Lincoln Electric LN-15 User's Manual

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IM910
LN-15 WIRE FEEDER
February, 2009
For use with machines having Code Number: 11372
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.
N80
IEC 60974-5
EN 60974-5
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
• 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
i
i
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 ‘95
ii
ii
SAFETY
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.
ARC RAYS can burn.
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 within applicable OSHA PEL and
ACGIH TLV limits 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.
3.j. Also see Items 6.c. and 8.
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 manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09
iii
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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.
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.
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.
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 manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Jan ‘09
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du 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 approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles 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 tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du 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” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
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SAFETY
60974-10
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SAFETY
EN 60974-10:
vi
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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 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 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.
viii
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TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Location ................................................................................................................................A-2
High Frequency Protection ...................................................................................................A-2
Weld Cable Connections ......................................................................................................A-2
Electrode Connection ...........................................................................................................A-3
Work Connection ..................................................................................................................A-3
Power Source Connection....................................................................................................A-3
Engine Drive Power Source Connection ..............................................................................A-3
Connection Diagram.............................................................................................................A-3
Guns and Cables..................................................................................................................A-4
Electrode Polarity .................................................................................................................A-4
Control Cable Connections ..................................................................................................A-4
Procedure to Install Drive Rolls and Wire Guides ................................................................A-5
Feeding Wire Electrode ........................................................................................................A-5
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Graphic Symbols that appear on this Machine or in this Manual .........................................B-1
General Description..............................................................................................................B-2
Duty Cycle ............................................................................................................................B-2
Recommended Processes ...................................................................................................B-2
Process Limitations ..............................................................................................................B-2
Equipment Limitations ..........................................................................................................B-2
Operational Features and Controls .....................................................................................B-2
Case Front Controls .............................................................................................................B-3
83% Procedure.....................................................................................................................B-3
LN-15 POWER UP SEQUENCE ...........................................................................................B-4,B-5
Internal Controls ...................................................................................................................B-5
Spring Tension Arm..............................................................................................................B-5
Wire Drive Configuration ......................................................................................................B-6
Cold Feed/Gas Purge Switch ...............................................................................................B-6
2 Step-Trigger Interlock Switch ............................................................................................B-7
Flow Meter............................................................................................................................B-7
Spindle Brake .......................................................................................................................B-7
Shielding Gas Connection ....................................................................................................B-7
Constant Current Operation .................................................................................................B-8
Setting Arc Sensing wire Feed Speed For Constant Current Operation ..............................B-9
Making a Weld....................................................................................................................B-10
________________________________________________________________________________
Accessories ....................................................................................................................Section C
Factory Installed Equipment.................................................................................................C-1
Optional Equipment..............................................................................................................C-1
Electrode, K-Kit used ...........................................................................................................C-1
________________________________________________________________________________
Maintenance ....................................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Calibration Specification.......................................................................................................D-1
________________________________________________________________________________
Troubleshooting .............................................................................................................Section E
Safety Precautions ...............................................................................................................E-1
How to Use Troubleshooting Guide .....................................................................................E-1
Troubleshooting Guide ...........................................................................................E-2 thru E-4
________________________________________________________________________________
Wiring Diagram & Dimension Prints .............................................................................Section F
________________________________________________________________________________
Parts Pages ............................................................................................................................P-544
_______________________________________________________________________________
A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – LN-15 (K1871-3 CE)
INPUT VOLTAGE
42 VAC/1/50/60 (5 Amps Maximum)
CONTROL CABLE MODEL
RATED CURRENT
500 Amps 60% Duty Cycle
350 Amps 100% Duty Cycle
ELECTRODE DIAMETERS and SPEED RANGE
Electrode Size Speed Range
Solid Electrode 0.023 - 0.052" 50 - 700 in/min
(0.6 - 1.3 mm) (1.3 - 17.8 m/min)
Steel
Flux Cored
Electrode
0.035 - 5/64" 50 - 400 in/min
(0.9 - 2.3 mm) (1.3 - 10.1 m/min)
PHYSICAL DIMENSIONS
HEIGHT
12.7 Inches
(323 mm)
WIDTH
DEPTH
WEIGHT
8.7 Inches
(221mm)
23 Inches
(584 mm)
28lbs
(13kg)
TEMPERATURE RANGE
OPERATION:
- 20° C to +50° C (- 4° F to +122° F)
STORAGE:
- 40° C to +70° C (- 40° F to +158° F)
LN-15 CONTROL CABLE MODEL (CE)
SPOOL SIZE CAPABILITY
8 (200mm) Dia. x 4 (100mm)
Wide Spools including
AWS 8 DIA. (10-15lbs)
JIS S-3 200mm max. (5 - 7 kg)
DIN 200 (5 kg)
A-2
A-2
INSTALLATION
WELD CABLE CONNECTIONS
SAFETY PRECAUTIONS
WARNING
WARNING
ELECTRIC SHOCK CAN KILL.
• ONLY QUALIFIED PERSONNEL
SHOULD
PERFORM
THIS
INSTALLATION.
• Turn off input power to the power
source at the disconnect switch or
fuse box before working on this equipment. Turn
off the input power to any other equipment
connected to the welding system at the
disconnect switch or fuse box before working on
the 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 power
source, or a PLASMA CUTTING power source.
-------------------------------------------------------------------
ELECTRIC SHOCK CAN KILL.
• Only a qualified electrician should
connect the electrode leads to the
LN-15. Connections should be
made in accordance with all local
and national electrical codes.
Failure to do so may result in bodily
injury or death.
-----------------------------------------------------------------------The size of the electrode cable and work cable must
be sufficient for the maximum weld current and total
cable length used. To avoid interference problems
with other equipment and to achieve the best possible
operation, route all cables directly to the work or wire
feeder. Avoid excessive lengths and do not coil
excess cable. Be sure the connection to the work
makes tight metal-to-metal electrical contact. (See
Table A.1)
LOCATION
TABLE A.1
The LN-15 should be positioned upright on a
horizontal surface. Do not submerge the LN-15 in
water. The best practice is to keep the wire feeder in
a dry environment. When working outdoors in severe
wet weather, place the LN-15 with the door facing up.
Weld Current
60% Duty
Cycle
200 Amps
300 Amps
400 Amps
Total Cable Length
(electrode cable + work cable)
50 - 100' 100 - 150' 150 - 200' 200 - 250'
(15-30 m) (30 - 46m) (46 - 61m) (61m - 76m)
2 AWG
2 AWG
1 AWG
1/0
1 AWG
1 AWG
1/0
2/0
2/0
2/0
3/0
3/0
HIGH FREQUENCY PROTECTION
WARNING
To prevent possible damage to the
LN-15, do not connect the LN-15 to
non-Lincoln TIG or SQUARE WAVE
power sources. TIG high frequency
should never be applied to the LN15.
------------------------------------------------------------------------------------------
Locate the LN-15 away from radio controlled machinery. The normal operation of the LN-15 may adversely
affect the operation of RF controlled equipment, which
may result in bodily injury or damage to the equipment
total.
LN-15 CONTROL CABLE MODEL (CE)
A-3
INSTALLATION
ELECTRODE CONNECTION
Route the electrode cable through the strain relief in
the rear of the case. Connect the electrode cable to
the LN-15 connection block using the mounting hardware provided. Secure the cable by tightening the
strain relief.
All domestic models are supplied with an optional pigtail for customers that prefer to make a taped and bolted connection externally. CE models have a male
twist connector for the electrode connection.
WORK CONNECTION
A-3
4. Set the WELD TERMINALS switch to WELD TERMINALS OFF.
5. Set the WIRE FEEDER VOLTMETER switch to
either "+" or "-" as required by the electrode polarity
being used.
6. Set the ARC CONTROL knob to "0" initially and
adjust to suit.
7. Set the IDLE switch to the AUTO position.
Important: Some older engine drives may the IDLE
switch to be in the HIGH position for proper LN-15
operation.
Connect a work lead of sufficient size between the
proper output stud on the power source and the work.
Be sure the connection to the work makes tight metal
to metal electrical contact. Poor work lead connections can result in poor welding performance.
POWER SOURCE CONNECTION
The LN-15 can be used with any DC welding power
source. A constant voltage power source is recommend; however, the LN-15 can also be used with a
constant current power source as long as the open
circuit voltage is less than 110VDC.
CAUTION
To prevent possible damage to the LN-15, do not
connect the LN-15 to non-Lincoln TIG or square
wave power sources. TIG high frequency should
never be applied to the LN-15.
------------------------------------------------------------------------------------------
ENGINE DRIVE POWER SOURCE
CONNECTION
The LN-15 sends a control signal to the engine drive
and the electrode is not energized until the gun trigger
is closed. When the gun trigger is closed the wire will
begin to feed and the welding process is started.
1. Shut the welder off.
2. For electrode Positive polarity welding, connect the
electrode cable to the "+" terminal of the welder
and work cable to the "-" terminal of the welder. For
Electrode Negative welding, connect the electrode
cable to the "-" terminal of the welder and work
cable to the "+" terminal of the welder.
3. Set the MODE switch on the engine drive to CVWIRE.
LN-15 CONTROL CABLE MODEL (CE)
A-4
INSTALLATION
A-4
CONNECTION DIAGRAM, CONTROL
CABLE MODELS ( See Figure A.1)
FIGURE A.1
-3
-3
-3
GUNS AND CABLES ASSEMBLIES
CONTROL CABLE CONNECTIONS
A variety of Lincoln 10' (3.0m) or 15' (4.6m) gun and
cable assemblies are available for use with the LN-15,
including the Magnum™ models for GMAW, K126 or
K115 models for Innershield®, and more.
For Control Cable model, attach the control cable from
the LN-15 to power source. Do not use more than 150
ft (45 m) of cable.
Table A.2 Trigger Connector J1 (5 Pin)
PIN
Lead #
Function
A
556
Trigger
B
Not used
C
554
Trigger/ 83%
Procedure ground
D
555
83% Procedure
E
554
Trigger/ 83%
Procedure ground
The LN-15 comes factory equipped with a K1500-2
gun connection kit, designed for guns having a
Magnum Tweco™ compatible #2-#4 connector. Many
other guns can easily be used with the LN-15 with
other K1500 series gun connection kits.
Gun Cable Connection to the Feeder
Lay the cable out straight. Insert the connector on the
welding conductor cable into the brass bushing on the
front of the wire drive unit. Keep the all mating surfaces clean. Make sure it is fully seated and tighten
the thumb screw.
Connect the control cable plug into the 5 pin receptacle on the front panel of the wire feeder.
ELECTRODE POLARITY
Table A.3 Control Cable Receptacle (8 Pin
PIN
Lead #
Function
A
41
42 VAC
B
42
42 VAC
C
2
Output Control (trigger)
D
4
Output Control (trigger)
E
21
Work Sense Lead
F
75
Remote Voltage Control
G
76
Remote Voltage Control
H
77
Remote Voltage Control
The LN-15 automatically adjusts for positive and negative polarity. When welding with negative polarity
procedures, the voltmeter will display a "-" sign; example "-23.6" Volts.
LN-15 CONTROL CABLE MODEL (CE)
A-5
A-5
INSTALLATION
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
FEEDING WIRE ELECTRODE
WARNING
WARNING
• ELECTRIC SHOCK CAN KILL.
• Turn off input power at the welding
power source before installation or
changing drive roll and/or wire
guides.
• Do not touch electrically live parts such as the
wire drive or internal wiring.
• When feeding with the gun trigger, the electrode
and wire drive mechanism are "hot" to work and
ground and could remain energized several seconds after the gun trigger is released.
• Only qualified personnel should perform this
operation.
-----------------------------------------------------------------------1. Turn OFF the welding power source.
• ELECTRIC SHOCK CAN KILL.
• When feeding electrode with the
gun trigger, the electrode and wire
drive mechanism are always "hot"
to work and ground and could
remain "hot" several seconds after
the gun trigger is released.
----------------------------------------------------------------------COLD FEED/GAS PURGE SWITCH
2. Open the LN-15 case and then release the idle roll
pressure arm.
3. Remove the outer wire guide by turning the knurled
thumbscrews counter-clockwise to unscrew them
from the feed plate.
4. Rotate the triangular shaped drive roll retaining
mechanism to unlock the drive rolls and remove the
drive rolls.
1. Turn the reel or spool until the free end of the electrode is accessible.
2. While tightly holding the electrode, cut off the bent
end and straighten the first 6" (15 cm). Cut off the
first 1" (2.5 cm). If the electrode is not properly
straightened, it may not feed or may jam.
3. Insert the free end through the incoming guide
bushing.
4. Press the Cold Feed switch and push the electrode
into the drive roll.
5. Feed the electrode through the gun.
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.
6. Adjust the brake tension with the thumbscrew on
the spindle hub, until the reel turns freely but with
little or no overrun when the wire feeding stops. Do
not overtighten.
7. Install a drive roll on each hub assembly and lock
by rotating the triangular drive roll retaining mechanism.
8. Install the outer wire guide by aligning it with the
pins and tightening the knurled thumbscrews.
9. Close the idle arm and engage the idle roll pressure
arm. Adjust the pressure appropriately.
LN-15 CONTROL CABLE MODEL (CE)
B-1
B-1
OPERATION
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
INPUT POWER
WARNING
• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive
mechanism are always electrically energized and could
remain energized several seconds after the welding ceases..
• Do not attach the work clip to the roll cage or
bottom skids. The work clip is energized any
time the output of the welding power source is
“ON”, even when the feeder is not welding.
• Do not touch electrically live part or electrode
with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
• The serviceability of a product or structure utilizing the LN-15 wire feeder is and must be the
sole responsibility of the builder/user. Many
variables beyond the control of The Lincoln
Electric Company affect the results obtained in
using the LN-15 wire feeder. These variables
include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service
requirements. The available range of the LN-15
wire feeder may not be suitable for all applications, and the builder/user is and must be solely 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 fumes
and gases from breathing zone
and general area.
--------------------------------------------------------------------• WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
ON
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
INPUT POWER
DIRECT CURRENT
U0
OPEN CIRCUIT
VOLTAGE
U1
INPUT VOLTAGE
U2
OUTPUT VOLTAGE
I1
INPUT CURRENT
I2
OUTPUT CURRENT
---------------------------------------------------------------------ARC RAYS can burn.
• Wear eye, ear and body protection.
--------------------------------------------------------------------SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MANUAL.
---------------------------------------------------------------------LN-15 CONTROL CABLE MODEL (CE)
PROTECTIVE
GROUND
WARNING OR
CAUTION
B-2
B-2
OPERATION
GENERAL DESCRIPTION
DUTY CYCLE
The LN-15 is a light weight, portable, durable semiautomatic wire feeder.
The LN-15 wire feeders are intended for semi-automatic use. The maximum rating of the LN-15 is based
upon a 60% duty cycle; 6 minutes of welding followed
by 4 minutes of idling within a 10 minute period.
The LN-15 accommodates spools 8" (200mm) diameter up to 4" (100mm) wide.
RECOMMENDED PROCESSES
The domestic feeders comes factory equipped with a
K1500-2 Magnum Tweco-compatible style #2-#4 gun
bushing. Other K1500 series gun bushings are available as field installed options. European models are
factory 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 source
is recommended for flux-cored arc welding (FCAW)
and gas metal arc welding (GMAW) to obtain code
quality results. However, the LN-15 may also be used
with a constant current (CC) power source to obtain
passable results for non-critical quality applications.
The “dual procedure” mode drops the WFS to 83% of
the original set point. The voltage setting remains the
same.
• 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 seconds, with a default of 0.00 seconds.
• The postflow time is adjustable from 0.0 to 25.0 seconds, with a default setting of 0.0 seconds.
The Control Cable Model features remote voltage
control with a potentiometer on the front of the feeder.
The operation of the voltage control is similar to other
feeders having "remote control" kits, such as the LN25. While welding, the voltage may be adjusted as
desired. The voltage setting is not a "preset" value.
Electrode output is energized in response to the gun
trigger by signals sent to the power source via the
control cable.
The LN-15 wire drive feeds electrode for various
processes as defined below in Table B.1.
The Control Cable Model is suitable for GMAW,
GMAW-Pulse, GMAW-STT and FCAW semi-automatic applications within the rated duty cycle.
PROCESS LIMITATIONS
• The control cable model is not recommended for
SAW, SMAW, GTAW or CAG.
• The control cable model works only with power
sources 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 AND
CONTROLS
•
•
•
•
•
•
•
•
•
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)
TABLE B.1
Process
Wire Diameter Range
Wire Feed Speed Range
GMAW
0.023 - 0.052" (0.6 - 1.3 mm)
50 - 700 ipm (1.3 - 17.8 m/minute)
FCAW
0.045 - 0.052" (1.2 - 1.3 mm)
50 - 700 ipm (1.3 - 17.8 m/minute)
FCAW
1/16 - 5/64"
50 - 400 ipm (1.3 - 10.2 m/minute)
(1.6 - 2.0 mm)
LN-15 CONTROL CABLE MODEL (CE)
B-3
B-3
OPERATION
CASE FRONT CONTROLS (See Figure B.1)
ACROSS THE ARC MODEL
1. WIRE FEED SPEED DISPLAY-The Wire Feed Speed
display shows the rate the LN-15 will feed electrode during welding. The default WFS units for domestic models
are inches/minute and can be changed to meters/minute
through the configuration menu. The default WFS units
for the European models are m/min. The wire feed
speed is calibrated to within ±2%.
2. VOLTAGE DISPLAY-The voltage display shows the
average arc voltage during the welding. A minus sign "-"
appears when welding with electrode negative welding
procedures. While welding, an LED will illuminate below
the voltage display. After welding, the average voltage
will continue to be shown for 5 seconds after the end and
the LED will flash. of the weld. When not welding, the
display 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 Speed
knob is a 3-3/4 turn potentiometer that adjusts of the rate
of feeding electrode. The wire feed speed range is 50 700 inches/min (1.3 - 17.8 m/min)
FIGURE B.1a
4. VOLTAGE KNOB-The voltage knob is present only on
control cable models.
Adjusting the voltage knob varies the power source voltage to the LN-15. The value displayed is not a "preset"
voltage. Only actual average arc voltage is shown on the
voltage display.
For codes 10864, 10865:
The voltage knob controls the output of the power source
through a 3-3/4 turn, 10K ohm potentiometer.
For codes 11033 and above:
The voltage knob controls the output of the power source
through a _ turn, 10K ohm potentiometer.
5. TRIGGER CONNECTOR-5 Pin Receptacle is used to
activate the Magnum Gun Switch.
6. CONNECTOR BUSHING-This connection is for welding conductor cable assembly.
7. ON / OFF SWITCH-For codes 11033 and above:
The ON / OFF Switch turns power on and off to the wire
feeder.
83% PROCEDURE
The LN-15 supports a special "dual procedure" mode.
When activated, the wire feed speed is reduced to
83% of the set value, but no less than 50 inches/minute (1.27 m/min). The 83% procedure is most
commonly used during pipe and out of position welding. Requires Magnum 400 Dual Procedure Gun
Equivalent.
FIGURE B.1
1
3
7
5
LN-15 CONTROL CABLE MODEL (CE)
2
4
6
B-4
B-4
OPERATION
LN-15 POWER-UP SEQUENCE
Normal Power-Up Display
When power is first applied to the LN-15, the display
will momentarily show set-up information. For example, it may show "CV" and "HI", indicating operation
from a CV power source and the wire drive is configured for the high speed gear. Because of limitations in
the display, "CV" will appear as "Cu".
Preflow:
Postflow:
Burnback:
3. Activate and then release the GAS PURGE switch
to select the timer. The time will then display in the
right hand side of the display. Example:
After a brief moment, the LN-15 will then display the
WFS and "---". No voltage is displayed until the trigger
is pressed.
4. Rotate the WFS knob to adjust the time to the new
setting.
WFS
Preflow, Postflow and Burnback Times
Preflow, Postflow and Burnback times are all
adjustable on the LN-15. The LN-15 is factory set with
all 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 seconds.
• The postflow time is adjustable from 0.0 to 25.0 seconds.
Changing Preflow, Postflow or Burnback times:
1. Enter the “Press Spin” Set-Up Mode:
While the power to the LN-15 is off, activate and
hold the GAS PURGE switch (Down Position). Turn
on power to the LN-15, and continue to hold the
GAS PURGE switch until the LN-15 displays "Press
spin". Release the GAS PURGE switch.
COLD
FEED
GAS PURGE
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.
5. Press the GAS PURGE switch again to save the
setting. 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 power
to the LN-15, or simply wait 15 seconds and the
LN-15 will enter normal operation.
Welding Mode CV/CC mode and WFS units
The CV/CC mode and WFS units are all readily
changed during the power-up sequence. The LN-15 is
factory set for "CV" welding power sources and "inches per minute" for the wire feed speed units.
• The CV/CC mode is selectable for either CV for
Constant Voltage power sources and CC for
Constant Current power sources. Use CV power
sources when making critical welds.
• The WFS units is selectable for either in/min and
m/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 and
hold the GAS PURGE switch (Down Position). Turn
on power to the LN-15, and continue to hold the
GAS PURGE switch until the LN-15 displays "Press
spin". Release the GAS PURGE switch.
COLD
FEED
2. Rotate the WFS knob until the desired timer is displayed.
GAS PURGE
The LN-15 is now in the "Press Spin" set-up mode.
If after 15 seconds no other action is taken, the LN15 will then revert to normal operation.
LN-15 CONTROL CABLE MODEL (CE)
B-5
B-5
OPERATION
Rotate the WFS knob until the desired parameter is
displayed.
INTERNAL CONTROLS (Figure B.2)
SPRING
TENSION
ARM
CV/CC Mode:
COLD FEED/
GAS PURGE
SWITCH
2 STEP/TRIGGER
INTERLOCK
SWITCH
SPINDLE
BRAKE
WFS Units:
2. Activate and release the GAS PURGE switch to
select the parameter. The present value will then
display in the right hand side of the display.
Example:
FLOWMETER
SPRING TENSION ARM
3. Rotate the WFS knob to change the parameter setting.
WFS
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 "Press
Spin" mode in step 1.
5. To exit the "Press Spin" set-up mode, turn off power
to the LN-15, or simply wait 15 seconds and the
LN-15 will enter normal operation.
The pressure arm controls the amount of force the drive
rolls exert on the wire. Proper adjustment of both pressure arm gives the best welding performance. For best
results, set both pressure arms to the same value.
Set the pressure arm as follows (See Figure B.2a):
Aluminum wires
between 1 and 3
Cored wires
between 3 and 4
Steel, Stainless wires between 4 and 6
Figure B.2a
CORED WIRES
OUTERSHIELD
METALSHIELD
INNERS HIELD
LN-15 CONTROL CABLE MODEL (CE)
12
34
56
SOLID WIRES
ALUMINUM
STEEL
STAINLE SS
B-6
B-6
OPERATION
WIRE DRIVE CONFIGURATION
6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the precision fit, light tapping may be required to remove
the gun bushing.
7. Disconnect the shielding gas hose from the gun
bushing, if required.
8. Connect the shielding gas hose to the new gun
bushing, if required.
9. Rotate the gun bushing until the thumb screw hole
aligns with the thumb screw hole in the feed plate.
Slide the gun receiver bushing into the wire drive
and 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.
(See Figure B.2b)
Changing the Gun Receiver Bushing
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the
welding power source before
installation or changing drive rolls
and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.
• Only qualified personnel should perform maintenance work.
----------------------------------------------------------------------Tools required:
• 1/4" hex key wrench.
COLD FEED/GAS PURGE SWITCH
Cold Feed and Gas Purge are combined into a single
spring centered toggle switch.
Note: Some gun bushings do not require the use of
the thumb screw.
To activate Cold Feeding, hold the switch
in the UP position. The wire drive will feed
electrode but neither the power source
nor the gas solenoid will be energized.
Adjust the speed of cold feeding by rotating the WFS knob. Cold feeding, or "cold
inching" the electrode is useful for threading the electrode through the gun.
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 remove
the socket head cap screw.
FIGURE B.2b
THUMB SCREW
GUN RECEIVER BUSHING
OUTER WIRE GUIDE
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN
TIGHTEN
LN-15 CONTROL CABLE MODEL (CE)
B-7
B-7
OPERATION
Hold with toggle switch in the DOWN position to activate Gas Purge and let the shielding gas flow. The
gas solenoid valve will energize but neither the power
source output nor the drive motor will be turned on.
The Gas Purge switch is useful for setting the proper
flow rate of shielding gas. Flow meters should always
be adjusted while the shielding gas is flowing.
2 STEP - TRIGGER INTERLOCK SWITCH
The 2 Step - Trigger Interlock switch
changes the function of the gun trigger.
2 Step trigger operation turns welding on
and off in direct response to the trigger.
Trigger Interlock operation allows welding to continue when the trigger is
released for comfort on long welds.
SCFH
10
20
30
40
50
60
70
80
Liter/Min.
4.7
9.4
14.2
18.9
23.6
28.3
33.1
37.8
SPINDLE BRAKE
Adjust the spindle brake tension to allow the spool to
spin freely, yet have enough resistance for little or no
overrun when wire feeding is stopped.
SHIELDING GAS CONNECTION
Place the toggle switch in the UP position for 2 Step operation or in the DOWN
position for Trigger Interlock operation.
2 Step Trigger
2 Step trigger operation is the most common. When
the gun trigger is pulled, the welding power source
energizes the electrode output and the wire feeder
feeds wire for welding. The power source and wire
feeder continue welding until the trigger is released.
Trigger Interlock
Trigger Interlock operation provides for operator comfort when making long welds. When the gun trigger is
first pulled, the welding power source energizes the
output and the wire feeder feeds wire for welding.
The gun trigger is then released while the weld is
made. To stop welding, the gun trigger is pulled again,
and when it is released the welding power source output turns off and the wire feeder stops feeding wire.
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.
-----------------------------------------------------------------------
WARNING
CAUTION
If the arc goes out while welding with trigger interlock operation, the electrode output from the
welding power source remains energized and the
wire feeder will continue to feed wire until the gun
trigger is again pulled and then released.
------------------------------------------------------------------------
FLOW METER
The flowmeter shows the flow rate of shielding gas
and has a valve to adjust the flow. The flow meter is
calibrated for CO2, Ar, and CO2/Ar blends. The middle of the ball indicates the flow rate of shielding gas.
Adjust the flow rate by turning the valve at the bottom
of 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 and
wind conditions may effect the amount of shielding
gas required.
• BUILD UP 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 LN-15.
Connect a supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on the
back of the LN-15.
LN-15 CONTROL CABLE MODEL (CE)
B-8
B-8
OPERATION
CONSTANT CURRENT OPERATION
( See Figure B.3)
CAUTION
Lincoln Electric does NOT recommend constant
current semiautomatic welding for applications
which need to meet specified weld metal chemical
or mechanical property requirements or weld
quality requirements.
-----------------------------------------------------------------------Most semiautomatic welding processes perform better
using constant voltage power sources.
Welding codes usually do not address the power source
selection or specifically, whether the welding process is
to be operated in the constant voltage or constant current
mode. Instead, codes typically specify limitations on the
current, voltage, heat input and preheat temperature
based on the material to be welded. The intention is to
assure that proper weld material properties will develop.
If the contact tip to work distance is properly maintained, a satisfactory operating voltage range may be
achieved, and a sound weld may result. However,
when a welder uses a longer contact tip to work distance, an arc-sensing wire feeder compensates by
increasing the wire feed speed to regulate the voltage.
Even if the voltage and current remain unchanged, the
increased wire feed speed may result in a deposition
rate well beyond the specified range of the electrode.
Under these conditions, the specified weld metal properties may not be achieved.
Constant voltage power sources deliver large current
surges to stabilize the arc when the electrode is shorted or the arc length is very short. However, a constant
current power source does not provide such a
response to stabilize the arc. It may be difficult to
achieve required weld metal properties, or to achieve
the required quality of welds needed to pass nondestructive tests, when such welds are made under constant current operation.
Welding is sometimes performed using constant current
power sources. The operation can be more convenient
because it may allow the use of an existing stick (SMAW)
power source and the power source can be placed at a
distant location without any provision for adjusting the
output settings.
For constant current operation, the power source is set to
deliver the specified current. The power source regulates
this current regardless of changes in the welding circuit,
including cable length, electrode diameter, wire feed
speed, contact tip to work distance, etc.
Changes in the wire feed speed (WFS) or contact tip
to work distance (CTWD) affect the arc voltage when
constant current power sources are used. Lowering
the wire feed speed raises the voltage, raising the
wire feed speed lowers the voltage. Lengthening the
contact tip to work distance raises the voltage, shortening the contact tip to work distance lowers the voltage.
FIGURE B.3
LN-15
Current
+ Welding Cable
(Electrode)
GUN AND CABLE
ASSEMBLY
Wire
Feeder
CTWD
WFS
Constant Current
Power Source
-
Current
Welding Cable
LN-15 CONTROL CABLE MODEL (CE)
B-9
B-9
OPERATION
SETTING ARC SENSING WIRE FEED SPEED
FOR CONSTANT CURRENT OPERATION
The wire will feed at the DESIRED IN/MIN speed when the welding
power source is set to the arc voltage to be used for the weld
procedure (375 in/min. at 29V for example used).
When using a constant current (formerly variable voltage)
power source, welding performance is improved using arc
sensing wire feed speed (CC operation). In this wire feed
mode the wire speed increases if arc voltage increases,
and decreases if arc voltage decreases, but remains constant at any specific voltage level.
The CC wire speed setting graph is shown in TABLE B.1, giving
the Wire Speed dial setting required for the DESIRED IN/MIN
and ARC VOLTS used for the welding procedures:
TABLE B.1 CC WIRE SPEED SETTING
Arc Volts Used
Desired
In/Min
30
32
34
97
117
136
156
175
88 80 73 67 63 58
105 95 88 81 75 70
123 111 102 94 88 82
140 127 117 108 100 93
158 143 131 121 113 105
55
66
77
88
98
51
62
72
82
93
219
241
263
284
306
194
214
233
253
272
175
193
210
228
245
159
175
191
207
223
146
160
175
190
204
135
148
162
175
188
125
138
150
163
175
117
128
140
152
163
109
120
131
142
153
103
113
124
134
144
150
160
170
180
190
328
350
372
394
416
292
311
331
350
369
263
280
298
315
333
239
255
270
286
302
219
233
248
263
277
202
215
229
242
256
188
200
213
225
238
175
187
198
210
222
164
175
186
197
208
154
165
175
185
196
200
210
220
230
240
438
459
481
503
525
389
408
428
447
467
350
368
385
403
420
318
334
350
366
382
292
306
321
335
350
269
283
296
310
323
250
263
275
288
300
233
245
257
268
280
219
230
241
252
263
206
216
226
237
247
250
260
270
280
290
547
569
591
613
634
486
506
525
544
564
438
455
473
490
508
398
414
430
445
461
365
379
394
408
423
337
350
365
377
390
313
325
338
350
363
292
303
315
327
338
273
284
295
306
317
257
268
278
288
299
300
310
320
330
340
656 583 525 477
678 603 543 493
700 622 560 509
642 578 525
661 595 541
438
452
467
481
496
404
417
431
444
458
375
388
400
413
425
350
362
373
385
397
328
339
350
361
372
309
319
329
340
350
b. Referring to the graph located above the Mode switch
(also shown in Figure B.4):
350
360
380
400
420
681 613 557
700 630 572
666 604
700 636
668
510
526
554
584
612
471
484
512
538
566
438
450
472
500
526
408
420
444
466
490
383
394
416
438
460
360
370
392
412
432
1. Select the horizontal line representing the DE SIRED IN/MIN. for the welding procedure. (See
example arrow line for 375 in/min.)
440
460
480
500
700 642 592 550 514
670 620 576 536
700 646 600 560
674 626 584
482
504
526
546
452
472
494
514
The LN-15 permits accurate presetting of the desired
wire feed speed, for the desired arc voltage to be used,
by setting the Wire Feed Speed in the following manner
before welding:
a. Activate press and spin during power up and change
to the CC mode. See “Changing the CV/CC mode
or WFS units” in this Operation Section.
FIGURE B.4 CC WIRE SPEED SETTING
2. Select the diagonal line representing the ARC
VOLTS to be used for the welding procedure. (See
example arrow line for 29 volts.)
3. Determine the vertical line representing the CC
WIRE SPEED SETTING where the above two lines
cross. (See example arrow line for 450.)
c. Adjust the WFS display to the value determined in
Step (3) above (450 for example used).
16
18
50
60
70
80
90
109
131
153
175
197
100
110
120
130
140
20
22
24
26
28
520
540
560
580
600
700 650 606 568 536
676 630 590 556
700 654 612 576
676 634 598
700 656 618
620
640
660
680
700
678 638
700 658
680
700
CC Speed Setting = Desired IPM X 35
Arc Volts
LN-15 CONTROL CABLE MODEL (CE)
B-10
OPERATION
MAKING A WELD
The serviceability of a product or structure utilizing the
LN-15 wire feeder is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results
obtained in using the LN-15 wire feeder. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment
design, fabrication methods and service requirements.
The available range of the LN-15 wire feeder may not
be suitable for all applications, and the builder/user is
and 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 to
the work. The work must also be grounded as stated
in "Arc Welding Safety Precautions".
• Connect the LN-15 electrode cable to the power
source for the polarity and process to be used.
Check that the appropriate power source settings
are made for the procedure to be used. (Refer to the
power source operating and connection instructions.)
• Place the LN-15 conveniently near the work area in
a safe location to minimize exposure to weld spatter
and 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 being
used is in the gun.
• Turn on the welding power source, as well as the
shielding gas supply (if used.)
• Cut the electrode within approximately 3/8" (10mm)
of the end of the contact tip for solid wire and within
3/4" (19mm) of the extension guide for cored wire.
• Position the electrode over the joint. The end of the
electrode should be slightly off the work.
• Lower welding helmet, close the gun trigger and
begin welding. Hold the gun so the contact tip to
work distance gives the correct electrical stickout as
required for the procedure being used.
• To stop welding, release the gun trigger and the pull
the gun away from the work.
LN-15 CONTROL CABLE MODEL (CE)
B-10
C-1
C-1
ACCESSORIES
OPTIONAL EQUIPMENT
• K1797-[ ] control cable extensions
• K1798 Adapter Cable for Control Cable to Terminal
Strip Power Sources
• K1500-1, -2, -3, -5 Gun Receiver Bushings
• Drive Roll Kits (Include drive rolls and guide tube necessary to feed the identified wire
size and type.
WIRE TYPE
ELECTRODE SIZE
KP KIT
Steel Wires:
.023-.030" (0.6-0.8mm)
KP1696-030S
(Including stainless steel)
.035"
(0.9mm)
KP1696-035S
.040-.045" (1.0-1.2mm)
KP1696-045S
.052"
(1.4mm)
KP1696-052S
.035-.045" (0.9-1.2mm)
KP1696-1
.040"
(1.0mm)
KP1696-2
Cored Wires:
.030-.035"
.040-.045"
.052"
1/16"
.068"
5/64"
(0.8-0.9mm)
(1.0-1.2mm)
(1.4mm)
(1.6mm)
(1.7mm)
(2.0mm)
KP1697-035C
KP1697-045C
KP1697-052C
KP1697-1/16C
KP1697-068
KP1697-5/64
Aluminum Wires:
.035"
.040"
3/64"
(0.9mm)
(1.0mm)
(1.2mm)
KP1695-035A
KP1695-040A
KP1695-3/64A
LN-15 CONTROL CABLE MODEL (CE)
D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
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 power
source off at the fuse box before working in the
terminal strip.
• Only qualified personnel should install, use or
service this equipment.
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing
out the machine, using a low pressure airstream, to
remove accumulated dust and dirt from inside the
feeder.
PERIODIC MAINTENANCE
• Replace the drive rolls and inner wire guide when
they are worn.
• Replace the pig tail if the insulation is cut, abraded
or damaged.
CALIBRATION SPECIFICATION
All calibration is factory set on the LN-15.
To verify the wire feed speed:
• Assemble a .045 (1.2mm) drive roll kit into the LN15.
• 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 feed
speed 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 the
arc.
• While a weld is being made, measure the voltage
from the feedplate to work.
• The displayed voltage on the LN-15 should be within 2% of the measured value.
LN-15 CONTROL CABLE MODEL (CE)
D-1
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-15 CONTROL CABLE MODEL (CE)
TROUBLESHOOTING
E-2
E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
POSSIBLE
CAUSE
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized
is evident when the sheet metal cov- Lincoln Electric Field Service facilers are removed.
ity for technical assistance.
The wire drive turns off periodically 1. The supply voltage for the LN-15
while operating on an engine drive.
is too low.
No shielding gas flow.
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 failed
5. The feed head board has failed.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
The shielding gas turns on sporadi- 1. The pressure in the gas line is
cally, or remains on all the time.
exceeding 80 psi (5.5 bar)
2. The gas solenoid has failed.
FEEDING PROBLEM
The wire drive stops feeding wire 1. The motor has exceeded the current rating.
after about 10 seconds.
2. Check to make sure the electrode
slides easily through the liner of
the gun.
3. Verify that the spindle brake is not
set too tight.
4. For best results, use only Lincoln
electrodes.
5. Wait 10 minutes for the wire feeder to cool.
The wire feed speed varies during 1. The drive rolls are slipping
welding but the meter reading because of feeding problems.
2. The LN-15 is in CC mode instead
remains constant
of CV mode.
3. Reduce the spindle brake resistance.
4. Increase the amount of tension in
the wire drive pressure arm.
5. For best results, use only Lincoln
electrodes.
6. Verify on power-up that the LN-15
is set for CV welding.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
The Wire Feed Speed Range is only 1. The 83% wire feed speed dual
50 - 601 in/min ( 1.3 - 15.3 m/min).
procedure is activated with the
high speed gear. Check dual procedure switch in gun.
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-15 CONTROL CABLE MODEL (CE)
E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
POSSIBLE
CAUSE
The Wire Feed Speed Range is only 1. The 83% wire feed speed dual
procedure is activated with the low
50 - 374 in/min ( 1.3 - 9.5 m/min)
speed gear. Check dual procedure
switch in gun.
DISPLAY PROBLEMS
"POS", "PRE" or "BRN" show on the 1. The LN-15 is in the Press and
Spin set-up mode.
display.
2. One of the DIP switches on the
feed head board is set to "ON" for
timer setting mode.
3. Cycle power to the LN-15 or wait
45 seconds.
4. The LN-15 is an old ALPHA unit
and a DIP switch is in the wrong
position.
The voltage display reads "0.0" volts 1. The power source meter polarity
during welding
switch is in the wrong position.
2. Set the power source meter polarity switch to match the welding
process.
WELDING PROBLEMS
1. The part being welded is wet, dirty
Porosity in the weld.
Variable or "hunting" arc.
or rusty.
2. The electrode being used is wet,
dirty or rusty.
3. There is insufficient shielding gas
flow from possible cuts in the gas
hose
4. There is moisture or water in the
shielding gas line.
5. There is too much shielding gas
6. 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.
Variable or "hunting" arc.
2. Worn work cable or poor work
connection.
3. Loose electrode connection.
4. Wrong electrode polarity for the
process being used.
The arc burns back to the tip.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
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 improperly set.
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-15 CONTROL CABLE MODEL (CE)
E-4
TROUBLESHOOTING
E-4
Observe all Safety Guidelines detailed throughout this manual
ERRORS ON THE DISPLAY
Fault Code
Err 0081
Description
Average motor over current shutdown
Possible Adjustments
• The wire drive motor has overheated.
• Check to make sure the electrode
slides easily through the liner of the
gun.
• Reduce the amount of tension in the
wire drive tension arm.
• Verify that the spindle brake is not set
too tight.
• For best results, use only Lincoln electrodes.
• Wait 10 minutes for the wire feeder to
cool.
Err 0086
Trigger lockout.
• The ripple of the power source OCV is
too high, greater than 110V. (Across
the Arc Models only)
• Verify the power source is reconnected for the proper input voltage.
• Repair or replace the power source.
The power source does not conform to
NEMA
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-15 CONTROL CABLE MODEL (CE)
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-15 CONTROL CABLE MODEL (CE)
F-1
F-2
DIMENSION PRINT
LN-15 CONTROL CABLE MODEL (CE)
F-2
NOTES
LN-15 CONTROL CABLE MODEL (CE)
● 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