Lincoln Electric IM734 User Manual
LN-15 WIRE FEEDER
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For use with machines having Code Number:10865
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
IM734
July, 2002
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2002 Lincoln Global Inc.
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
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
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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
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.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.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
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
ii
SAFETY
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.
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.
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.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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.
vapors
Mar ‘95
to
iii
SAFETY
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.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
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
iv
SAFETY
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.
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.
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.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
vv
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Location................................................................................................................................A-2
High Frequency Protection...................................................................................................A-2
Weld Cable Connections......................................................................................................A-2
Electrode Connection ...........................................................................................................A-2
Work Connection..................................................................................................................A-2
Power Source Connection....................................................................................................A-2
Connection Diagram.............................................................................................................A-3
Guns and Cables..................................................................................................................A-3
Electrode Polarity .................................................................................................................A-3
Control Cable Connections ..................................................................................................A-3
Procedure to Install Drive Rolls and Wire Guides ................................................................A-4
Feeding Wire Electrode........................................................................................................A-4
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Graphic Symbols that appear on this Machine or in this Manual .........................................B-1
General Description..............................................................................................................B-2
Duty Cycle ............................................................................................................................B-2
Recommended Processes ...................................................................................................B-2
Recommended Equipment...................................................................................................B-2
Processes Limitations ..........................................................................................................B-2
Operational Features and Controls .....................................................................................B-3
Case Front Controls .............................................................................................................B-3
Dual Procedure ....................................................................................................................B-3
LN-15 P
Internal Controls ...................................................................................................................B-6
Spring Tension Arm..............................................................................................................B-6
Cold Feed/Gas Purge Switch ...............................................................................................B-6
Spindle Brake .......................................................................................................................B-6
Flow Meter............................................................................................................................B-6
Shielding Gas Connection .............................................................................................B-6,B-7
Constant Current Operation .................................................................................................B-7
Setting Arc Sensing Wire Feed Speed for Constant Current ...............................................B-8
Making a Weld......................................................................................................................B-9
________________________________________________________________________________
OWER UP SEQUENCE ...........................................................................................B-4,B-5
vi
Accessories ....................................................................................................................Section C
Factory Installed Equipment.................................................................................................C-1
Optional Equipment..............................................................................................................C-1
Electrode, K-Kit used ...........................................................................................................C-1
________________________________________________________________________________
Maintenance....................................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Calibration Specification.......................................................................................................D-1
________________________________________________________________________________
Troubleshooting .................................................................................................................Section E
Safety Precautions ...............................................................................................................E-1
How to Use Troubleshooting Guide .....................................................................................E-1
Troubleshooting Guide ...........................................................................................E-2 thru E-4
________________________________________________________________________________
Wiring Diagram & Dimension Prints .............................................................................Section F
________________________________________________________________________________
Parts Pages .............................................................................................................................P414
_______________________________________________________________________
________
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – LN-15 K1871-1 (CODE NUMBER 10865)
INPUT VOLTAGE
42 VAC/1/50/60 (110VDC 5Amps Maximum)
CONTROL CABLE MODEL
RATED CURRENT
500 Amps 60% Duty Cycle
350 Amps 100% Duty Cycle
ELECTRODE DIAMETERS and SPEED RANGE
Electrode Size Speed Range
A-1
Solid Electrode
Steel
Flux Cored
Electrode
0.023 - 0.052" 50 - 700 in/min
(0.6 - 1.3 mm) (1.3 - 17.8 m/min)
0.035 - 0.052" 50 - 700 in/min
(1.2 - 1.3 mm) (1.3 - 17.8 m/min)
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
12.7 Inches 8.7 Inches 23 Inches 28lbs
(323 mm) (221mm) (584 mm) (13kg)
TEMPERATURE RANGE
OPERATION: - 40° C to +50° C (- 40° F to +122° F)
STORAGE: - 40° C to +70° C (- 40° F to +158° F)
SPOOL SIZE CAPABILITY
8 (200mm) Dia. x 4 (100mm)
Wide Spools including
AWS 8 DIA. (10-15lbs)
JIS S-3 200mm max. (5 - 7 kg)
DIN 200 (5 kg)
LN-15 CONTROL CABLE MODEL
A-2
INSTALLATION
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off input power to the power
source at the disconnect switch
or fuse box before working on
this equipment.
• Turn off the input power to any
other equipment connected to the welding
system at the disconnect switch or fuse box
before working on the equipment.
• Do not touch electrically hot parts.
• Do not touch metal portions of the LN-15 work
lead clip when the welding power source is on.
• Do not connect the LN-15 to a non-lincoln tig
power source, a square wave tig power source,
or a plasma cutting power source.
-------------------------------------------------------------------
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 machine in a
dry environment. When using the LN-15 in severe
weather conditions, place the LN-15 on its side with
the door facing upwards. Keep the door closed.
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.
------------------------------------------------------------------------------------------
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.
WELD CABLE CONNECTIONS
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 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)
TABLE A.1
Weld Current Total Cable Length
60% Duty (electrode cable + work cable)
Cycle 50 - 100' 100 - 150' 150 - 200' 200 - 250'
(15-30 m) (30 - 46m) (46 - 61m) (61m - 76m)
200 Amps 2 AWG 2 AWG 1 AWG 1/0
300 Amps 1 AWG 1 AWG 1/0 2/0
400 Amps 2/0 2/0 3/0 3/0
ELECTRODE CONNECTION
Route the electrode cable through the strain relief in
the rear of the case. Connect the electrode cable to
the LN-15 connection block using the mounting hardware provided. Secure the cable by tightening the
strain relief.
All units are supplied with an optional pigtail for customers that prefer to make a taped and bolted connection externally.
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.
POWER SOURCE CONNECTION
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.
------------------------------------------------------------------------------------------
Recommended power sources are Lincoln Electric
Company constant voltage power sources with
42VAC auxiliary power and a 14-pin connector
receptacle. At the time of printing these include:
• CV-250 •
• CV300-I •
• CV-300 •
• CV-400-I •
• CV-400 •
• Invertec STT II •
DC-400 • Ranger 9
DC600 • Ranger 250
CV-655 • Ranger 305
V350-PRO • Ranger 300 DLX
DC-655 • Commander 300
Commander 500
A-2
LN-15 CONTROL CABLE MODEL
A-3
INSTALLATION
CONNECTION DIAGRAM, CONTROL
CABLE MODELS ( See Figure A.1)
A-3
FIGURE A.1
WELDING CABLE
(ELECTODE)
WELDING CABLE (WORK)
GUNS AND CABLES ASSEMBLIES
A variety of Lincoln 10' (3.0m) or 15' (4.6m) gun and
cable assemblies are available for use with the LN-15,
including the Magnum™ models for GMAW, K126 or
K115 models for Innershield®, and more.
The LN-15 comes factory equipped with a K1500-2
gun receiver bushing, designed for guns having a
Tweco™ #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.
8 Pin Control Cable Receptacle
5 Pin Trigger Connector
Table A.2 Trigger Connector J1 (5 Pin)
PIN Lead # Function
A 556 Trigger
B - Not used
C 554 Trigger/ 83%
Procedure ground
D 555 83% Procedure
E 554 Trigger/ 83%
Procedure ground
Table A.3 Control Cable Receptacle (8 Pin
PIN Lead # Function
A 41 42 VAC
B 42 42 VAC
C 2 Output Control (trigger)
D 4 Output Control (trigger)
E 21 Work Sense Lead
F 75 Remote Voltage Control
G 76 Remote Voltage Control
H 77 Remote Voltage Control
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.
CONTROL CABLE CONNECTIONS
For Control Cable model, attach the control cable from
the LN-15 to power source. Do not use more than 150
ft (45 m) of cable.
LN-15 CONTROL CABLE MODEL
A-4
INSTALLATION
A-4
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
WARNING
• Turn off input power at the welding power source before installation or changing drive roll and/or
wire guides.
• Do not touch electrically live parts
such as the wire drive or internal wiring.
• When feeding with the gun trigger, the electrode
and wire drive mechanism are "hot" to work and
ground and could remain energized several seconds after the gun trigger is released.
• Only qualified personnel should perform this
operation.
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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.
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.
FEEDING WIRE ELECTRODE
WARNING
• 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.
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COLD FEED/GAS PURGE 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 overtighten.
LN-15 CONTROL CABLE MODEL
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