol box.
Contact your local Lincoln
Authorized Field Service Facility.
5. Damaged control p.c. board.

Wire feed speed is consistent and
adjustable, but operates at the
wrong speed.

1. DIP switch S1 is incorrectly set for
the wrong wire drive or gear ratio.
2. Damaged control p.c. board.

E-8

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)
ʻErʼ is displayed on power up.

POSSIBLE
CAUSE

RECOMMENDED
COURSE OF ACTION

1. EEPROM error detected.
2. Damaged control p.c. board.

ʻGLPʼ is displayed.

1. Ground Loop Protection fault
occurred
2. GLP reed switch failure.
3. Damaged control p.c. board.

1. Power source work & electrode
After pressing the trigger, wire
sense lead polarity switch or
feeds for a couple seconds, but
jumper is not correctly set.
stops. The voltage display reads
less than 8.0 volts while the wire is
2. Damaged wiring between the confeeding.
trol p.c. board and the work and
electrode connections.
3. Damaged control p.c. board

The knobs do not control the complete range of wire feed speed or
voltage.

If all recommended possible areas
of misadjustment have been
1. Limits are set for wire feed speed checked and the problem persists,
or voltage.
Contact your local Lincoln
Authorized Field Service Facility.
2. DIP switch S1 is incorrectly set for
the wrong wire drive or gear ratio.
3. Improper power source selection
on the control p.c. board.

Gas solenoid not operating properly 1. Inlet gas pressure exceeding 80
psi(5.5 bar). Verify that gas presor intermittent.
sure regulator is operating properly.

E-9

TROUBLESHOOTING

E-9

Observe all Safety Guidelines detailed throughout this manual

PC BOARD TROUBLESHOOTING
GUIDE - CONTROL P.C. BOARD

c. If PC board is visibly damaged mechanically,
inspect for cause, then remedy before installing a
replacement PC board.

WARNING
ELECTRIC SHOCK can kill.
• Have a qualified individual install and
service this equipment.
• Turn the power source input power off
at the disconnect switch before working on this equipment.
• Do not touch electrically hot parts.
---------------------------------------------------------------------

If there is damage to the PC board or if replacing
PC board corrects problem, return it to the local
Lincoln Electric Field Service Shop.

Procedure for Replacing PC Boards
Before replacing a PC board which is suspected of
being defective, visually inspect the PC board in question for any electrical or mechanical damage to any of
its components and conductors on the back of the
board.
a. If there is no visible damage to the PC board, install
a new one and see if this remedies the problem. If
the problem is remedied, reinstall the old PC board
to see if the problem still exists. If it does no longer
exist with old PC board:
1. Check the PC board harness connector pins for
corrosion, contamination, or looseness.
2. Check leads in the plug harness for loose or
intermittent connection.
b. If PC board is visibly damaged electrically, before
possibly subjecting the new PC board to the same
cause of failure, check for possible shorts, opens, or
grounds caused by:
1. Frayed or pinched lead insulation.
2. Poor lead termination, such as a poor contact or
a short to adjacent connection or surface.
3. Shorted or open motor leads, or other external
leads.
4. Foreign matter or interference behind the PC
boards.

NOTE: This diagram is for reference only. 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.

F-1

DIAGRAMS

LN-10

F-1

F-2

DIAGRAMS

LN-10

F-2

1
A

3 4

1 2

539

3
3
3
3

1
1
1
1

2
2

14 7 9 8 10 11 13 5 1 4 12 2 3 6

C D B A

K L F G H N I J

WI RE DRI VERECEPTACL E

541

B W

E M

GE ARBOX

TACH.

GA S

GU N
TRI GGER AND
DUAL PROCE DURE
SWI TCH
RE CEP TACLE

N. A.

CHO KE PCB

P. M.

512

522

A B C D E

M19828

3-9-2001E

N. A. HOK
C E PCB ASSEMBLY NOT
I NCL UDED ON EARLI ER WI RE
DRI VES.

ELECTRO DE
CA BLE
FROM
CURR ENT
SENSOR

DIAGRAMS

P1
P2
P3

512
512

539
539

522
522

541

U
R
B
U
R
B

561

67
560
67
560

519
520

561
519
520

J1
J2
J3

ELECT RI CAL SYMBOL S PER E1537.

HEAD
ASSEMBLY

CON NEC TOR CAVI TY NUMBER I NG SEQUENCE
(NON LEAD SI D
E OF CONNEC TOR )

560

541

WIRING DI AGRAM (LN-10 / STT- 10 W
IRE DRI VE)

520

LN-10

561
519

F-3
F-3

(15.30)

(30.35)

BENCH MODEL DIMENSION PRINT

M 18903

7-2000

(14.43)

(5.25)

(10.66)

(20.46)

F-4

DIAGRAMS

LN-10

F-4

DIMENSION PRINT

LN-10

6.00

3.00

2.25

10.40

11.00

2.42

5/16-18UNC-2B
(4 PLACES)

4.08

14.71

4.44

5.25

6.55

12.74

M18904

7-2000

WIRE DRIVE
DIMENSION PRINT

7.81

F-5

DIAGRAMS
F-5

DIMENSION PRINT

14.65

LN-10

10.10

12.75

R .141
(3 SLOTS)

14.67

2.63

2.80

GRAPHICS SHOWN REPRESENT M17869-1.

5.25

10.92

13.75

5-2-97
M18299

4.58

YEAR
WARRANTY

WARNING

4.27

Boom Model Control Box
Dimension Print

F-6

DIAGRAMS
F-6

DIMENSION PRINT

● Do not touch electrically live parts or

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

● Keep flammable materials away.

● Wear eye, ear and body protection.

● Mantenga el material combustible

● Protéjase los ojos, los oídos y el

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 mojada.
● 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 Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Mantenha inflamáveis bem guarda-

dos.

● Use proteção para a vista, ouvido e

corpo.

Japanese

Chinese

Korean

Arabic

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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.
● Use ventilation or exhaust to

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

remove fumes from breathing zone.
● Los humos fuera de la zona de res-

piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von

Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Strom vor Wartungsarbeiten

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

oder Innenschutzverkleidung in
Betrieb setzen!

● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer

● Mantenha-se afastado das partes

serviço.
● Não toque as partes elétricas nuas.

● Não opere com os paineis abertos

moventes.

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

ou guardas removidas.
Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• 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

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Lincoln Electric Ln 10 Heads And Controls Im587 B Users Manual

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