Safety Depends on YouLincoln arc welding and cuttingequipment is designed and built withsafety in mind. However, your overallsafety can be increased by properinstallation ... and thoughtful opera-t ion on your part. DO NOTINSTALL, OPERATE OR REPAIRTHIS EQUIPMENT WITHOUTREADING THIS MANUAL ANDTHE SAFETY PRECAUTIONSCONTAINED THROUGHOUT. And,most importantly, think before youact and be careful.
IEC 60974-5EN 60974-5
N80
This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.
FOR ENGINEpowered equipment.
1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
____________________________________________________1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumesoutdoors.
____________________________________________________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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine 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 andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.
1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
___________________________________________________1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.
___________________________________________________1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
iSAFETYi
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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC ANDMAGNETIC FIELDSmay be dangerous
2.a. Electric current flowing through any conductor causeslocalized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines
2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem 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 andwork cables. If the electrode cable is on your rightside, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.
The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
iiSAFETYii
ARC RAYS can burn.4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL andACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.
5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.
5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09
iiiSAFETYiii
FOR ELECTRICALLYpowered equipment.
8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.
Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘09
Refer to http://www.lincolnelectric.com/safety for additional safety information.
ivSAFETYiv
PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:
Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dansles positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:
a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.
c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
Mar. ‘93
vSAFETYv
60974-10
viSAFETYvi
EN 60974-10:
viivii
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.
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 youhave 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 packetaccompanying 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.
CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty 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 controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying 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.comfor any updated information.
viii viii TABLE OF CONTENTSPage
Installation.......................................................................................................................Section ATechnical Specifications.......................................................................................................A-1Safety Precautions ...............................................................................................................A-2Location................................................................................................................................A-2High Frequency Protection...................................................................................................A-2Weld Cable Connections......................................................................................................A-2Electrode Connection ...........................................................................................................A-3Work Connection..................................................................................................................A-3Power Source Connection....................................................................................................A-3Engine Drive Power Source Connection ..............................................................................A-3Connection Diagram.............................................................................................................A-3Guns and Cables..................................................................................................................A-4Electrode Polarity .................................................................................................................A-4Control Cable Connections ..................................................................................................A-4Procedure to Install Drive Rolls and Wire Guides ................................................................A-5Feeding Wire Electrode........................................................................................................A-5
________________________________________________________________________________Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1Graphic Symbols that appear on this Machine or in this Manual .........................................B-1General Description..............................................................................................................B-2Duty Cycle ............................................................................................................................B-2Recommended Processes ...................................................................................................B-2Process Limitations ..............................................................................................................B-2Equipment Limitations ..........................................................................................................B-2Operational Features and Controls .....................................................................................B-2Case Front Controls .............................................................................................................B-383% Procedure.....................................................................................................................B-3LN-15 POWER UP SEQUENCE ...........................................................................................B-4,B-5Internal Controls ...................................................................................................................B-5Spring Tension Arm..............................................................................................................B-5Wire Drive Configuration ......................................................................................................B-6Cold Feed/Gas Purge Switch ...............................................................................................B-62 Step-Trigger Interlock Switch ............................................................................................B-7Flow Meter............................................................................................................................B-7Spindle Brake .......................................................................................................................B-7Shielding Gas Connection....................................................................................................B-7Constant Current Operation .................................................................................................B-8Setting Arc Sensing wire Feed Speed For Constant Current Operation ..............................B-9Making a Weld....................................................................................................................B-10
Accessories ....................................................................................................................Section CFactory Installed Equipment.................................................................................................C-1Optional Equipment..............................................................................................................C-1Electrode, K-Kit used ...........................................................................................................C-1
________________________________________________________________________________Maintenance....................................................................................................................Section D
________________________________________________________________________________Troubleshooting .............................................................................................................Section E
Safety Precautions ...............................................................................................................E-1How to Use Troubleshooting Guide .....................................................................................E-1Troubleshooting Guide ...........................................................................................E-2 thru E-4
Wiring Diagram & Dimension Prints .............................................................................Section F________________________________________________________________________________
Parts Pages ............................................................................................................................P-544_______________________________________________________________________________
42 VAC/1/50/60 (5 Amps Maximum)CONTROL CABLE MODEL
ELECTRIC SHOCK CAN KILL.• ONLY QUALIFIED PERSONNEL
SHOULD PERFORM THISINSTALLATION.
• Turn off input power to the powersource at the disconnect switch or
fuse box before working on this equipment. Turnoff the input power to any other equipmentconnected to the welding system at thedisconnect switch or fuse box before working onthe equipment.• Do not touch electrically hot parts.• Do not touch metal portions of the LN-15 work
lead clip when the welding power source is on.• Do not connect the LN-15 to a non-Lincoln TIG
power source, a SQUARE WAVE TIG powersource, or a PLASMA CUTTING power source.
The LN-15 should be positioned upright on ahorizontal surface. Do not submerge the LN-15 inwater. The best practice is to keep the wire feeder ina dry environment. When working outdoors in severewet weather, place the LN-15 with the door facing up.
HIGH FREQUENCY PROTECTION
To prevent possible damage to theLN-15, do not connect the LN-15 tonon-Lincoln TIG or SQUARE WAVEpower sources. TIG high frequencyshould never be applied to the LN-15.
Locate the LN-15 away from radio controlled machin-ery. The normal operation of the LN-15 may adverselyaffect the operation of RF controlled equipment, whichmay result in bodily injury or damage to the equipmenttotal.
WELD CABLE CONNECTIONS
ELECTRIC SHOCK CAN KILL.• Only a qualified electrician shouldconnect the electrode leads to theLN-15. Connections should bemade in accordance with all localand national electrical codes.Failure to do so may result in bodilyinjury or death.
------------------------------------------------------------------------The size of the electrode cable and work cable mustbe sufficient for the maximum weld current and totalcable length used. To avoid interference problemswith other equipment and to achieve the best possibleoperation, route all cables directly to the work or wirefeeder. Avoid excessive lengths and do not coilexcess cable. Be sure the connection to the workmakes tight metal-to-metal electrical contact. (SeeTable A.1)
WARNING WARNING
Weld Current Total Cable Length 60% Duty (electrode cable + work cable)
ELECTRODE CONNECTIONRoute the electrode cable through the strain relief inthe rear of the case. Connect the electrode cable tothe LN-15 connection block using the mounting hard-ware provided. Secure the cable by tightening thestrain relief.
All domestic models are supplied with an optional pig-tail for customers that prefer to make a taped and bolt-ed connection externally. CE models have a maletwist connector for the electrode connection.
WORK CONNECTIONConnect a work lead of sufficient size between theproper output stud on the power source and the work.Be sure the connection to the work makes tight metalto metal electrical contact. Poor work lead connec-tions can result in poor welding performance.
POWER SOURCE CONNECTIONThe LN-15 can be used with any DC welding powersource. A constant voltage power source is recom-mend; however, the LN-15 can also be used with aconstant current power source as long as the opencircuit voltage is less than 110VDC.
To prevent possible damage to the LN-15, do notconnect the LN-15 to non-Lincoln TIG or squarewave power sources. TIG high frequency shouldnever be applied to the LN-15.------------------------------------------------------------------------------------------
ENGINE DRIVE POWER SOURCECONNECTION
The LN-15 sends a control signal to the engine driveand the electrode is not energized until the gun triggeris closed. When the gun trigger is closed the wire willbegin to feed and the welding process is started.
1. Shut the welder off.
2. For electrode Positive polarity welding, connect theelectrode cable to the "+" terminal of the welderand work cable to the "-" terminal of the welder. ForElectrode Negative welding, connect the electrodecable to the "-" terminal of the welder and workcable to the "+" terminal of the welder.
3. Set the MODE switch on the engine drive to CV-WIRE.
4. Set the WELD TERMINALS switch to WELD TER-MINALS OFF.
5. Set the WIRE FEEDER VOLTMETER switch toeither "+" or "-" as required by the electrode polaritybeing used.
6. Set the ARC CONTROL knob to "0" initially andadjust to suit.
7. Set the IDLE switch to the AUTO posit ion.Important: Some older engine drives may the IDLEswitch to be in the HIGH position for proper LN-15operation.
CAUTION
GUNS AND CABLES ASSEMBLIESA variety of Lincoln 10' (3.0m) or 15' (4.6m) gun andcable assemblies are available for use with the LN-15,including the Magnum™ models for GMAW, K126 orK115 models for Innershield®, and more.
The LN-15 comes factory equipped with a K1500-2gun connection kit, designed for guns having aMagnum Tweco™ compatible #2-#4 connector. Manyother guns can easily be used with the LN-15 withother K1500 series gun connection kits.
Gun Cable Connection to the FeederLay the cable out straight. Insert the connector on thewelding conductor cable into the brass bushing on thefront of the wire drive unit. Keep the all mating sur-faces clean. Make sure it is fully seated and tightenthe thumb screw.
Connect the control cable plug into the 5 pin recepta-cle on the front panel of the wire feeder.
ELECTRODE POLARITYThe LN-15 automatically adjusts for positive and neg-ative polarity. When welding with negative polarityprocedures, the voltmeter will display a "-" sign; exam-ple "-23.6" Volts.
A-4INSTALLATION
LN-15 CONTROL CABLE MODEL (CE)
A-4
CONNECTION DIAGRAM, CONTROLCABLE MODELS ( See Figure A.1)
CONTROL CABLE CONNECTIONSFor Control Cable model, attach the control cable fromthe LN-15 to power source. Do not use more than 150ft (45 m) of cable.Table A.2 Trigger Connector J1 (5 Pin)PIN Lead # FunctionA 556 TriggerB - Not usedC 554 Trigger/ 83%
Procedure groundD 555 83% Procedure E 554 Trigger/ 83%
Procedure ground
Table A.3 Control Cable Receptacle (8 Pin PIN Lead # FunctionA 41 42 VACB 42 42 VACC 2 Output Control (trigger)D 4 Output Control (trigger)E 21 Work Sense LeadF 75 Remote Voltage ControlG 76 Remote Voltage ControlH 77 Remote Voltage Control
-3
-3
-3
FIGURE A.1
FEEDING WIRE ELECTRODE
• ELECTRIC SHOCK CAN KILL.• When feeding electrode with the
gun trigger, the electrode and wiredrive mechanism are always "hot"to work and ground and couldremain "hot" several seconds afterthe gun trigger is released.
1. Turn the reel or spool until the free end of the elec-trode is accessible.
2. While tightly holding the electrode, cut off the bentend and straighten the first 6" (15 cm). Cut off thefirst 1" (2.5 cm). If the electrode is not properlystraightened, it may not feed or may jam.
3. Insert the free end through the incoming guidebushing.
4. Press the Cold Feed switch and push the electrodeinto the drive roll.
5. Feed the electrode through the gun.
6. Adjust the brake tension with the thumbscrew onthe spindle hub, until the reel turns freely but withlittle or no overrun when the wire feeding stops. Donot overtighten.
WARNING
A-5INSTALLATION
LN-15 CONTROL CABLE MODEL (CE)
A-5
PROCEDURE TO INSTALL DRIVE ROLLSAND WIRE GUIDES
• ELECTRIC SHOCK CAN KILL.
• Turn off input power at the weldingpower source before installation orchanging drive roll and/or wireguides.
• Do not touch electrically live parts such as thewire drive or internal wiring.
• When feeding with the gun trigger, the electrodeand wire drive mechanism are "hot" to work andground and could remain energized several sec-onds after the gun trigger is released.
• Only qualified personnel should perform thisoperation.
------------------------------------------------------------------------1. Turn OFF the welding power source.
2. Open the LN-15 case and then release the idle rollpressure arm.
3. Remove the outer wire guide by turning the knurledthumbscrews counter-clockwise to unscrew themfrom the feed plate.
4. Rotate the triangular shaped drive roll retainingmechanism to unlock the drive rolls and remove thedrive rolls.
5. Remove the inner wire guide.
6. Insert the new inner wire guide, groove side out,over the two locating pins in the feed plate.
7. Install a drive roll on each hub assembly and lockby rotating the triangular drive roll retaining mecha-nism.
8. Install the outer wire guide by aligning it with thepins and tightening the knurled thumbscrews.
9. Close the idle arm and engage the idle roll pressurearm. Adjust the pressure appropriately.
WARNING
COLD FEED/GAS PURGE SWITCH
B-1OPERATION
LN-15 CONTROL CABLE MODEL (CE)
B-1
• ELECTRIC SHOCK CAN KILL.Unless using COLD FEED fea-ture, when feeding with gun trig-ger, the electrode and drivemechanism are always electri-cally energized and couldremain energized several sec-onds after the welding ceases..
• Do not attach the work clip to the roll cage orbottom skids. The work clip is energized anytime the output of the welding power source is“ON”, even when the feeder is not welding.
• Do not touch electrically live part or electrodewith skin or wet clothing.
• Insulate yourself from work and ground.• Always wear dry insulating gloves.• The serviceability of a product or structure uti-
lizing the LN-15 wire feeder is and must be thesole responsibility of the builder/user. Manyvariables beyond the control of The LincolnElectric Company affect the results obtained inusing the LN-15 wire feeder. These variablesinclude, but are not limited to, welding proce-dure, plate chemistry and temperature, weld-ment design, fabrication methods and servicerequirements. The available range of the LN-15wire feeder may not be suitable for all applica-tions, and the builder/user is and must be sole-ly responsible for welding settings.
---------------------------------------------------------------------• FUMES AND GASSES can be
dangerous.• Keep your head out of fumes.• Use ventilation or exhaust at the
arc, or both, to remove fumesand gases from breathing zoneand general area.
---------------------------------------------------------------------• WELDING SPARKS can cause
fire or explosion.• Keep flammable material away.
----------------------------------------------------------------------ARC RAYS can burn.• Wear eye, ear and body protec-
tion.
---------------------------------------------------------------------SEE ADDITIONAL WARNING INFORMATIONUNDER ARC WELDING SAFETY PRECAUTIONSAND IN THE FRONT OF THIS OPERATING MAN-UAL.----------------------------------------------------------------------
WARNING
SAFETY PRECAUTIONSREAD AND UNDERSTAND ENTIRE SECTIONBEFORE OPERATING MACHINE.
INPUT POWER
ON
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
INPUT POWER
DIRECT CURRENT
OPEN CIRCUIT VOLTAGE
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVEGROUND
WARNING ORCAUTION
U0
U1
U2
I1
I2
GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL
B-2OPERATIONB-2
GENERAL DESCRIPTIONThe LN-15 is a light weight, portable, durable semi-automatic wire feeder.
The LN-15 accommodates spools 8" (200mm) diame-ter up to 4" (100mm) wide.
The domestic feeders comes factory equipped with aK1500-2 Magnum Tweco-compatible style #2-#4 gunbushing. Other K1500 series gun bushings are avail-able as field installed options. European models arefactory equipped with a Fast-Mate adapter.
The wire drive is capable of operating in either a "CV"or "CC" mode. A constant voltage (CV) power sourceis recommended for flux-cored arc welding (FCAW)and gas metal arc welding (GMAW) to obtain codequality results. However, the LN-15 may also be usedwith a constant current (CC) power source to obtainpassable results for non-critical quality applications.
The “dual procedure” mode drops the WFS to 83% ofthe original set point. The voltage setting remains thesame.
• Burn-back is adjustable from 0.0 to 0.25 seconds,with a default of 0.00 seconds.
• The preflow time is adjustable from 0.00 to 25.0 sec-onds, with a default of 0.00 seconds.
• The postflow time is adjustable from 0.0 to 25.0 sec-onds, with a default setting of 0.0 seconds.
The Control Cable Model features remote voltagecontrol with a potentiometer on the front of the feeder.The operation of the voltage control is similar to otherfeeders having "remote control" kits, such as the LN-25. While welding, the voltage may be adjusted asdesired. The voltage setting is not a "preset" value.
Electrode output is energized in response to the guntrigger by signals sent to the power source via thecontrol cable.
LN-15 CONTROL CABLE MODEL (CE)
DUTY CYCLEThe LN-15 wire feeders are intended for semi-auto-matic use. The maximum rating of the LN-15 is basedupon a 60% duty cycle; 6 minutes of welding followedby 4 minutes of idling within a 10 minute period.
RECOMMENDED PROCESSESThe LN-15 wire drive feeds electrode for variousprocesses as defined below in Table B.1.
The Control Cable Model is suitable for GMAW,GMAW-Pulse, GMAW-STT and FCAW semi-auto-matic applications within the rated duty cycle.
PROCESS LIMITATIONS
• The control cable model is not recommended forSAW, SMAW, GTAW or CAG.
• The control cable model works only with powersources having remote control output.
EQUIPMENT LIMITATIONS
Codes 11033 and higher• The LN-15 cannot be used with the K1500-4 gun
adapter bushing.
OPERATIONAL FEATURES ANDCONTROLS
• Remote voltage control at the LN-15.• Built in flow meter for adjusting shielding gas.• Cold Feed/Gas Purge switch.• 2 step / Trigger Interlock switch (codes 11033 and
above only)• Digital wire feed speed control.• Digital display of welding voltage.• Adjustable preflow and postflow times• Adjustable burnback times.• ON / OFF switch (codes 11033 and above only)
CASE FRONT CONTROLS (See Figure B.1)ACROSS THE ARC MODEL
1. WIRE FEED SPEED DISPLAY-The Wire Feed Speeddisplay shows the rate the LN-15 will feed electrode dur-ing welding. The default WFS units for domestic modelsare inches/minute and can be changed to meters/minutethrough the configuration menu. The default WFS unitsfor the European models are m/min. The wire feedspeed is calibrated to within ±2%.
2. VOLTAGE DISPLAY-The voltage display shows theaverage arc voltage during the welding. A minus sign "-"appears when welding with electrode negative weldingprocedures. While welding, an LED will illuminate belowthe voltage display. After welding, the average voltagewill continue to be shown for 5 seconds after the end andthe LED will flash. of the weld. When not welding, thedisplay shows "- - - ". The voltage is calibrated to ±2%over a range of 10 to 45 volts.
The voltage display is not a "preset" voltage.Refer to the examples from Figure B.1a.
3. WIRE FEED SPEED KNOB-The Wire Feed Speedknob is a 3-3/4 turn potentiometer that adjusts of the rateof feeding electrode. The wire feed speed range is 50 -700 inches/min (1.3 - 17.8 m/min)
4. VOLTAGE KNOB-The voltage knob is present only oncontrol cable models.
Adjusting the voltage knob varies the power source volt-age to the LN-15. The value displayed is not a "preset"voltage. Only actual average arc voltage is shown on thevoltage display.
For codes 10864, 10865:The voltage knob controls the output of the power sourcethrough a 3-3/4 turn, 10K ohm potentiometer.
For codes 11033 and above:The voltage knob controls the output of the power sourcethrough a _ turn, 10K ohm potentiometer.
5. TRIGGER CONNECTOR-5 Pin Receptacle is used toactivate the Magnum Gun Switch.
6. CONNECTOR BUSHING-This connection is for weld-ing conductor cable assembly.
7. ON / OFF SWITCH-For codes 11033 and above:The ON / OFF Switch turns power on and off to the wirefeeder.
83% PROCEDUREThe LN-15 supports a special "dual procedure" mode.When activated, the wire feed speed is reduced to83% of the set value, but no less than 50 inch-es/minute (1.27 m/min). The 83% procedure is mostcommonly used during pipe and out of position weld-ing. Requires Magnum 400 Dual Procedure GunEquivalent.
FIGURE B.1
FIGURE B.1a
1
7
3
5
6
4
2
B-4OPERATION
LN-15 CONTROL CABLE MODEL (CE)
B-4
LN-15 POWER-UP SEQUENCE
Normal Power-Up DisplayWhen power is first applied to the LN-15, the displaywill momentarily show set-up information. For exam-ple, it may show "CV" and "HI", indicating operationfrom a CV power source and the wire drive is config-ured for the high speed gear. Because of limitations inthe display, "CV" will appear as "Cu".
After a brief moment, the LN-15 will then display theWFS and "---". No voltage is displayed until the triggeris pressed.
Preflow, Postflow and Burnback TimesPreflow, Postflow and Burnback times are alladjustable on the LN-15. The LN-15 is factory set withall the times set to 0.0 seconds.• The burnback time is adjustable from 0.00 to 0.25
seconds.• The preflow time is adjustable from 0.0 to 25.0 sec-
onds.• The postflow time is adjustable from 0.0 to 25.0 sec-
onds.
Changing Preflow, Postflow or Burnback times:
1. Enter the “Press Spin” Set-Up Mode:While the power to the LN-15 is off, activate andhold the GAS PURGE switch (Down Position). Turnon power to the LN-15, and continue to hold theGAS PURGE switch until the LN-15 displays "Pressspin". Release the GAS PURGE switch.
The LN-15 is now in the "Press Spin" set-up mode. Ifafter 15 seconds no other action is taken, the LN-15will then revert to normal operation.
2. Rotate the WFS knob until the desired timer is dis-played.
Preflow:
Postflow:
Burnback:
3. Activate and then release the GAS PURGE switchto select the timer. The time will then display in theright hand side of the display. Example:
4. Rotate the WFS knob to adjust the time to the newsetting.
5. Press the GAS PURGE switch again to save thesetting. The LN-15 will then return to the original"Press Spin" mode in step 1.
6. To exit the "Press Spin" set-up mode, turn off powerto the LN-15, or simply wait 15 seconds and theLN-15 will enter normal operation.
Welding Mode CV/CC mode and WFS unitsThe CV/CC mode and WFS units are all readilychanged during the power-up sequence. The LN-15 isfactory set for "CV" welding power sources and "inch-es per minute" for the wire feed speed units.• The CV/CC mode is selectable for either CV for
Constant Voltage power sources and CC forConstant Current power sources. Use CV powersources when making critical welds.
• The WFS units is selectable for either in/min andm/min.
Changing the CV/CC mode, or WFS units:
1. Enter the “Press Spin” Set-Up Mode:While the power to the LN-15 is off, activate andhold the GAS PURGE switch (Down Position). Turnon power to the LN-15, and continue to hold theGAS PURGE switch until the LN-15 displays "Pressspin". Release the GAS PURGE switch.
The LN-15 is now in the "Press Spin" set-up mode.If after 15 seconds no other action is taken, the LN-15 will then revert to normal operation.
COLDFEED
GAS PURGE
COLDFEED
GAS PURGE
WFS
B-5OPERATION
LN-15 CONTROL CABLE MODEL (CE)
B-5
Rotate the WFS knob until the desired parameter isdisplayed.
CV/CC Mode:
WFS Units:
2. Activate and release the GAS PURGE switch toselect the parameter. The present value will thendisplay in the right hand side of the display.Example:
3. Rotate the WFS knob to change the parameter set-ting.
CV/CC Mode:• "CU" for Constant Voltage power sources• "CC" for Constant Current power sources
WFS Units:• "US" for in/min• "Eur" for m/min
4. Press the GAS PURGE switch to save the setting.The LN-15 will then return to the original "PressSpin" mode in step 1.
5. To exit the "Press Spin" set-up mode, turn off powerto the LN-15, or simply wait 15 seconds and theLN-15 will enter normal operation.
WFS
SPRING TENSION ARM
The pressure arm controls the amount of force the driverolls exert on the wire. Proper adjustment of both pres-sure arm gives the best welding performance. For bestresults, set both pressure arms to the same value.
Set the pressure arm as follows (See Figure B.2a):Aluminum wires between 1 and 3Cored wires between 3 and 4Steel, Stainless wires between 4 and 6
Figure B.2a
FLOWMETER
SPRING
TENSION
ARM
COLD FEED/
GAS PURGE
SWITCH
2 STEP/TRIGGER
INTERLOCK
SWITCH
SPINDLE
BRAKE
INTERNAL CONTROLS (Figure B.2)
ALUMINUMOUTERSHIELDMETALSHIELDINNERSHIELD STEEL
STAINLESS
CORED WIRES SOLID WIRES
6
13
2
54
B-6OPERATIONB-6
LN-15 CONTROL CABLE MODEL (CE)
6. Remove the outer wire guide, and push the gunbushing out of the wire drive. Because of the pre-cision fit, light tapping may be required to removethe gun bushing.
7. Disconnect the shielding gas hose from the gunbushing, if required.
8. Connect the shielding gas hose to the new gunbushing, if required.
9. Rotate the gun bushing until the thumb screw holealigns with the thumb screw hole in the feed plate.Slide the gun receiver bushing into the wire driveand verify the thumb screw holes are aligned.
10. Tighten the socket head cap screw.11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
COLD FEED/GAS PURGE SWITCH
Cold Feed and Gas Purge are combined into a singlespring centered toggle switch.
To activate Cold Feeding, hold the switchin the UP position. The wire drive will feedelectrode but neither the power sourcenor the gas solenoid will be energized.Adjust the speed of cold feeding by rotat-ing the WFS knob. Cold feeding, or "coldinching" the electrode is useful for thread-ing the electrode through the gun.
WIRE DRIVE CONFIGURATION(See Figure B.2b)Changing the Gun Receiver Bushing
ELECTRIC SHOCK can kill.• Turn the input power OFF at the
welding power source beforeinstallation or changing drive rollsand/or guides.
• Do not touch electrically live parts.• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and groundand could remain energized several secondsafter the gun trigger is released.
• Only qualified personnel should perform mainte-nance work.
Note: Some gun bushings do not require the use ofthe thumb screw.
1. Turn power off at the welding power source.2. Remove the welding wire from the wire drive.3. Remove the thumb screw from the wire drive.4. Remove the welding gun from the wire drive.5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.Important: Do not attempt to completely removethe socket head cap screw.
SPINDLE BRAKEAdjust the spindle brake tension to allow the spool tospin freely, yet have enough resistance for little or nooverrun when wire feeding is stopped.
SHIELDING GAS CONNECTION
CYLINDER may explode ifdamaged.
• Keep cylinder upright andchained to support.
• Keep cylinder away from areas where it may bedamaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other liveelectrical circuits.
• BUILD UP OF SHIELDING GAS MAY HARMHEALTH 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 theAmerican Welding Society.
------------------------------------------------------------------------Customer must provide a cylinder of shielding gas, apressure regulator, a flow control valve and a hosefrom the flow valve to the gas inlet fitting of the LN-15.
Connect a supply hose from the gas cylinder flowvalve outlet to the 5/8-18 female inert gas fitting on theback of the LN-15.
WARNING
WARNING
Hold with toggle switch in the DOWN position to acti-vate Gas Purge and let the shielding gas flow. Thegas solenoid valve will energize but neither the powersource output nor the drive motor will be turned on.The Gas Purge switch is useful for setting the properflow rate of shielding gas. Flow meters should alwaysbe adjusted while the shielding gas is flowing.
2 STEP - TRIGGER INTERLOCK SWITCH
The 2 Step - Trigger Interlock switchchanges the function of the gun trigger.2 Step trigger operation turns welding onand off in direct response to the trigger.Trigger Interlock operation allows weld-ing to continue when the trigger isreleased for comfort on long welds.
Place the toggle switch in the UP posi-tion for 2 Step operation or in the DOWNposition for Trigger Interlock operation.
2 Step Trigger2 Step trigger operation is the most common. Whenthe gun trigger is pulled, the welding power sourceenergizes the electrode output and the wire feederfeeds wire for welding. The power source and wirefeeder continue welding until the trigger is released.
Trigger InterlockTrigger Interlock operation provides for operator com-fort when making long welds. When the gun trigger isfirst pulled, the welding power source energizes theoutput and the wire feeder feeds wire for welding.The gun trigger is then released while the weld ismade. To stop welding, the gun trigger is pulled again,and when it is released the welding power source out-put turns off and the wire feeder stops feeding wire.
If the arc goes out while welding with trigger inter-lock operation, the electrode output from thewelding power source remains energized and thewire feeder will continue to feed wire until the guntrigger is again pulled and then released.------------------------------------------------------------------------FLOW METER The flowmeter shows the flow rate of shielding gasand has a valve to adjust the flow. The flow meter iscalibrated for CO2, Ar, and CO2/Ar blends. The mid-dle of the ball indicates the flow rate of shielding gas.
Adjust the flow rate by turning the valve at the bottomof the meter. Most weld procedures require 25-40 scfh(11.8 - 18.9 lpm) for sufficient shielding gas coverage.Gun angle, nozzle diameter, joint configuration andwind conditions may effect the amount of shieldinggas required.
CAUTION
B-8OPERATIONB-8
LN-15 CONTROL CABLE MODEL (CE)
CONSTANT CURRENT OPERATION( See Figure B.3)
Lincoln Electric does NOT recommend constantcurrent semiautomatic welding for applicationswhich need to meet specified weld metal chemicalor mechanical property requirements or weldquality requirements.------------------------------------------------------------------------
Most semiautomatic welding processes perform betterusing constant voltage power sources.
Welding codes usually do not address the power sourceselection or specifically, whether the welding process isto be operated in the constant voltage or constant currentmode. Instead, codes typically specify limitations on thecurrent, voltage, heat input and preheat temperaturebased on the material to be welded. The intention is toassure that proper weld material properties will develop.
Welding is sometimes performed using constant currentpower sources. The operation can be more convenientbecause it may allow the use of an existing stick (SMAW)power source and the power source can be placed at adistant location without any provision for adjusting theoutput settings.
For constant current operation, the power source is set todeliver the specified current. The power source regulatesthis current regardless of changes in the welding circuit,including cable length, electrode diameter, wire feedspeed, contact tip to work distance, etc.
Changes in the wire feed speed (WFS) or contact tipto work distance (CTWD) affect the arc voltage whenconstant current power sources are used. Loweringthe wire feed speed raises the voltage, raising thewire feed speed lowers the voltage. Lengthening thecontact tip to work distance raises the voltage, short-ening the contact tip to work distance lowers the volt-age.
If the contact tip to work distance is properly main-tained, a satisfactory operating voltage range may beachieved, and a sound weld may result. However,when a welder uses a longer contact tip to work dis-tance, an arc-sensing wire feeder compensates byincreasing the wire feed speed to regulate the voltage.Even if the voltage and current remain unchanged, theincreased wire feed speed may result in a depositionrate well beyond the specified range of the electrode.Under these conditions, the specified weld metal prop-erties may not be achieved.
Constant voltage power sources deliver large currentsurges to stabilize the arc when the electrode is short-ed or the arc length is very short. However, a constantcurrent power source does not provide such aresponse to stabilize the arc. It may be difficult toachieve required weld metal properties, or to achievethe required quality of welds needed to pass nonde-structive tests, when such welds are made under con-stant current operation.
Constant CurrentPower Source
Current
Current
Wire Feeder
WFSCTWD
Welding Cable(Electrode)
Welding Cable
LN-15GUN AND CABLE ASSEMBLY+
-
FIGURE B.3
CAUTION
B-9OPERATIONB-9
SETTING ARC SENSING WIRE FEED SPEEDFOR CONSTANT CURRENT OPERATION
When using a constant current (formerly variable voltage)power source, welding performance is im proved using arcsensing wire feed speed (CC operation). In this wire feedmode the wire speed increases if arc voltage increases,and decreases if arc voltage de creases, but remains con-stant at any specific voltage level.
The LN-15 permits accurate presetting of the desiredwire feed speed, for the desired arc voltage to be used,by setting the Wire Feed Speed in the fol lowing mannerbefore welding:
a. Activate press and spin during power up and changeto the CC mode. See “Changing the CV/CC modeor WFS units” in this Operation Section.
FIGURE B.4 CC WIRE SPEED SETTING
b. Referring to the graph located above the Mode switch(also shown in Figure B.4):
1. Select the horizontal line representing the DE -SIRED IN/MIN. for the welding procedure. (Seeexample arrow line for 375 in/min.)
2. Select the diagonal line representing the ARCVOLTS to be used for the welding procedure. (Seeexample arrow line for 29 volts.)
3. Determine the vertical line representing the CCWIRE SPEED SETTING where the above two linescross. (See example arrow line for 450.)
c. Adjust the WFS display to the value determined inStep (3) above (450 for example used).
The wire will feed at the DESIRED IN/MIN speed when the weldingpower source is set to the arc voltage to be used for the weldprocedure (375 in/min. at 29V for example used).
The CC wire speed setting graph is shown in TABLE B.1, givingthe Wire Speed dial setting required for the DESIRED IN/MINand ARC VOLTS used for the welding procedures:
The serviceability of a product or structure utilizing theLN-15 wire feeder is and must be the sole responsibil-ity of the builder/user. Many variables beyond the con-trol of The Lincoln Electric Company affect the resultsobtained in using the LN-15 wire feeder. These vari-ables include, but are not limited to, welding proce-dure, plate chemistry and temperature, weldmentdesign, fabrication methods and service requirements.The available range of the LN-15 wire feeder may notbe suitable for all applications, and the builder/user isand must be solely responsible for welding settings.
• Close the door on the LN-15.
• Connect the work cable to the metal to be welded.The work cable must make good electrical contact tothe work. The work must also be grounded as statedin "Arc Welding Safety Precautions".
• Connect the LN-15 electrode cable to the powersource for the polarity and process to be used.Check that the appropriate power source settingsare made for the procedure to be used. (Refer to thepower source operating and connection instructions.)
• Place the LN-15 conveniently near the work area ina safe location to minimize exposure to weld spatterand to avoid sharp bends in the gun cable.
• Connect the LN-15 work clip to the work.
• Be sure the proper contact tip for the wire size beingused is in the gun.
• Turn on the welding power source, as well as theshielding gas supply (if used.)
• Cut the electrode within approximately 3/8" (10mm)of the end of the contact tip for solid wire and within3/4" (19mm) of the extension guide for cored wire.
• Position the electrode over the joint. The end of theelectrode should be slightly off the work.
• Lower welding helmet, close the gun trigger andbegin welding. Hold the gun so the contact tip towork distance gives the correct electrical stickout asrequired for the procedure being used.
• To stop welding, release the gun trigger and the pullthe gun away from the work.
• Drive Roll Kits (Include drive rolls and guide tube necessary to feed the identified wiresize and type.
D-1MAINTENANCED-1
LN-15 CONTROL CABLE MODEL (CE)
ELECTRIC SHOCK can kill.• Do not operate with covers
removed.• Turn off power source before
installing or servicing.• Do not touch electrically hot
parts.
• Turn the input power to the welding powersource off at the fuse box before working in theterminal strip.
• Only qualified personnel should install, use orservice this equipment.
WARNING
SAFETY PRECAUTIONS
ROUTINE MAINTENANCERoutine maintenance consists of periodically blowingout the machine, using a low pressure airstream, toremove accumulated dust and dirt from inside thefeeder.
PERIODIC MAINTENANCE• Replace the drive rolls and inner wire guide when
they are worn.
• Replace the pig tail if the insulation is cut, abradedor damaged.
CALIBRATION SPECIFICATIONAll calibration is factory set on the LN-15.
To verify the wire feed speed:• Assemble a .045 (1.2mm) drive roll kit into the LN-
15.• Load a spool of .045 (1.2mm) electrode and thread
the electrode through the wire drive.• Adjust the wire feed speed to 300 in/min
(7.62m/min).• Press the COLD INCH switch and measure the
actual wire feed speed with a calibrated wire feedspeed tachometer.
• The measured wire feed speed should be within 2%of the set value.
To verify the voltage display:• Set the welding power source and LN-15 to a CV
procedure that gives steady "spray" transfer in thearc.
• While a weld is being made, measure the voltagefrom the feedplate to work.
• The displayed voltage on the LN-15 should be with-in 2% of the measured value.
E-1TROUBLESHOOTINGE-1
LN-15 CONTROL CABLE MODEL (CE)
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Major physical or electrical damageis evident when the sheet metal cov-ers are removed.
The wire drive turns off periodicallywhile operating on an engine drive.
No shielding gas flow.
The shielding gas turns on sporadi-cally, or remains on all the time.
The wire drive stops feeding wireafter about 10 seconds.
The wire feed speed varies duringwelding but the meter readingremains constant
The Wire Feed Speed Range is only50 - 601 in/min ( 1.3 - 15.3 m/min).
1. Contact your local authorizedLincoln Electric Field Service facil-ity for technical assistance.
1. The supply voltage for the LN-15is too low.
1. The gas bottle empty.2. The gas hose is cut or clogged.3. The flow meter valve is closed.4. The gas solenoid has failed5. The feed head board has failed.
1. The pressure in the gas line isexceeding 80 psi (5.5 bar)
2. The gas solenoid has failed.
1. The motor has exceeded the cur-rent rating.
2. Check to make sure the electrodeslides easily through the liner ofthe gun.
3. Verify that the spindle brake is notset too tight.
4. For best results, use only Lincolnelectrodes.
5. Wait 10 minutes for the wire feed-er to cool.
1. The drive rolls are sl ippingbecause of feeding problems.
2. The LN-15 is in CC mode insteadof CV mode.
3. Reduce the spindle brake resis-tance.
4. Increase the amount of tension inthe wire drive pressure arm.
5. For best results, use only Lincolnelectrodes.
6. Verify on power-up that the LN-15is set for CV welding.
1. The 83% wire feed speed dualprocedure is activated with thehigh speed gear. Check dual proce-dure switch in gun.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
OUTPUT PROBLEMS
FEEDING PROBLEM
E-3TROUBLESHOOTINGE-3
LN-15 CONTROL CABLE MODEL (CE)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
The Wire Feed Speed Range is only50 - 374 in/min ( 1.3 - 9.5 m/min)
"POS", "PRE" or "BRN" show on thedisplay.
The voltage display reads "0.0" voltsduring welding
Porosity in the weld.Variable or "hunting" arc.
Variable or "hunting" arc.
The arc burns back to the tip.
1. The 83% wire feed speed dualprocedure is activated with the lowspeed gear. Check dual procedureswitch in gun.
1. The LN-15 is in the Press andSpin set-up mode.
2. One of the DIP switches on thefeed head board is set to "ON" fortimer setting mode.
3. Cycle power to the LN-15 or wait45 seconds.
4. The LN-15 is an old ALPHA unitand a DIP switch is in the wrongposition.
1. The power source meter polarityswitch is in the wrong position.
2. Set the power source meter polar-ity switch to match the weldingprocess.
1. The part being welded is wet, dirtyor rusty.
2. The electrode being used is wet,dirty or rusty.
3. There is insufficient shielding gasflow from possible cuts in the gashose
4. There is moisture or water in theshielding gas line.
5. There is too much shielding gas6. There is too much wind or drafts.7. The arc voltage is set too high.8. The wrong shielding gas is being
used.1. Worn and/or melted contact tip.2. Worn work cable or poor work
connection.3. Loose electrode connection.4. Wrong electrode polarity for the
process being used.
1. The spool of electrode is tangled.2. The electrode and work leads are reversed
(welding with the wrong polarity.)3. The liner is clogged.4. The contact tip is worn.5. The wire drive tension is improp-
erly set.
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
WELDING PROBLEMS
DISPLAY PROBLEMS
E-4TROUBLESHOOTINGE-4
LN-15 CONTROL CABLE MODEL (CE)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
ERRORS ON THE DISPLAY
Fault Code Description Possible AdjustmentsErr 0081 Average motor over current shutdown • The wire drive motor has overheated.
• Check to make sure the electrodeslides easily through the liner of thegun.
• Reduce the amount of tension in thewire drive tension arm.
• Verify that the spindle brake is not settoo tight.
• For best results, use only Lincoln elec-trodes.
• Wait 10 minutes for the wire feeder tocool.
Err 0086 Trigger lockout. • The ripple of the power source OCV istoo high, greater than 110V. (Acrossthe Arc Models only)
• Verify the power source is reconnect-ed for the proper input voltage.
• Repair or replace the power source.The power source does not conform toNEMA
F-1DIAGRAMSF-1
LN-15 CONTROL CABLE MODEL (CE)
NO
TE
: T
his
dia
gra
m is
fo
r re
fere
nce
onl
y.
It m
ay n
ot
be
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y th
is m
anua
l. T
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pec
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or
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artic
ular
co
de
is p
aste
d in
sid
eth
e m
achi
ne o
n o
ne o
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e en
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sure
pan
els.
If
the
dia
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m is
ille
gib
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rite
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Ser
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Dep
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ent
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Giv
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t co
de
num
ber
.
F-2DIMENSION PRINTF-2
LN-15 CONTROL CABLE MODEL (CE)
NOTES
LN-15 CONTROL CABLE MODEL (CE)
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Do not touch electrically live parts orelectrode with skin or wet clothing.
● Insulate yourself from work andground.
● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
● Isolieren Sie sich von denElektroden und dem Erdboden!
● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
● Isole-se da peça e terra.
● Keep flammable materials away.
● Mantenga el material combustiblefuera del área de trabajo.
● Gardez à l’écart de tout matérielinflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-dos.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y elcuerpo.
● Protégez vos yeux, vos oreilles etvotre corps.
● Tragen Sie Augen-, Ohren- und Kör-perschutz!
● Use proteção para a vista, ouvido ecorpo.
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
● Keep your head out of fumes.● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona de res-piración.
● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
● Vermeiden Sie das Einatmen vonSchweibrauch!
● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Turn power off before servicing.
● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-tien.
● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
● Não opere com as tampas removidas.● Desligue a corrente antes de fazer
serviço.● Não toque as partes elétricas nuas.
● Do not operate with panel open orguards off.
● No operar con panel abierto oguardas quitadas.
● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
● Mantenha-se afastado das partesmoventes.
● Não opere com os paineis abertosou guardas removidas.
• Sales and Service through Subsidiaries and Distributors Worldwide •
