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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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And, most importantly, think before you act and be careful.
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LN-15 WIRE FEEDER
For use with machines having Code Number : 11033, 11035
SVM166-A
April, 2006
SERVICE MANUAL
Copyright © 2006 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 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.
i
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.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.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS may be dangerous
____________________________________________________
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.
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.
___________________________________________________
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.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
LN-15
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
SAFETY
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 below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
5.c. 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.d. 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.e. Also see item 1.b.
Mar ‘95 ii
LN-15
iii
WELDING 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.
SAFETY
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.
Mar ‘95 iii
LN-15
iv
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.
SAFETY zones où l’on pique le laitier.
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
iv
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
LN-15
v
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P482 Series
v
LN-15
Section A-1 TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1
Installation ..............................................................................................................Section A
LN-15
A-2 INSTALLATION
TECHNICAL SPECIFICATIONS – LN-15 (K1870-1), (K1870-2 CE)
INPUT VOLTAGE
15-110 VDC (5 Amps Maximum)
Across the Arc Model
RATED CURRENT
300 Amps 60% Duty Cycle
250 Amps 100% Duty Cycle
ELECTRODE DIAMETERS and SPEED RANGE
Electrode Size Speed Range
A-2
HEIGHT WIDTH
12.7 Inches 8.7 Inches
(323 mm) (221mm)
Solid Electrode
Steel
0.023 - 0.052" 50 - 700 in/min
(0.6 - 1.3 mm) (1.3 - 17.8 m/min)
Flux Cored
Electrode
0.0345 - 5/64" 50 - 400 in/min
(0.9 - 2.3 mm) (1.3 - 10.1 m/min)
PHYSICAL DIMENSIONS
DEPTH WEIGHT SPOOL SIZE CAPABILITY
23 Inches
(584 mm)
30lbs
(14kg)
TEMPERATURE RANGE
F to +104 o F)
F to +185 o F)
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)
LN-15
A-3
SAFETY PRECAUTIONS
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.
• 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.
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LOCATION
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.
WORK CLIP LEAD
INSTALLATION A-3
The work clip lead attached to the front of the LN-
15 must be connected directly to the work using the spring clip on the end of the lead.
If the work clip lead is not connected, the LN-15 will not operate.
The work clip lead also serves as a work sensing lead for the LN-15. If the work clip lead is extended by the user beyond the standard 15' (4.6m) length, the voltmeter reading will be lower than the actual arc volts due to resistance in the extended lead. To minimize the error, the following lead size is recommended for the maximum extended lengths shown.
AWG
#14
#12
#10
#6
Max. Length
25 ft (7.6m)
50 ft (15.2m)
100 ft (30.5m)
200 ft (61.0m)
CORRECT
WORK CLIP ATTACHED TO WORK
WARNING
ELECTRIC SHOCK CAN KILL.
• ONLY QUALIFIED PERSONNEL
SHOULD PERFORM THIS
INSTALLATION.
• Do not touch metal portions of the LN-15 work clip lead when the welding power source is on. The work clip lead is electrically "hot" to work if the input electrode cable to the LN-15 is electrically
"hot", even if the gun trigger is off. Care should be taken to only handle the LN-15 work clip lead by its nonmetal insulated portions and/or the welding power source should be turned off before handling the work clip.
• Do not attach the work clip lead to the roll cage or bottom skids of the LN-15.
• Attach the work clip only to the work piece.
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** The work clip lead is present only on Across-the-
Arc models.
INCORRECT
HIGH FREQUENCY PROTECTION
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.
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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
WORK CLIP ATTACHED TO ROLL CAGE
A-4 INSTALLATION A-4
WELD CABLE CONNECTIONS
CAUTION
WARNING
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 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.
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ENGINE DRIVE POWER SOURCE
CONNECTION
The LN-15 has an internal contactor 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.
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)
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.
TABLE A.1
Weld Current Total Cable Length
60% Duty (electrode cable + work cable)
Cycle 50 - 100' 100 - 150' 150 - 200' 200 - 250'
200 Amps
300 Amps
(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
400 Amps 2/0 2/0 3/0 3/0
3. Attach the work clip lead from the front of the LN-15 to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire feeder motor; it does not carry welding current.
4. Set the MODE switch on the engine drive to CV-
WIRE.
ELECTRODE CONNECTION
Route the electrode cable through the strain relief in the rear of the case. Connect the electrode cable to the
LN-15 input stud using the mounting hardware provided. Secure the cable by tightening the strain relief.
5. Set the WELD TERMINALS switch to WELD TER-
MINALS ON.
6. Set the WIRE FEEDER VOLTMETER switch to either "+" or "-" as required by the electrode polarity being used.
All domestic models are supplied with pigtail for customers that prefer to make a taped and bolted connection externally. CE models have a male twist connector for the electrode connection.
7. Set the ARC CONTROL knob to "0" initially and adjust to suit.
WORK CONNECTION
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.
8. Set the IDLE switch to the AUTO position.
Important: Some older engine drives may require the IDLE switch to be in the HIGH position for proper LN-15 operation.
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.
LN-15
A-5 INSTALLATION A-5
CONNECTION DIAGRAM, ACROSS THE ARC MODEL Set-Up
( See Figure A.1)
Typically used for general fabrication, maintenance and repair jobs because it’s easy to set up and operate.
Requires only one cable-less to carry. Contactor standard on Across The Arc Model.
FIGURE A.1
RANGER 8
SAE 400 WITH CV ADAPTER
ENGINE DRIVEN WELDERS
WITH WIRE FEED MODULE
(LOCAL MODE AND CV ADAPTER)
Always Hot.
Electrode Cable semiautomatic
Work
Clamp
CV250
CV300
CV400
Always Hot.
Plug Kit.
Electrode Cable
CV655, DC400, DC600,
DC655, V350-PRO,
RANGER 9, RANGER 300 DLX
COMMANDER 300
COMMANDER 500
RANGER 250
RANGER 305G
K848 Junper Plug Kit.
Electrode Cable semiautomatic wire feeder
K1870-1 semiautomatic wire feeder
K1870-1
Work
Clamp
Work
Clamp semiautomatic wire feeder
K1870-1
CC POWER SOURCE
Electrode Cable
Work
Clamp
Although a constant voltage (CV) power source is recommended for best results with Innershield® and gas metal arc (GMAW) open arc welding, satisfactory general purpose welding may be obtained using the LN-15 with a constant current (CC) power source for non-critical commercial quality mild steel welding applications.
LN-15
A-6
GUN AND CABLE ASSEMBLIES
INSTALLATION
A-6
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
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®.
WARNING
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
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.
• 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
0such 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.
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.
CONNECTIONS
Across the Arc LN-15 models do not use a control cable.
Table A.2 Trigger Connector J1 (5 Pin)
PIN Lead # Function
A
B
C
556
-
554
Trigger
Not used
Trigger/ 83%
Procedure ground
D
E
555
554
83% Procedure
Trigger/ 83%
Procedure ground
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 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
A-7
FEEDING WIRE ELECTRODE
WARNING
INSTALLATION
• 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
2 STEP/TRIGGER
INTERLOCK
SWITCH
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.
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 over tighten.
LN-15
A-7
A-8 NOTES A-8
LN-15
Section B-1 TABLE OF CONTENTS
- OPERATION SECTION -
Section B-1
Operation ................................................................................................................Section B
LN-15
B-2 OPERATION
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
B-2
--------------------------------------------------------------------
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.
U0
U1
U2
I1
I2
ON
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
INPUT POWER
DIRECT CURRENT
OPEN CIRCUIT
VOLTAGE
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
----------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear and body protection.
PROTECTIVE
GROUND
---------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MANU-
AL.
LN-15
WARNING OR
CAUTION
B-3
GENERAL DESCRIPTION
OPERATION
DUTY CYCLE
B-3
The LN-15 is a light weight, portable, durable semiautomatic wire feeder.
The LN-15 accommodates spools 8" (200mm) diameter up to 4" (100mm) wide.
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; welding 6 minutes of welding followed by 4 minutes of idling within a 10 minute period.
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.
RECOMMENDED PROCESSES
The LN-15 wire drive feeds electrode for various processes as follows:(See Table B.1)
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 Across the Arc Model is suitable for GMAW,
GMAW-Pulse and FCAW semi-automatic applications within the rated duty cycle.
PROCESS LIMITATIONS
The “dual procedure” mode drops the WFS to 83% of the original set point. The voltage setting remains the same.
• The across the arc model is not recommended for spot or stitch welding.
• The across the arc model is not recommended for
GMAW-STT, SAW, SMAW, GTAW or CAG.
EQUIPMENT LIMITATIONS
• 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 2.50 seconds, with a default of 0.00 seconds.
• The postflow time is adjustable from 0.0 to 10.0 seconds, with a default setting of 0.0 seconds.
The Across the Arc Model is capable of operating with
Lincoln DC power sources supplying between 15VDC and 110 VDC. Simply attach the work clip to the work piece and then connect the LN-15 to the electrode cable to the power source and it is ready to weld.
Codes 10864, 10865
• The LN-15 cannot be used with K489-7 Fast Mate
Gun receiver bushing or K1500-4 gun adapter bushing.
Codes 11033 and higher
• The LN-15 cannot be used with the K1500-4 gun adapter bushing.
OPERATIONAL FEATURES AND
CONTROLS
An internal contactor in Across the Arc Models energizes the electrode output in response to the gun trigger.
Process
GMAW
FCAW
FCAW
TABLE B.1
Wire Diameter Range
0.023 - 0.052" (0.6 - 1.3 mm)
0.045 - 0.052" (1.2 - 1.3 mm)
1/16 - 5/64" (1.6 - 2.0 mm)
• 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.)
Wire Feed Speed Range
50 - 700 ipm (1.3 - 17.8 m/minute)
50 - 700 ipm (1.3 - 17.8 m/minute)
50 - 400 ipm (1.3 - 10.2 m/minute)
LN-15
B-4 OPERATION
CASE FRONT CONTROLS
(See Figure B.1)
ACROSS THE ARC MODEL
B-4
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) 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%.
4. TRIGGER CONNECTOR-5 Pin Receptacle is used to activate the Magnum Gun Switch.
5. CONNECTOR BUSHING-This connection is for welding conductor cable assembly.
2. VOLTAGE DISPLAY
-
The voltage display shows the average arc voltage during 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.
FIGURE B.1a
6. WORK CLIP LEAD-This lead must be connected directly to the work using the spring clip.
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
2
1
7
4
3
5
6
LN-15
B-5
LN-15 POWER-UP SEQUENCE
OPERATION
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:
B-5
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.
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 2.50 seconds.
• The postflow time is adjustable from 0.0 to 10.0 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
COLD
FEED
GAS PURGE
Spin". 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.
2. Rotate the WFS knob until the desired timer is displayed.
WFS
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.
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.
COLD
FEED
GAS PURGE
LN-15
B-6
CV/CC Mode:
OPERATION
Rotate the WFS knob until the desired parameter is displayed.
INTERNAL CONTROLS
(Figure B.2)
COLD FEED/
GAS PURGE
SWITCH
SPRING
TENSION
ARM
2 STEP/TRIGGER
INTERLOCK
SWITCH
SPINDLE
BRAKE
B-6
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:
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.
FLOWMETER
SPRING TENSION ARM
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
1
3
5
2
4
6
SOLID WIRES
ALUMINUM
STEEL
STAINLE SS
LN-15
B-7
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 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.
OPERATION B-7
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.
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.
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.
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.
FIGURE B.2b
THUMB SCREW
GUN RECEIVER BUSHING
OUTER WIRE GUIDE
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LN-15
LOOSEN TIGHTEN
B-8 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
SCFH
10
20
30
40
50
60
70
80
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.
Liter/Min.
4.7
9.4
14.2
18.9
23.6
28.3
33.1
37.8
B-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.
WARNING
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.
CYLINDER may explode if damaged.
• Keep cylinder upright and chained to support.
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.
• 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.
-----------------------------------------------------------------------
CAUTION
WARNING
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.
• 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.
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.
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.
B-9
CONSTANT CURRENT OPERATION
( See Figure B.3)
CAUTION
OPERATION
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.
------------------------------------------------------------------------
B-9
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.
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.
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
+
Current
Welding Cable
(Electrode)
Constant Current
Power Source
LN-15
Wire
Feeder
WFS
GUN AND CABLE
ASSEMBLY
CTWD
Current
Welding Cable
(Work)
LN-15
B-10 OPERATION
SETTING ARC SENSING WIRE FEED SPEED FOR
CONSTANT CURRENT OPERATION
B-10
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).
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:
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.
Desired
In/Min
TABLE B.1 CC WIRE SPEED SETTING
Arc Volts Used
16 18 20 22 24 26 28 30 32 34
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:
50
60
70
80
90
109 97 88 80 73 67 63 58 55 51
131 117 105 95 88 81 75 70 66 62
153 136 123 111 102 94 88 82 77 72
175 156 140 127 117 108 100 93 88 82
197 175 158 143 131 121 113 105 98 93 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.
100
110
120
130
140
219 194 175 159 146 135 125 117 109 103
241 214 193 175 160 148 138 128 120 113
263 233 210 191 175 162 150 140 131 124
284 253 228 207 190 175 163 152 142 134
306 272 245 223 204 188 175 163 153 144
200
210
220
230
240
150
160
170
180
190
250
260
270
280
290
328 292 263 239 219 202 188 175 164 154
350 311 280 255 233 215 200 187 175 165
372 331 298 270 248 229 213 198 186 175
394 350 315 286 263 242 225 210 197 185
416 369 333 302 277 256 238 222 208 196
438 389 350 318 292 269 250 233 219 206
459 408 368 334 306 283 263 245 230 216
481 428 385 350 321 296 275 257 241 226
503 447 403 366 335 310 288 268 252 237
525 467 420 382 350 323 300 280 263 247
547 486 438 398 365 337 313 292 273 257
569 506 455 414 379 350 325 303 284 268
591 525 473 430 394 365 338 315 295 278
613 544 490 445 408 377 350 327 306 288
634 564 508 461 423 390 363 338 317 299
300
310
320
330
340
656 583 525 477 438 404 375 350 328 309
678 603 543 493 452 417 388 362 339 319
700 622 560 509 467 431 400 373 350 329
642 578 525 481 444 413 385 361 340
661 595 541 496 458 425 397 372 350
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. (See example arrow line for 375 in/min.)
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.)
350
360
380
400
420
440
460
480
500
520
540
560
580
600
681 613 557 510 471 438 408 383 360
700 630 572 526 484 450 420 394 370
666 604 554 512 472 444 416 392
700 636 584 538 500 466 438 412
668 612 566 526 490 460 432
700 642 592 550 514 482 452
670 620 576 536 504 472
700 646 600 560 526 494
674 626 584 546 514 c. Adjust the WFS display to the value determined in
Step (3) above (450 for example used).
LN-15
620
640
660
680
700
CC Speed Setting = Desired IPM X 35
Arc Volts
700 650 606 568 536
676 630 590 556
700 654 612 576
676 634 598
700 656 618
678 638
700 658
680
700
B-11 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
B-11
B-12 NOTES B-12
LN-15
Section C-1 TABLE OF CONTENTS
- ACCESSORIES SECTION -
Section C-1
Accessories ............................................................................................................Section C
LN-15
C-2 ACCESSORIES
FACTORY INSTALLED EQUIPMENT
• K1500-2 Gun Receiver Bushing.
OPTIONAL EQUIPMENT
• K1500-1,-3,-5 Gun Receiver Bushings
• Drive Roll Kits
• Drive Roll Kits (Includes drive rolls and guide tube necessary to feed the identified wire size and type.
WIRE TYPE
Steel Wires:
(Including stainless steel)
ELECTRODE SIZE
.023-.030" (0.6-0.8mm)
.035"
.052"
(0.9mm)
.040-.045" (1.0-1.2mm)
(1.4mm)
KP KIT
KP1696-030S
KP1696-035S
KP1696-045S
KP1696-052S
Cored Wires:
Aluminum Wires:
.030-.035" (0.8-0.9mm)
.040-.045" (1.0-1.2mm)
.052"
1/16"
(1.4mm)
(1.6mm)
.068"
5/64"
(1.7mm)
(2.0mm)
.035" (0.9mm)
.040" (1.0mm)
3/64" (1.2mm)
KP1697-035C
KP1697-045C
KP1697-052C
KP1697-1/16C
KP1697-068
KP1697-5/64
KP1695-035A
KP1695-040A
KP1695-3/64A
C-2
LN-15
Section D-1 TABLE OF CONTENTS
- MAINTENANCE SECTION -
Section D-1
Maintenance ...........................................................................................................Section D
LN-15
D-2 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 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 FEED 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 feed plate to work.
• The displayed voltage on the LN-15 should be within 2% of the measured value.
LN-15
D-2
D-3 MAINTENANCE
FIGURE D.1 – MAJOR COMPONENT LOCATIONS
1. Molded Case Assembly
2. Control Box Assembly
3. Control Box Cover Assembly
4. Wire Drive & Contactor Assembly
1
2
3
D-3
4
LN-15
D-4 NOTES D-4
LN-15
Section E-1 TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
Section E-1
Theory of Operation ...............................................................................................Section E
ELECTRODE
INPUT VOLTAGE
WORK
SENSING
LEAD
TOROID
ASSEMBLY
FULL
WAVE
BRIDGE
ON/OFF
SWITCH
MOV
FIGURE E.1 – LN-15 BLOCK LOGIC DIAGRAM
LN-15 WIRE FEEDER
DISPLAY BOARD
CONTACTOR
GAS
SOLENOID
"ELECTRODE"
FEEDBACK
VOLTAGE #67
FEED
PLATE
M
O
T
O
R
ARMATURE
WELDING GUN
HALL
EFFECT
MODULE
RPM FEEDBACK
BOOST
POWER
SUPPLY
BOARD
FEED HEAD
BOARD SUPPLY
DRIVE MOTOR
SUPPLY
FEED HEAD
CONTROL BOARD
"WORK" VOLTAGE FEEDBACK #21
SPI COMMUNICATIONS
SHIELDED CABLE
COLD
INCH
SWITCH
WIRE
FEED
SPEED
CONTROL
TRIGGER
INPUT &
PROCEDURE
TRIGGER
INTERLOCK
SWITCH
DISPLAY
BOARD
LN-15
E-2
ELECTRODE
INPUT VOLTAGE
WORK
SENSING
LEAD
TOROID
ASSEMBLY
FULL
WAVE
BRIDGE
THEORY OF OPERATION
FIGURE E.2 – GENERAL DESCRIPTION & INPUT POWER
CONTACTOR
ON/OFF
SWITCH
MOV
BOOST
POWER
SUPPLY
BOARD
FEED HEAD
BOARD SUPPLY
DRIVE MOTOR
SUPPLY
"WORK" VOLTAGE FEEDBACK #21
GAS
SOLENOID
"ELECTRODE"
FEEDBACK
VOLTAGE #67
FEED
PLATE
M
O
T
O
R
ARMATURE
WELDING GUN
HALL
EFFECT
MODULE
RPM FEEDBACK
FEED HEAD
CONTROL BOARD
SPI COMMUNICATIONS
SHIELDED CABLE
E-2
COLD
INCH
SWITCH
WIRE
FEED
SPEED
CONTROL
TRIGGER
INPUT &
PROCEDURE
TRIGGER
INTERLOCK
SWITCH
DISPLAY
BOARD
GENERAL DESCRIPTION
The LN-15 is a lightweight portable semi-automatic wire feeder. The “Across the Arc” model is capable of operating with Lincoln DC power sources supplying between 15VDC to 110VDC. The LN-15 is designed for semi-automatic use and has a 60% duty cycle rating.
By attaching the work clip to the work piece and the
LN-15 electrode cable to the Lincoln power source the
LN-15 is ready to feed wire and weld. The LN-15 can be connected for either welding polarity without any changes to the LN-15. When the gun trigger is activated and wire feeds and an internal contactor energizes the electrode output.
The wire drive is capable of operating in either the constant voltage or the constant current mode. A constant current voltage power source is recommended for flux-cored arc welding (FCAW) and gas metal arc welding (GMAW) to obtain code quality results.
For non-critical quality applications a constant current power source may be used.
The LN-15 comes factory equipped with a K1500-2
Tweco style #2-#4 gun bushing.
The “dual procedure” mode drops the wire feed speed
83% from the original set point. The voltage setting remains the same.
INPUT POWER
The DC voltage supplied from the power source is applied to the LN-15 through the electrode cable and the work sensing lead. The voltage is applied to the full wave bridge through a toroid assembly. When the
ON/OFF switch is put in the ON position the positive
DC voltage from the bridge is applied to the
Boost/Power Supply board through an M.O.V. assembly. This M.O.V. is needed to protect the Boost/Power board from inductive energy stored in the welding cables.
The Boost/Power Board takes the weld voltage and boosts it to 80VDC or the actual arc voltage being applied. (Whichever is greater). The outputs of the
Boost/Power board are two separate 80VDC+ supply voltages. One of these is utilized and regulated by the
Feed Head Control board to power the wire drive motor. The other 80VDC supply is regulated to create several plus and minus regulated DC supplies. These
+/-15VDC and +/-5VDC supplies are used to power the electronics within the Feed Head board and other components in the LN-15 such as the gas solenoid.
LN-15
E-3
ELECTRODE
INPUT VOLTAGE
WORK
SENSING
LEAD
TOROID
ASSEMBLY
FULL
WAVE
BRIDGE
ON/OFF
SWITCH
THEORY OF OPERATION
FIGURE E.3 – TRIGGER & CONTROL CIRCUITS
CONTACTOR
GAS
SOLENOID
"ELECTRODE"
FEEDBACK
VOLTAGE #67
FEED
PLATE
M
O
T
O
R
WELDING GUN
HALL
EFFECT
MODULE
ARMATURE
RPM FEEDBACK
E-3
MOV
BOOST
POWER
SUPPLY
BOARD
FEED HEAD
BOARD SUPPLY
DRIVE MOTOR
SUPPLY
FEED HEAD
CONTROL BOARD
"WORK" VOLTAGE FEEDBACK #21
SPI COMMUNICATIONS
SHIELDED CABLE
COLD
INCH
SWITCH
WIRE
FEED
SPEED
CONTROL
TRIGGER
INPUT &
PROCEDURE
TRIGGER
INTERLOCK
SWITCH
DISPLAY
BOARD
TRIGGER AND CONTROL CIRCUITS
When the gun trigger is closed (activated) the Feed
Head Board is “signaled” to apply armature voltage to the drive motor, activate the gas solenoid and close the LN-15 internal contactor. When the contactor is closed the welding current path from the electrode cable to the conductor block is completed.
This sequence will supply electrode wire, arc voltage and current to the welding gun.
The Cold Inch/Gas Purge Switch allows the user to feed wire without closing the contactor. This feature gives the operator an electrically “cold” electrode even though the power source’s output terminals are electrically “hot”. This switch also allows the user to activate the gas solenoid without feeding wire or closing the contactor.
When activated the Trigger Interlock Switch keeps the gun trigger circuit closed even when the operator releases the trigger. This is useful when making long welds.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
LN-15
E-4
ELECTRODE
INPUT VOLTAGE
WORK
SENSING
LEAD
TOROID
ASSEMBLY
FULL
WAVE
BRIDGE
.THEORY OF OPERATION
FIGURE E.4 – WIRE FEED SPEED CONTROL & FEEDBACK
CONTACTOR
ON/OFF
SWITCH
MOV
BOOST
POWER
SUPPLY
BOARD
FEED HEAD
BOARD SUPPLY
DRIVE MOTOR
SUPPLY
"WORK" VOLTAGE FEEDBACK #21
GAS
SOLENOID
"ELECTRODE"
FEEDBACK
VOLTAGE #67
FEED
PLATE
M
O
T
O
R
WELDING GUN
HALL
EFFECT
MODULE
ARMATURE
RPM FEEDBACK
FEED HEAD
CONTROL BOARD
SPI COMMUNICATIONS
SHIELDED CABLE
E-4
COLD
INCH
SWITCH
WIRE
FEED
SPEED
CONTROL
TRIGGER
INPUT &
PROCEDURE
TRIGGER
INTERLOCK
SWITCH
DISPLAY
BOARD
WIRE FEED SPEED CONTROL AND
FEEDBACK
The combination of the Procedure Switch and the Wire
Feed Speed control provide a command voltage for the Feed Head Control Board. The Hall Effect module
(Tach) monitors the motor RPM and outputs a digital voltage frequency “feed back” that is delivered to the
Feed Head Board. ule and the arc voltage. These three factors are compared and the appropriate armature voltage is applied to the wire feed motor to compensate for the varying arc lengths and associated arc voltages.
When operating in the constant voltage (CV) mode the
Feed Head Board monitors the feedback signal and compares it to the command voltage and delivers the appropriate armature voltage to the wire feed motor.
In this manner a constant wire feed speed is maintained.
When the LN-15 is connected to a constant current
(CC) power source a variable wire feed speed is desirable to compensate for the varying arc voltages associated with the constant current process. To accomplish this the Feed Head Board monitors the command voltage, the feed back signal from the Hall Effect mod-
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
LN-15
E-5
ELECTRODE
INPUT VOLTAGE
WORK
SENSING
LEAD
TOROID
ASSEMBLY
FULL
WAVE
BRIDGE
ON/OFF
SWITCH
MOV
THEORY OF OPERATION
FIGURE E.5 – DISPLAY BOARD
CONTACTOR
GAS
SOLENOID
"ELECTRODE"
FEEDBACK
VOLTAGE #67
FEED
PLATE
M
O
T
O
R
WELDING GUN
HALL
EFFECT
MODULE
ARMATURE
RPM FEEDBACK
E-5
BOOST
POWER
SUPPLY
BOARD
FEED HEAD
BOARD SUPPLY
DRIVE MOTOR
SUPPLY
FEED HEAD
CONTROL BOARD
"WORK" VOLTAGE FEEDBACK #21
SPI COMMUNICATIONS
SHIELDED CABLE
COLD
INCH
SWITCH
WIRE
FEED
SPEED
CONTROL
TRIGGER
INPUT &
PROCEDURE
TRIGGER
INTERLOCK
SWITCH
DISPLAY
BOARD
DISPLAY BOARD
The Display Board provides information to the user through digital displays and LED’s. The Display Board communicates with the Feed Head Board via the SPI
Bus cable.
The wire feed speed display shows the rate that the
LN-15 will feed wire during the welding process. The wire feed speed is calibrated to within +/-2%. It always displays the preset WFS.
The arc voltage display shows the average actual arc voltage during the welding process. When welding ceases the average arc voltage will continue to be shown for 5 seconds. When not welding the display show “----“. The voltage is calibrated to +/-2% over a range of 10 to 45VDC. A negative “-“ will be automatically displayed when the LN-15 is configured for electrode negative processes.
All of the LEDs will briefly light when the machine is first turned on.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
LN-15
E-6 NOTES E-6
LN-15
Section F-1 TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -
Section F-1
Troubleshooting & Repair Section ........................................................................Section F
PC Board Troubleshooting Procedures and Replacement...........................................F-3
Test Procedures
Replacement Procedures
Feedhead Control Board Removal and Replacement .........................................F-27
Boost Power Supply Board Removal and Replacement .....................................F-31
Wire Drive Assembly Removal and Replacement ................................................F-35
Cover & Spindle Mount Removal and Replacement............................................F-37
LN-15
F-2 TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
CAUTION
Service and repair should be performed by only 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.
F-2
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. Symptoms are grouped into three main categories: Feeding
Problems and Welding Problems.
Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of
Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.
Step 2. PERFORM EXTERNAL TESTS.
The second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.
All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
LN-15
F-3 TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.
CAUTION
Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:
1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.
2. Check for loose connections at the PC board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC board can be damaged by static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
- Remove your body’s static charge before opening the staticshielding bag. Wear an anti-static wrist strap. For safety, use a 1
Meg ohm resistive cord connected to a grounded part of the equipment frame.
- If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
F-3
- Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.
a. If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.
6. Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.
LN-15
F-4 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-4
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
Major physical or electrical damage is evident when the sheet metal cover(s) are removed.
The LN-15 does not “power-up” when the on/off switch is turned to the ”ON”position.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
1. Contact your local authorized
Lincoln Electric Field Service
Facility for assistance.
1. Make sure the correct input voltage is being applied (15 to
2. Make certain the “Work Clip” is attached securely to the work piece.
RECOMMENDED
COURSE OF ACTION
1. Contact the Lincoln Electric
Service Department,
1-888-935-3877.
1. Check the on/off switch. See the wiring diagram.
2. Check the input rectifier bridge.
See the wiring diagram.
4. The control board may be faulty.
5. If the Display Board is not lit check the input voltages to the
Display Board. See the Wiring
Diagram.
When the gun trigger is activated the wire drive runs and electrode wire feeds, but there is no welding output.
1. Make sure the contactor is functioning correctly.
2. Check the current carrying leads at the contactor and between the contactor and the feed plate for loose or faulty connections.
See the Wiring Diagram.
1. Perform The Contactor Test.
2. The Control Board may be faulty.
3. Make sure the welding gun is connected correctly and functioning correctly.
4. Make certain the DC power source is functioning correctly.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
LN-15
F-5 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-5
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
When the gun trigger is activated there is no wire feed.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
1. Check to see if the drive rolls are turning when the gun trigger is pulled. If the drive rolls are turning, then check for a mechanical restriction in the wire feed path.
2. If the drive rolls do not turn then check to make sure the correct DC voltage is being applied to the LN-15. (15-
110VDC).
3. Make sure the gun trigger is functioning correctly.
RECOMMENDED
COURSE OF ACTION
1. With the gun trigger circuit activated (see the Wiring Diagram) and the LN-15 set for constant voltage operation, check the presence of 2.6 to 27.4VDC at leads 550+ to 551-. This is the voltage that is applied to the wire drive motor. This voltage is dependent upon the wire feed speed setting.
2. If the correct voltage is being applied to the drive motor and the motor does not run the motor or motor brushes may be faulty.
3. If the correct voltage is not being applied to the drive motor the Control Board may be faulty.
The wire feeds for a short period of time but then stops feeding.
When the gun trigger is released then re-activated the wire resumes feeding but soon stops again.
1. The drive motor may be overloaded. Check the wire feeding path for mechanical restrictions.
2. While welding make certain the power source arc voltage is staying above 15VDC. The feeder will not function properly on less than 15VDC.
1. Check the motor armature current through either of the armature leads (550 or 551). It should not exceed 3.5 amps
DC.
2. If more than 3.5 amps is indicated, then the motor is drawing too much current. Check or replace the motor brushes.
3. If less than 3.5 amps is indicated and the motor is being disabled by the Control Board, then the Control Board may be faulty. Replace.
4. The motor or gearbox may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
LN-15
F-6 TROUBLESHOOTING & REPAIR F-6
PROBLEMS
(SYMPTOMS)
The wire stops or stubs while welding.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
1. If the LN-15 is connected to a constant current power source the arc voltage may be “dipping” below the 15VDC threshold that is essential for proper operation.
2. Try connecting the LN-15 to a constant voltage power source.
2. If the motor armature voltage is not correct then the Control
Board may be faulty.
3. Check for mechanical restrictions in the wire feeding path.
1. Monitor the motor armature voltage (leads 550 to 551).
Normal voltage range is 2.6VDC
to 27.4VDC dependent upon wire feed speed. If the armature voltage is correct then check or replace the motor brushes.
The wire feed speed range is only
50 to 374 IPM.(1.3 to 9.5m/min.
1. The 83%wire feed speed dual procedure is activated with the low speed gear.
1. Turn off the 83% procedure switch to return to the full wire feed speed range.
2. Check the wiring between the procedure switch and the control board. See the Wiring
Diagram.
3. The control board may be faulty.
Replace.
The wire feed speed range is only
50 to 600 IPM.(1.3 to 15.3 m/min)
1. The 83%wire feed speed dual procedures switch is activated with the high speed gear in place.
1. Turn off the 83% procedure switch to return to the full wire feed speed range.
2. Check the wiring between the procedure switch and the
Control Board. See the wiring diagram.
3. The Control Board may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
LN-15
F-7 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-7
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
The wire feed motor runs very fast and there is no control.
1. Make sure the LN-15 is operating in the CV mode.
2. Make sure the wire speed control and procedure switch are operating correctly. See the wiring diagram
1. Perform the Wire Drive Motor
2. Perform the Hall Effect Module
3. The Control Board may be faulty.
Replace.
The wire feed speed varies during welding but the meter reading remains constant.
1. The drive rolls may be slipping causing feeding problems.
2. The LN-15 may be in the
Constant Current mode. Verify on power-up that the LN-15 is set for Constant Voltage welding.
3. Reduce the spindle brake resistance.
1. Perform the Wire Drive Motor
2. Perform the Hall Effect Module
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
LN-15
F-8 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-8
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
No shielding gas.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
WELDING PROBLEMS
1. Make sure the gas supply is adequate and the gas hoses are not loose or kinked.
RECOMMENDED
COURSE OF ACTION
1. If the gas solenoid is not operat-
2. The Control Board may be faulty.
The shielding gas turns on sporadically, or remains on all the time.
1. The pressure in the gas line may have exceeded 80psi (5.5 bar)
1. Perform the Gas Solenoid Test.
2. The Control Board may be faulty.
The Display board shows “POS”
“PRE” or “BRN”.
1. The LN-15 is in the “Press and
Spin” set-up mode.
1. The Control board may be faulty.
2. The Display Board may be faulty.
2. One of the dip switches on the control board is set to “ON” for the timer setting mode.
1. The part being welded may be wet or very dirty.
There is porosity in the weld.
2. The electrode being used may be wet or rusty.
3. The shielding gas may be wrong for the process.
4. There may not be enough shielding gas.
5. Make sure the wire feed speed and arc voltage are correct for the process.
The welding arc burns back to the tip.
1. Check the wire feeding path for mechanical restrictions,
2. Make sure the polarity is correct for the process.
3. The contact tip may be worn.
4. The welding voltage may be set too high or the wire feed speed set too low.
5. Check the wire drive tension.
1. Perform the Wire Drive Motor
2. Perform the Hall Effect Module
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
LN-15
F-9 TROUBLESHOOTING & REPAIR F-9
FAULT CODES
0081
DESCRIPTION/
DEFINITION
Average motor over current shutdown
•
•
•
•
•
•
RESOLUTION
The wire drive motor has overheated.
Check to make sure the electrode slides easily through the liner of the gun.
Reduce the spindle brake resistance.
Reduce the amount of tension in the wire drive tension arm.
For the best results, use only Lincoln electrodes.
Wait 10 minutes for the wire feeder to cool.
0082
Locked rotor condition on the wire drive motor.
• Verify that nothing is jammed in the wire drive or gears.
0086
Trigger lockout.
•
•
•
The ripple of the power source OCV is too high, greater than 110V.
(Across the Arc Models only)
Verify that the power source is reconnected for the proper input voltage.
Repair or replace the power source.
The power source does not conform to NEMA.
NOTE:
If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board
LN-15
F-10 NOTES F-10
LN-15
F-11 TROUBLESHOOTING & REPAIR
BOOST POWER BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the correct input voltage is being applied to the Boost
Power Board and if the correct output voltage is being produced by the Boost Power
Board.
F-11
MATERIALS NEEDED
Volt/Ohm Meter
DC Voltage Source (15 to 110 VDC)
LN-15
F-12 TROUBLESHOOTING & REPAIR F-12
BOOST POWER BOARD TEST (continued)
TEST PROCEDURE
1. Remove input power to the LN-15.
6. Check for approximately 80 VDC at leads 501(+) to
2. Perform the Cover and Spindle Mount removal procedure.
7. Check for approximately 80 VDC at leads labeled
3. Locate the Boost Power Board. See Figure F.1.
4. Apply the correct DC voltage to the LN-15 (15-110
VDC).
8. If the correct input voltage is present in step 5 and either of the voltages in steps 6 or 7 are not present the Boost Power Board is faulty. Replace.
5. Check for the correct input voltage to the Boost
Power Board at leads 526A (+) to 527A(-) (15-110
VDC). See Figure F.3. If the input voltage is not
present check the input rectifier bridge and associiated circuits. See the wiring diagram.
FIGURE F.1 – BOOST POWER BOARD LOCATION
BOOST POWER BOARD
LN-15
F-13
J47
TROUBLESHOOTING & REPAIR
BOOST POWER BOARD TEST (continued)
FIGURE F.2 – BOOST POWER BOARD
+ -
C9
+ -
C10
R2 R1 R71 R72
F-13
FIGURE F.3 – PLUG J47 LEAD LOCATIONS
526A Neg.
Pos.
501 502 527A
LN-15
F-14 NOTES F-14
LN-15
F-15 TROUBLESHOOTING AND REPAIR
GAS SOLENOID VALVE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the gas solenoid valve is functional.
F-15
MATERIALS NEEDED
12 VDC Supply
Volt/Ohmmeter
DC Voltage Source (15 to 110 VDC)
LN-15
F-16 TROUBLESHOOTING AND REPAIR
GAS SOLENOID VALVE TEST
(continued)
FIGURE F.4 – LEADS 552 & 553
LEADS 552 &553
F-16
GAS SOLENOID
TEST PROCEDURE
1. Remove power to the LN-15 machine.
2. Perform the Cover and Spindle
3. Locate and remove the two solenoid leads 552 & 553 from the solenoid valve. See Figure F.4.
4. Make sure the gas supply for the solenoid is hooked up, and then apply
12 VDC to the gas solenoid.
5. If the solenoid activates and allows gas flow, then the solenoid valve is good.
NOTE: There should not be any gas flow until the solenoid is activated.
6. If the solenoid does not activate and allow gas to flow, then the solenoid is faulty. Replace.
7. The normal solenoid resistance is approximately 20 to 21 ohms.
8. Normal voltage (with gun trigger activated) measured at the solenoid is 6.5 VDC (leads 552 & 553).
9. If the voltage is not present at leads
552 & 553 the feed head control board may be faulty.
LN-15
F-17 TROUBLESHOOTING AND REPAIR
CONTACTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the contactor is functional.
F-17
MATERIALS NEEDED
12 VDC Supply
Volt/Ohmmeter
LN-15
F-18 TROUBLESHOOTING AND REPAIR
CONTACTOR TEST
(continued)
FIGURE F.5 – CONTACTOR
LEADS 507 & 578 (blue)
LARGE TERMINAL
STUDS
F-18
TEST PROCEDURE
1. Remove input power to the LN-15.
2. Perform the Wire Drive Assembly removal procedure.
3. Locate the contactor and leads 507 and 578 (blue) and separate the two in line connectors. See Figure F.5.
4. Apply 12 VDC to the contactor coil leads.
CAUTION
Do not leave the 12 VDC applied to the contactor coil for a prolonged period of time (15 seconds maximum). Damage to contactor may result.
5. If the contactor does not activate when the 12 VDC is applied, the contactor is faulty. Replace.
Note: The normal contactor coil resistance is approximately 4.4 ohms.
6. If the contactor activates when the 12
VDC is applied, check the resistance between the two large terminal studs with the contactor activated. The resistance should be very low (0 to
1 ohm).
7. If the resistance is “high” or “open” between the two large terminal studs when the contactor is activated, the contactor is faulty. Replace.
8. If the contactor activates and the resistance between the terminals is low when the 12 VDC is applied, the contactor is good.
NOTE: When the contactor is not activated, the resistance between the terminals should be very high (infinite). If the resistance is always low, the contacts are “stuck” and the contactor is faulty. Replace.
LN-15
F-19 TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the Wire Drive Motor is functioning properly.
F-19
MATERIALS NEEDED
Voltage Source (variable 3 to 26 VDC)
Volt/Ohmmeter
LN-15
F-20 TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST (Continued)
Figure F.6- Motor Leads
F-20
LEADS
550 & 551
TEST PROCEDURE
1. Remove the input power to the LN-15.
2. Perform the Wire Drive Assembly
3. Locate the Positive lead 550 (white) and disconnect from motor. Note pin location for reassembly. See Figure
F.6.
4. Locate the Negative lead 551 (gray) and disconnect from motor. Note pin location for reassembly.
See
Figure F.6.
5. Apply a variable DC voltage to the drive motor from lead 550(white)(+) to lead 551(gray)(-).
6. When the supply voltage is varied from 3 to 26 VDC, the drive motor speed (RPM) should vary accordingly.
If the motor does not run or vary in speed, the motor, gearbox or motor brushes may be faulty. Check or replace.
7. Check the resistance between each of the motor leads and the motor case. The resistance should be very high (at least 500,000 ohms). If the resistance is low, the motor is grounded to the motor case and should be replaced.
LN-15
F-21 TROUBLESHOOTING AND REPAIR
HALL EFFECT MODULE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the Hall Effect Module is functioning properly.
F-21
MATERIALS NEEDED
Voltage Source (variable 15 to 110 VDC)
Volt/Ohmmeter
LN-15
F-22 TROUBLESHOOTING AND REPAIR
HALL EFFECT MODULE TEST (Continued)
Figure F.7 - PLUG J2 LEAD LOCATION
Blue
(562)
Red
(563)
F-22
TEST PROCEDURE
1. Remove the input power to the LN-15.
2. Perform the Wire Drive Assembly
3. Locate the three Hall Effect leads at
Plug J2. See Figure F7.
4. Apply at least 15VDC but no more than 115VDC to the LN-15 from the electrode cable to the work sensing lead.
5. Check for the presence of 5VDC from lead 563 (Red+) to lead 561 (Black-).
If the 5VDC is not present or low, the feed head control board may be faulty.
6. Activate the LN-15 trigger circuit, make sure the drive motor is running and check for the presence of approximately 2.8VDC from lead 562
(Red+) to lead 561 (Black-). The value of 2.8VDC represents the correct feedback voltage from the Hall
Effect device to the control board.
Black
(561)
This value can also be measured using a frequency counter
50 in./min. = 120 HZ
700 in./min. = 1.6 KHZ
7. If the above voltage reading is not correct, the Hall Effect device may be faulty.
LN-15
F-23 TROUBLESHOOTING AND REPAIR
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE
F-23
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the contactor.
MATERIALS NEEDED
7/16” Wrench
3/4” Wrench
11/16” Wrench
Screwdriver
LN-15
F-24 TROUBLESHOOTING AND REPAIR F-24
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.8 - CONTACTOR LEAD LOCATION
Divider Plate
7/16" Bolts
Welding Cable
Copper Bus Bar
Leads 567 & 567A
3/4" Nut
REMOVAL PROCEDURE
1. Remove the input power to the LN-15.
2. Perform the Roll Cage Removal
3. Perform the Wire Drive Assembly
4. Remove the two rubber roll cage mounts that hold the contactor assembly to the case bottom.
5. Using the 3/4” wrench remove the welding cable from the contactor assembly stud. See Figure F.8. Also leads 567 & 567A.
6. Disconnect the two coil leads at their in line connectors.
7. Disconnect and clear ground leads as necessary.
8. Using the 7/16” wrench remove the two bolts mounting the contactor assembly to the divider plate. See
Figure F.8.
9. Carefully remove the contactor assembly from the LN-15.
10. Using the 11/16” wrench remove the cable and copper bus bar from the contactor.
11. The contactor may now be removed by using the screwdriver to remove the four screws mounting the contactor to the mounting plate.
LN-15
F-25 TROUBLESHOOTING AND REPAIR F-25
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (Continued)
REPLACEMENT PROCEDURE
1. Install the new contactor using the four screws previously removed.
2. Replace the copper bus bar and cable.
3. Install the the contactor assembly into the case.
4. Using the 7/16” wrench mount the contactor assembly to the divider plate.
5. Install the two rubber mounts previously removed.
6. Connect the two coil leads.
7. Connect all group leads previously removed.
8. Using the 3/4” wrench replace the welding cable and lead 567 and 567A.
9. Replace the wire drive assembly.
10. Replace the roll cage.
LN-15
F-26 NOTES F-26
LN-15
F-27 TROUBLESHOOTING AND REPAIR
FEED HEAD CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Feed head
Control Board.
F-27
MATERIALS NEEDED
3/8” Wrench
LN-15
F-28 TROUBLESHOOTING AND REPAIR
FEED HEAD CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.9 - FEED HEAD CONTROL BOARD LOCATION
F-28
FEEDHEAD CONTROL BOARD
REMOVAL PROCEDURE
1. Remove input power to the LN-15.
2. Perform the Cover and Spindle
3. Locate the Feed head Control Board.
and plugs J81, J82, J83, J84, J85, J86
and J88. See Figure F.9 & See Figure
4. Remove the seven plugs from the board taking note of placement for reassembly.
5. Using the 3/8” wrench remove the four nuts holding the board in place.
6. Carefully remove the Feed head
Control Board.
REPLACEMENT PROCEDURE
1. Set the new Feed head Control Board on the four mounting studs.
2. Secure with the four nuts previously removed.
3. Replace the seven plugs previously
4. Replace the Cover and Spindle mount.
LN-15
F-29 TROUBLESHOOTING AND REPAIR
FEED HEAD CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.10 - FEED HEAD CONTROL BOARD
3/8" Mounting
Nuts
F-29
J81
J82
J83
J84
J88
J85
3/8" Mounting
Nuts
J86
LN-15
F-30 NOTES F-30
LN-15
F-31 TROUBLESHOOTING AND REPAIR
BOOST POWER SUPPLY BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Boost Power
Supply Board.
F-31
MATERIALS NEEDED
3/8” Wrench
LN-15
F-32 TROUBLESHOOTING AND REPAIR
BOOST POWER SUPPLY BOARD
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.11 - BOOST POWER BOARD LOCATION
F-32
BOOST POWER BOARD
REMOVAL PROCEDURE
1. Remove input power to the LN-15.
2. Perform the Cover and Spindle
3. Locate the Boost Power Supply Board.
See Figure F.11.
4. Disconnect plug J47. See Figure F.12.
5. Using the 3/8” wrench remove the three nuts holding the board in place.
6. Carefully remove the Boost Power
Supply Board.
REPLACEMENT PROCEDURE
1. Set the new Board on the mounting studs.
2. Secure with the three nuts previously removed.
3. Replace plug J47 previously removed.
4. Replace the Cover and Spindle mount.
LN-15
F-33 TROUBLESHOOTING AND REPAIR
BOOST POWER SUPPLY BOARD
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.12 - BOOST POWER BOARD PLUG/MOUNT LOCATION
3/8" Mounting
Nut
F-33
J47
+ -
C9
+ -
C10
R2 R1 R71 R72
3/8" Mounting
Nuts
LN-15
F-34 NOTES F-34
LN-15
F-35 TROUBLESHOOTING AND REPAIR
WIRE DRIVE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Wire Drive
Assembly.
F-35
MATERIALS NEEDED
3/8” Wrench
3/4” Wrench
Screwdriver
Small Pliers
LN-15
F-36 TROUBLESHOOTING AND REPAIR
WIRE DRIVE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.13 - WIRE DRIVE MOUNTING SCREW LOCATION
F-36
MOUNTING SCREWS
REMOVAL PROCEDURE
1. Remove input power to the LN-15.
2. Open door.
3. Remove the four screws mounting the wire drive assembly to the case. See
Figure F.13.
4. Using small pliers disconnect the gas hose from the conductor block.
5. Carefully maneuver the drive assembly out of the case.
6. Using the 3/4” wrench remove the cable from the conductor block.
7. Remove lead 67 from the conductor block. See Wiring Diagram.
8. Remove plug J2.
REPLACEMENT PROCEDURE
1. Connect previously removed plug J2 to the new conductor block.
2. Replace lead 67 into the conductor block.
3. Replace the cable onto the conductor block.
4. Replace the gas hose onto the conductor block.
5. Carefully maneuver the Wire Drive
Assembly into the case.
6. Secure assembly to machine using the four previously removed screws.
LN-15
F-37 TROUBLESHOOTING AND REPAIR
COVER AND SPINDLE MOUNT
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Cover and
Spindle Mount Assembly.
F-37
MATERIALS NEEDED
3/8” Wrench
1/2” Wrench
Large Pliers
LN-15
F-38 TROUBLESHOOTING AND REPAIR
COVER AND SPINDLE MOUNT
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.14 - COVER AND SPINDLE MOUNT LOCATION
F-38
Cord Grip Nut
Spindle Mount
Cover
REMOVAL PROCEDURE
1. Remove input power to the LN-15.
2. Open door.
3. Locate the spindle mount and cover assembly. See Figure F.14.
4. Using the 1/2” wrench remove the one bolt from the top of the cover.
5. Using the 3/8” wrench remove the five
mounting screws. See Figure F.15.
6. Using the large pliers loosen and remove the cord grip nut. See Figure
F.14.
7. Pull the electrode cable inward through the rear case.
8. Disconnect the gas hose from the conductor block on the Wire Drive
Assembly.
9. Carefully remove the cover and spindle assembly from the case. Be careful not to damage the switches, leads or solenoid.
10. If complete removal is necessary disconnect the leads from the switches and solenoid. Be sure to label for reassembly.
LN-15
F-39 TROUBLESHOOTING AND REPAIR
COVER AND SPINDLE MOUNT
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.15 - COVER AND SPINDLE MOUNT SCREW LOCATION
1/2" Bolt
F-39
Screw
Screw
Screw
Screw
Screw
REPLACEMENT PROCEDURE
1. Replace all leads to switches and solenoid.
2. Maneuver assembly into case.
3. Connect gas hose to conductor block.
4. Replace five mounting screws.
5. Replace bolt into top of case.
6. Replace the electrode cable into the cord grip. Replace and tighten the nut.
LN-15
F-40 NOTES F-40
LN-15
F-41 TROUBLESHOOTING AND REPAIR
ROLL CAGE
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Roll Cage.
F-41
MATERIALS NEEDED
7/16” Wrench
LN-15
F-42 TROUBLESHOOTING AND REPAIR
ROLL CAGE
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
Figure F.16 - ROLL CAGE BOLT LOCATION
1/2" Bolt
F-42
7/16" Bolts
REMOVAL PROCEDURE
1. Remove input power to the LN-15.
2. Using a 7/16” Wrench remove the five bolts securing the roll cage to the LN-
15 case.
3. Carefully remove the roll cage.
LN-15
F-43 TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
F-43
If a failed test indicates that any mechanical part that could affect the machine’s electrical characteristics must be replaced or if any electrical components are repaired of replaced, the machine must be retested and meet the following standards.
Wire Feed Speed...................................... 50 thru 700 inches per minute
Gas Solenoid............................................. Must operate when gun trigger is activated
Contactor................................................... Must operate when gun trigger is activated
LN-15
F-44 NOTES F-44
LN-15
Section G-1 TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -
Section G-1
Electrical Diagrams ...............................................................................................Section G
* NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unserviceable. The Assembly drawings are provided for reference only.
LN-15
G-2
WIRING DIAGRAM - ENTIRE MACHINE - (L11436-1)
436-1 L11
ENGINEERING CONTROLLED
MANUFACTURER:
No
CHANGE DETAIL: RELEASED A.02 FROM "X"
ELECTRICAL DIAGRAMS
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
J81,J82
1
3
2
4
J83,J88
1
4
J1,J86
1
6
5
10
3
J2,J47,J84
6
J85,J87
9
1
1
5
8
16
8
4
LN-15 ACROSS THE ARC MODEL
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
COLOR CODE
B -
W -
R -
U -
BLACK
WHITE
RED
BLUE
150V, 300J
L1
N.C.
ON / OFF SWITCH
526B
526C
S3
BAFFLE
MOUNTED
RECTIFIER
DIODE
BRIDGE
21A
-
21B
526
MOV ASBLY
567
526C
527
L3
W
B
W B
MOTOR /
GEARBOX
MOV ASBLY
320V, 150J
TACH.
R
U
B
320V, 150J
67
L2
.0047/.005 mF,
1400VDC
FEED
PLATE
1M W
L4
N.A.
POWER SUPPLY P.C. BOARD
J47
526A
1 2 3 4 5 6 7 8
NEG 501
POS 527A
502
501
N.B.
R
U
B
1
4
5
2
3
6
7
8
J2
GND-A
GAS
SOLENOID
552
553
L6
CONTACTOR
507
578
GND-B
GND-D
N.C.
10K2W
WIRE FEED
SPEED
CONTROL
POTENTIOMETER
1
2
3
577
576
575
502
501
NEG
550
551
552
553
507
POS
1
2
3
4
5
6
1
2
3
4
1
2
3
4
J81
J82
J83
CONTROL P.C. BOARD
J88
1
2
3
4
5
6
L5
563
561
575
576
562
577
1
2
3
4
5
6
7
8
J84
J87
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
J85 J86
1 2 3 4 5 6 7 8 9 10 111213 14 15 16 1 2 3 4 5 6 7 8 9 10
556
554 555 587 589
559
512 558
21A
KEYING PLUG
67
578
N.A.
SHIELDED CABLE
DRAIN LEAD
21
TO
WORK
567A
567
TRIGGER
INPUT
83%
PROCEDURE
INPUT
GND-C
J3
A
B
C
D
E
554A
TRIGGER
CONNECTOR
N.B.
556
554
555
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.
N.C. TOGGLE SWITCHES AND POTENTIOMETERS SHOWN FROM CONNECTION SIDE OF SWITCH.
INPUT ELECTRODE
CABLE CONNECTION
558
512
559
COLD INCH/
GAS PURGE
S1
N.C.
1 2 3 4 5 6 7 8 9 10
DISPLAY P.C. BOARD
589
587
2-STEP
TRIGGER
INTERLOCK
J1
N.C.
S2
A
L11436-1
CLEVELAND, OHIO U.S.A.
PROPRIETARY & CONFIDENTIAL:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE t
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPROVED:
TJP/KJ
E. ENYEDY
REFERENCE:
L11436
SCALE:
1:1
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
SEMI-AUTOMATIC WIRE FEEDER
LN-15 WIRING DIAGRAM ACROSS THE ARC
APPROVAL
DATE:
5/23/03
PROJECT
NUMBER:
CRM35166
DOCUMENT
NUMBER:
L11436-1
DOCUMENT
REVISION:
A
STRP
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-2
LN-15
G-3
SCHEMATIC - ENTIRE MACHINE - (G4198-1)
8-1 G419
ENGINEERING CONTROLLED RELEASED A.03 FROM "X"
MANUFACTURER: No
General Notes: x Codes 10864,11033 & 11035 do not support the high/low speed gear change. Only the high speed (1.8" diameter) gear may be used.
Error
Code
Description
Err 0081 Average motor Overcurrent shutdown
Err 0086 Trigger lockout
Cause and Remedy
The wire drive has exceeded the current rating:
10 amps for 0.5 seconds or
3.5 amps for 10 seconds.
Wait 45 seconds for the error to reset.
Reduce the current load on the motor by:
Verifying the electrode slides easily through the liner of the gun.
Reduce the spindle brake resistance.
Reduce the amount of tension in the wire drive pressure arm.
Use only Lincoln electrodes.
The voltage into the feed head board exceeds 150
VDC.
Some inverters and choppers may have spikes on the output that charge the capacitors inside the LN-15 beyond limits. If this error occurs, lower the OCV of the power source. It may be likely that a different power source is required.
WFS Display
Voltage Display
Voltage LED
SPI DISPLAY L11757-1
YELLOW
RED RED
RED RED
Not Used
The display board communicates to the feedhead board through the SPI bus. Only the power supply signals can be monitored during servicing.
The WFS always shows the present WFS.
The voltage display shows the voltage while welding, plus holds the voltage for 5 seconds after the weld. It shows "- - -" when idle. A negative
"-" sign will automatically be shown when welding with reverse polarity procedures.
All the LEDs, including those not used, will briefly light on power up. The
LED's not used are visible behind the nameplate when lit.
15-110 VDC from welding power source
All LED’s light briefly
Show CC/CV mode and HI/LO gear
ELECTRICAL DIAGRAMS
LN-15 ACROSS THE ARC MODEL
Boost Board
Wire Drive
Circuit
Gas Solenoid
Circuit
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
J81,J82
1
3
2
4
J83,J88
1
4
J1,J86
6
1 5
10
3
6
J2,J47,J84
1
J85,J87
9
1
5
8
16
4
8
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
COLOR CODE
B -
W -
R -
U -
BLACK
WHITE
RED
BLUE
Positive
Voltage
Feedback
Input
Power
Circuit
ON/OFF
SWITCH
Input
526B
526C
Voltage
TOROID
Protection
67 FEEDPLATE
Schematic M19752
Located on the right side of the control box.
21A
Common to '-' input enabling circuit
- INPUT
COM
ISOLATION
SWITCH (FET)
Boost
Circuit
COM
COM
J47
8
7
6
5
4
3
2
1
BOOST BOARD
The boost board takes the weld voltage and boosts it to 80VDC for the rest of the LN-15. There are two supplies on the boost board, one for the motor and the other for the feedhead board. With two supplies, even if the motor supply should droop because of heavy loads, power to the feed head board is not affected.
The rectifier allows the LN-15 to be powered either electrode positive or electrode negative without any switches for the customer to set.
502
501
POS
NEG
526A
527A
This large MOV absorbs the inductive energy in the weld cables and power source when the contactor opens.
Located under the cover in the control box ably.
150V, 300J
BRIDGE
RECTIFIER
526B
526
MOV ASBLY
Located in the control box next to the Feedhead board.
21B
TOROID
-
567
526C
COM
FEEDHEAD SUPPLY
MOTOR SUPPLY
COM
80VDC or weld voltage, whichever is higher
502
NEG
501
POS
+ Vin
J81
1
2
3
4
J83
6
J82
3
4
1
2
J 8 1 4
J 8 2 4
J 8 3 5
J 8 3 6
J 8 1 3
J 8 2 3
INPUT VOLTAGE MONITOR
(MOTOR FETS ARE BOTH
OFF WHEN INPUT VOLTAGE
DROPS BELOW 20V)
+ V i n
+ motor
1200uF
+ MOTOR
DRIVE
COM
PWM
MOTOR
CONTROL
+
V i n
-
+ MOTOR
P O W E R
S U P P L Y
AVERAGE
CURRENT
LIMITING
M O T O R S
V O L T A G E
U P P L Y
M O N I T O R
+ 5 V
+15V
-15V
-5V
+5V(TA C H )
+5 V
527
15- 110 VDC
W B
MOTOR /
GEARBOX
TOROID
2.6 VDC @ 50 in/min
27.4 VDC @ 700 in/min
8 sec average Current limit = 3.5 Amps
(Limit is software set)
Located behind the insulating wire drive panel. Remove the wire drive ably to gain access.
MOV ASBLY
Not a PC board; no schematic.
Located behind the wire drive
1M ohms
320V, 150J
320V, 150J
TOROID
BRAKE
Measure B to U
120 Hz @ 50 in/min
1.6 kHz @ 700 in/min
TACH.
J2
8
7
552
553
GAS
SOLENOID
6.5 VDC when gas flowing
Motor +
550
Motor -
Gas Solenoid -
551
Gas Solenoid +
552
553 see power
Coil measures 21 ohms supply section molex
Located under the cover at the rear of the feeder
15 VDC Tach Supply
563
R
U
B
1
4
5
2
3
TOROID 6
Access this connector by removing the wire drive asbly.
WIRE FEED SPEED 10K Ohms
CONTROL
POTENTIOMETER
Located on the case front. Remove the wire
3-1/2 turns
1
2
3 drive asbly to gain access.
GND-B
Tach Signal
N.C.
562
Tach COM
561
Wiper to COM
5 VDC at 700 ipm
0 VDC at 50 ipm
577 POT Supply
576 Wiper
575
COM
GND-A
J83
1
8
6
2
3
4
J84
1
2
3
7
4
J84
5
+15V
+5V (TACH)
TACH INPUT
COM
COM
WFS
ANALOG
INPUT
A=1
A=1
COM
+5V
+15V
2 k
4 .
7 5 k
C OM
2k
4.75k
COM
INTERNAL
SWITCH
INPUTS
2 k
C O M
4 .
7 5 k
+ 1 5 V
5
4 .
0 0
7 5 k
PULSE BY PULSE
PEAK CURRENT
LIMIT (27 AMPS) gas solenoid
PWM control ckts
E X T E R N A L
I
S
N
W I
P
T
U
C H
T S
5 0 0
4 .
7 5 k
COM
5 0 0
4 .
7 5 k
CPLD
MICRO
CONTROLLER
For programming at LECo factory only.
Not field reprogrammable.
J87
FEED HEAD CONTROL
P.C. BOARD
Schematic G3883
+
-
ARC VOLTAGE
FEEDBACK
IN PUT
1M
78k
78k
+ V i n
J86
1M
PWM
CONTROL
FOR
CONTACTOR
SPI
CKTS
J88
4
40 k
1
J83
5
J88
5
67
21A
4.5 A PEAK
CURRENT
LIMIT
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.
N.C. TOGGLE SWITCHES AND POTENTIOMETERS SHOWN FROM CONNECTION SIDE OF SWITCH.
21
WORK
CLIP
Pigtail
567A
INPUT ELECTRODE
CABLE CONNECTION
.0047/.005 mfd,
1400VDC
WFS
Control
Circuit
Bussbar from input stud to contactor
Contactor
The contactor is located behind the glastic panel next to the motor.
CONTACTOR
300A 60%
250A 100%
Coil measures 4.4 ohms.
578
0 VDC Open
2.3 VDC Closed
12 VDC coil
PWM Controlled
507
GND-C
5
6 7 8
9
10 11 13 14 15
16
12
4 1
2
3 J85
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16
1
2 3 4 5
6 7 8 9 10
512
559
558
587 589
2 Step Trigger TRIGGER
15 VDC for 2 Step
INTERLOCK
0 VDC for Interlock
589
587
Gas Purge
15 VDC when Purge OFF
0 VDC when Purge ON
2-STEP
554 555
556
Trigger
15 VDC when Trigger and 83%
Switch Open
9 VDC when Trigger Open, 83%
Switch Closed
0 VDC when Trigger Closed
S2
556
554
555
83% Procedure Input
0 VDC Normal
9 VDC 83% switch Closed and Trigger Open
554A
TRIGGER
CONNECTOR
J3
Located on the lower left of the front of the case.
A
GUN
TRIGGER
B
C
D
INPUT
83%
PROCEDURE
E
INPUT
The 83% procedure reduces the
WFS to 83% of the set point, but no less than 50 in/min. It is used most often when pipe welding.
COLD INCH/
GAS PURGE
SHIELDED CABLE
DRAIN LEAD
558 (BLK)
512
559 (RED)
Cold Inch
15 VDC when Inch OFF
0 VDC when Inch ON
S1
1 2 3 4 5 6
7
8 9 10
J1
DISPLAY P.C. BOARD
Schematic L11756-x
N.A.
Enter Press and
Spin Mode
Idle:
Display WFS, “---”
Wire Drive: OFF
Gas Solenoid: OFF
Model Ranger 8,9 Classic
K1870-1,-2 Across the Arc
Recommended all CV operation.
Recommended for CV operation. (Wire
Feed Module
Required)
Ranger 250, 305
Commander 300,400,500
(Common Analog
Controls)
Recommended for CV operation.
V350
(Common Digital
Controls)
Recommended for
CV operation.
DC-400, 600
Recommended for CV and CC operation.
Square Wave TIG
300/355
Not recommended for CC operation because the customer may experience short contactor life from inductive nature of the power source.
Miller Inverters
Recommende d for CV voltage sense operation.
STT II
Not recommended for STT operation.
Note:
Most semiautomatic wire welding processes perform better using constant voltage power sources.
Be sure the proper power source is used for your application.
Contactor life may be shortened in applications using CC machines with high
OCV.
Interlock
Circuit
Inch/Purge
Circuit
Gun Trigger
Circuit
Display
Board
Circuit
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: LN-15 (ACROSS THE ARC)
DRAWN BY: E. ENYEDY/KJ G4198
ENGINEER:
APPROVED:
E. ENYEDY SCALE:
NONE
SUBJECT:
MATERIAL
DISPOSITION:
NA
MACHINE SCHEMATIC
APPROVAL
05/27/2003
DATE:
PROJECT
NUMBER:
CRM35166
DOCUMENT
NUMBER:
G4198-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
DOCUMENT
REVISION:
A
G-3
LN-15
G-4
SCHEMATIC - BOOST PC BOARD - (L11818-2)
ELECTRICAL DIAGRAMS G-4
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
LN-15
G-5
PC BOARD ASSEMBLY - BOOST - (M19753-2)
-2 753 M19
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: REVISED ITEM 4 WASHER
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY.
SEE E2454 BEFORE HANDLING.
N.B. MODULE IDENTIFICATION LABEL TO BE PLACED IN THIS AREA.
N.C. MOLEX CAVITES AND AREA AROUND LOCKING TAB TO BE FREE OF POTTING MATERIAL. MASK PER
APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
N.D. TORQUE TO 3.0 in. lbs. +/-10%.
N.E. ENCAPSULATE TO WITHIN .10 OF TRAY TOP. WHILE APPLYING ENCAPSULATION, APPLY SOME
OVER THE TOP OF ITEM 11.
N.F. PRINT “M19753-[ ] “ (LATEST DASH NUMBER AND I.D. CODE) BOARD LABEL.
N.G. ASSEMBLE ITEMS 1 THROUGH ITEMS 4 AS SHOWN. TORQUE MODULE TO 15-20 IN. LBS.
N.H. ASSEMBLE P.C. BOARD WITH CAPACITORS LOCATED AS SHOWN.
P.C. BOARD BLANK INFORMATION
BUY COMPLETE AS M19753-K (4 LAYER BOARD PER E3281)
(MAKES 8 BOARDS PER PANEL. SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
PANEL SIZE PER E1911
N.G.
1
6
N.B.
12
5
N.G.
3
N.G.
2
N.F.
N.H.
8
4
ELECTRICAL DIAGRAMS
N.C.
R19
L1
C9 C10
FTP6
TP1
C1
R2 R1
R71
TP2
C3
R75
R73
R74
R8
X1
R21
C5
FTP7
C6
DZ6
X2
C14
BOOST SUPPLY
M19753-
2
FTP8
Q1
C26
R72
A1
10 11
N.G.
4
ISO VIEW
REFERENCE ONLY
N.A.
ITEM
C1,C11
C3,C7,C14,C28
C4
C5,C6
C8,C12
C9,C10
C21,C26,C29
C24
D1
D2,D6,D7,D8,D9
DZ1
DZ2,DZ9
DZ6,DZ8
DZ7
FTP4,FTP5,FTP6,FTP7,FTP8
J47
L1
Q1
Q5,Q6,Q7
R1,R2,R71,R72
R5,R10
R6
R7,R52
R8
R9,R20
R11
R12
R14,R15,R16
R17,R18,R19
R21
R37,R38
R39,R40,R64,R65,R66,R67
R51
R55
R60
R61,R73,R74,R75
R62
R63
R68
R69
R70
TP1,TP2
X1
X2
REQ'D
1
2
3
3
1
1
1
2
3
4
1
1
2
1
2
5
1
2
1
1
2
1
5
3
1
2
2
2
4
1
2
1
1
4
1
1
1
6
1
1
1
2
1
1
PART NO.
DESCRIPTION
S13490-173
S16668-11
S16668-2
S16668-10
S13490-197
S13490-195
S16668-5
T11577-38
CAPACITOR,PEMF,1.0,63V,10%
CAPACITOR,CEMO,0.1, 50V,10%
CAPACITOR,CEMO,47P, 100V,5%
CAPACITOR,CEMO,4700P, 50V,2%
CAPACITOR,ALEL,82,35V,20%,LOW-ESR
CAPACITOR,ALEL,1200,160V,20%
CAPACITOR,CEMO,.022,50V,20%
CAPACITOR,CD,.02,600V,+80/-20%
T12705-23
T12705-34
T12702-58
T12702-45
DIODE,SCHOTTKY,AXLDS,1A,30V,1N5818
DIODE,AXLDS,1A,400V,FR,1N4936
ZENER DIODE,5W,16V,5% 1N5353B
ZENER DIODE, 1W,18V,5% 1N4746A
T12702-29
T12702-27
ZENER DIODE, 1W,15V,5% 1N4744A
ZENER DIODE, 1W,10V,5% 1N4740A
TESTPT_FUNTION FUNCTIONAL TEST POINT
S24020-8 CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
T12218-14
T12704-72K2
T12704-68
S25365-00R1
S19400-1002
S19400-9092
S19400-1821
S19400-20R0
S19400-2673
S19400-4321
S19400-2213
S25365-3300
S19400-8251
S19400-5622
S19400-3322
CHOKE,470UH,10%,11.4A,RADIAL
MOSFET/HEATSINK ASBLY,T12704-72&S20590-2(SS)
TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
RESISTOR,STAND-UP,WW,5W,0.1,5%
RESISTOR,MF,1/4W,10.0K,1%
RESISTOR,MF,1/4W,90.9K,1%
RESISTOR,MF,1/4W,1.82K,1%
RESISTOR,MF,1/4W,20.0,1%
RESISTOR,MF,1/4W,267K,1%
RESISTOR,MF,1/4W,4.32K,1%
RESISTOR,MF,1/4W,221K,1%
RESISTOR,STAND-UP,WW,5W,330,5%
RESISTOR,MF,1/4W,8.25K,1%
RESISTOR,MF,1/4W,56.2K,1%
RESISTOR,MF,1/4W,33.2K,1%
S19400-1003
S19400-1000
S19400-1503
S19400-3321
S19400-47R5
S19400-6810
S19400-2211
S19400-1004
S19400-7501
S19400-4753
T13640-24
M15458-8
S15128-4
RESISTOR,MF,1/4W,100K,1%
RESISTOR,MF,1/4W,100,1%
RESISTOR,MF,1/4W,150K,1%
RESISTOR,MF,1/4W,3.32K,1%
RESISTOR,MF,1/4W,47.5,1%
RESISTOR,MF,1/4W,681,1%
RESISTOR,MF,1/4W,2.21K,1%
RESISTOR,MF,1/4W,1.00M,1%
RESISTOR,MF,1/4W,7.50K,1%
RESISTOR,MF,1/4W,475K,1%
MOV,175VRMS,120J,20MM
IC,PWM-CONTROLLER,IMODE,2843A
OP-AMP,QUAD, GEN-PURPOSE,224N
G-5
7
N.D.
MANUFACTURED AS:
M19753-2K0
IDENTIFICATION CODE
MAKE PER E1911& E3875
TEST PER E4036-BT
ENCAPSULATE WITH ITEM 9
SCHEMATIC REFERENCE: L11818-2K0
ITEM PART NO.
DESCRIPTION
N.A.
1 M19996
2 S25347-1
HEAT SINK
THERMAL INTERFACE PAD
3 M16100-57 ELECTRONIC MODULE ASBLY
CF000012 1/4-20X.50HHCS
4 T12735-3 SPRING WASHER
CF000017
5 S25346-1
6 M19436-8
7 S8025-96
1/4-20 HN
GASKET
POTTING TRAY
SELF TAPPING SCREW
8 SEE ABOVE BOOST PC BD BLANK
* 9 E2527 EPOXY ENCAPSULATING RESIN
10 S20590-2
11 S25253-1
N.B., N.F.
12 E3768-4
HEAT SINK
HEAT SINK MOUNTING CLIP
LABEL
* THESE ITEMS NOT SHOWN
1
1
2
QTY
1
1
2
2
2
1
1
2
1
1
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: LN-15
DRAWN BY: FEI M19753-1
ENGINEER:
APPROVED:
SCALE:
1:1
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
BOOST BD HEATSINK ASBLY
05/12/2003
PROJECT
NUMBER:
CRM22115-EF
DOCUMENT
NUMBER:
M19753-2
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
DOCUMENT
REVISION:
C
STRP
LN-15
G-6
SCHEMATIC - FEEDHEAD P.C. BOARD - (G3883-1E0/1)
ELECTRICAL DIAGRAMS G-6
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
LN-15
G-7
SCHEMATIC - FEEDHEAD P.C. BOARD - (G3883-1E0/2)
ELECTRICAL DIAGRAMS G-7
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
LN-15
G-8
PC BOARD ASSEMBLY - FEEDHEAD - (G3884-1)
ELECTRICAL DIAGRAMS G-8
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
LN-15
G-9
SCHEMATIC - SPI DISPLAY P.C. BOARD - (L11756-1E1)
ELECTRICAL DIAGRAMS G-9
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
LN-15
G-10
PC BOARD ASSEMBLY - SPI DISPLAY P.C. BOARD - (L11757-1)
ELECTRICAL DIAGRAMS G-10
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
LN-15
SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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