Lincoln Electric IM922 User Manual

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LN -23P

IM922-A

Portable Innershield Semiautomatic Wire Feeder

For use with machines having Code Numbers 11384, 11671

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built wi th s afe ty in mind . H owever, you r ove ra ll s af et y ca n be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPER-

ATE OR REPAIR THIS EQUIPMEN T WIT H O UT RE ADING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THR O U GHOUT . And , mos t

importantly, think before you act and be careful.

October, 2009

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Salesand Service through Subsidiaries and Distributors Worldwide •

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

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 ventthe 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 fumeshave 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 engineis 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 arenow 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 tapewhen 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. Ifthe electrode cable is on your right side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasolineengines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire asappropriate.

2.d.4. Connect the work cable to the workpiece as close as possible to thearea being welded.

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

Mar ‘95

LN™-23P

SAFETY

ELE CTRIC SHOC K 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-f ree

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 mu s t be pe r for m ed un d er el e ctr i cal l y haz a rdou s con ditions (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, elect rode reel, weldin g head, n ozzle or semiauto matic 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 simultan eo usly t ouch e lectric al ly “ ho t” p ar ts o f 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.

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 prod uce fumes and gases hazardous to health. Avoid breathing these fumes and gas es. 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

we l ding w i th el e ctr o des wh i ch req u ire s p eci a l ve n til atio n suc h as st ainl ess o r har d faci ng (s ee in str uct ion s on c ont ainer o r MS DS) o r on l ead or cadmi um plated steel an d other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined s pa ce s or in so me circumst a nce s, ou t doo r s, a r e spi rato r may b e req u ire d. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon 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.d. Shielding gases used for arc welding can displace air and

cause i nj ur y or d ea th . Always u se enough ven ti la ti on , especially in confined areas, to insure breathing air is safe.

vapors

5.e. Read and understand the manufacturer’s instructions for this

5.f. Also see item 1.b.

LN™-23P

equipment and the consumables to be used, including the ma t eria l saf ety da ta sh eet ( MSD S ) an d fol l ow yo ur employer’s safety practices. MSDS forms are available from yo u r w e ldi n g d i str i but o r o r fro m the man u fac t ure r .

Jan ‘09

iii

SAFETY

iii

WELDING and CUTTING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Re m embe r th a t we l din g spa r ks an d ho t materials from welding can easily go through small cracks an d open in gs to adj acent ar eas . Avo id wel din g nea r 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 Standar d Z49. 1) and the opera ting informatio n 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 Co n tain ers and P ipi n g T hat H ave H eld H aza r dou s 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 incre ase the possibility of t he welding curr ent 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.

the w el di ng sparks from starti ng a f ir e.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use only com p ress ed g as c ylin ders containing the correct shielding gas for the pr o cess u s ed and pr ope r ly ope r ati n g re g ulat ors d esig ned f or the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Al ways kee p cylinders in an upright pos it io n secur el y 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 foll ow t he in struc tions on comp re sse d gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

LN™-23P

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isolerles 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 desgrilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corpspeut 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 latension 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.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risqued’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 unrisque 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 cequ’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 fumeéstoxiques.

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 produitsirritants.

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

2. Dans lecas de travail au dessus du niveau du sol, seprotéger 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 regardel’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’aided’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 zones où l’onpique le laitier.

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 àla terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par unélectricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteurà la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

LN™-23P

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

TABLE OF CONTENTS

Page

Installation...................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Installation Instructions.........................................................................................................A-2

Safety Precautions ...............................................................................................................A-2

Input Cable....................................................................................................................A-2

Working Cable and Remote Voltage Sensing Work Lead ............................................A-2

Wire Drive Rolls and Guide Tubes................................................................................A-3

Optional Features Installation .......................................................................................A-3

Innershield Gun and Cable ...........................................................................................A-3

K-350 Adapter Kit..........................................................................................................A-3

K-276 Enclsoed 50 Lb Wire Reel Supt..........................................................................A-3

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Operation.....................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Product Description ..............................................................................................................B-1

Loading the Wire Reel..........................................................................................................B-1

Instructions For Loading Wire into LN-23......................................................................B-2

Drive Roll Pressure ..............................................................................................................B-3

Adjusting Wire Feed Speed and Votlage .............................................................................B-3

Marking the Weld .................................................................................................................B-3

Accessories.....................................................................................................Section C

Optional Equipment...............................................................................................C-1

Gun and Cable Assemblies ............................................................................C-1

K-350 Adapter Kit

......................................................................................................

K-276 Enclosed Wire Reel Support..............................................................................

C-1 C-1

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Maintenance ....................................................................................................Section D

Safety Precautions................................................................................................D-1

Replacing or Reversing Drive Rolls.......................................................................D-1

Removing Idle Roll Assembly................................................................................D-1

Gun and Cable ......................................................................................................D-1

Wire Drive Assembly Maintenance........................................................................D-1

Circuit Protection...................................................................................................D-2

Nameplates ...........................................................................................................D-2

Power Soruce........................................................................................................D-2

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting ..........................................................................................E-2 to E-3

Connection and Wiring Diagrams..................................................................Section F

Parts List

....................................................................................................P-552, P-103, P-107

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – LN™-23P

OPERATING ARC VOLTAGE

Constant Voltage (CV) 14-50VDC (90VDC Maximum OCV)

RATED CURRENT

250-350 Amps 60% Duty Cycle

(Depending on Gun Used)

WIRE SPEED RANGE

30-170 Inches Per Minute (IPM)

(1.18-6.70 mm)

RECOMMENDED ELECTRODE WIRE SIZES

A-1

.068” INNERSHIELD

” INNERSHIELD

.072

” INNERSHIELD

5/64

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

20.5 Inches 9.0 Inches 19.0 Inches 27 lbs (520.7 mm) (228.6 mm) (482.6mm) (12.3 kg)

TEMPERATURE RANGE

OPERATION: - 30oCo* to +40oC (- 22oF to +104oF)

STORAGE: - 40

C to +40oC (- 40oF to +104oF)

ENVIRONMENTAL RATING

EENNVVIIRROONNMMEENNTTAALL RRAATTIINNGG

*At temperatures below 0°C, the gun cable may require a warm up operating time to improve flexibility.

LN™-23P

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation, maintenance and troubleshooting work.

• Turn off the input power at the fuse box before working on other equipment connected to the welding system at the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.

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

INPUT CABLE

The standard 25 foot input cable between the LN™23P and the power source with Adapter Kit consists of a six-conductor control cable and a 1/0 electrode cable. The control cable has lugged leads on the power source end and a polarized plug on the wire feeder end. With the power source turned off, install the input cable per the following instructions:

• Connect the end of the control cable with the lugged leads to the LN™-23P Adapter Kit. Connect the electrode cable to the negative output stud on the power source.

NOTE: If two LN™-23P’s are connected to an Adapter Kit, connect the feeder that will be used at the lowest voltage setting to Feeder “A” terminal strip. If one LN™-23P is used, connect it to Feeder “A” terminal strip.

WORK CABLE AND REMOTE VOLTAGE SENSING WORK LEAD

• Connect a work cable of sufficient size and length, per the following table, between the proper output stud on the power source and the work. Be sure the connection to the work makes tight metal to metal contact.

Electrode Work Copper Copper

Cable Cable Electrode Work Cable

Length Length Cable Size Size

0-25 ft. 0-75 ft. 1/0 1/0

0-25 76-125 1/0 2/0 26-75 26-75 2/0 2/0 26-75 76-125 2/0 4/0

76-100 76-125 3/0 4/0

Above cable sizes are based on a maximum voltage drop of

4.3 volts in the combined lengths of electrode and work cable at 350 amps.

•

Connect a 12 AWG or larger rubber covered flexible lead physically suitable for the installation to the voltage sensing work lead coming the Adapter Kit. For convenience, wrap the voltage sensing lead around the work lead and tape in place. Connect directly to the work or to the work cable connection on the work piece. This lead supplies the voltage to the voltmeter in the LN™-23P and also supplies the power to the LN™-23P drive motor.

• Connect the input control cable polarized plug into the mating 6 pin receptacle on the rear of the control section of the LN™-23P. Tighten the threaded locking collar until the connector is completely seated.

• Unclip the rubber retaining strap that holds the wire enclosure cover in place and remove the cover. Push the wire drive section door latch towards the rear of the LN™-23P and open the door. Route the electrode cable through the large rubber grommet in the rear of the wire feed section and connect the lug to the brass conductor block at the front of motor-gearbox assembly using the bolt provided. Attach the control cable strain relief hook to bracket on the frame of the LN™-23P.

LN™-23P

A-3

INSTALLATION

WIRE DRIVE ROLLS AND GUIDE TUBES

The LN™-23P is shipped with the proper drive rolls and guide tubes factory installed. Do not adjust the idle roll tension adjusting screw. If the idle roll tension must be relieved temporarily, see “A” and “B” of Maintenance Section.

OPTIONAL FEATURES INSTALLATION

INNERSHIELD GUN AND CABLE

•

Unclip the rubber retaining strap that holds the wire enclosure cover in place and remove the cover.

•

Push the wire drive section door latch towards the rear of LN™-23P and open door.

•

Loosen the gun locking set screw in the conductor block on the front of the gear box with a 3/16 hex Allen wrench.

•

DC-600: Attach the triangular mounting plate to the shock mounted plate of the Adapter with three of the #10 self-tapping screws provided. Attach the triangular plate to the side of the DC-600 adjacent to the control terminal strips using two roof screws and one front panel screw. Connect the Adapter control cable to the DC-600 terminal strips power the proper connection diagram.

•

Other Power Sources: Mount the Adapter Kit to the side of the power source or some convenient location so its control cable can be connected to the power source 14 pin connector. Use the shock mounted mounting plate as a template to locate the four 5/32" diameter holes that must be drilled in the case side. (Use caution not to drill into or get chips into any internal components.) Mount the Adapter Kit with four of the #10 self-tapping screws provided. Connect the Adapter control cable to power source terminal strips per the proper connection diagram.

CAUTION

A-3

•

Lay the cable out straight. Insert the connector on the conductor cable thru the large grommet in the front of the wire drive section and into the brass block on the front of the gear box. Make sure it is all the way in and tighten the locking set screw with a 3/16 hex Allen wrench. Keep this connection clean and bright.

•

Connect the 3 pin gun trigger connector to the lower receptacle.

•

If the gun cable being used has a reduced speed switch, connect the 4 pin reduced speed switch connector to the upper receptacle. If the reduced speed switch is not used, install the protective cap on the upper receptacle.

K-350 ADAPTER KIT– Turn off power source and all power to power source.

•

SAM-400 Engine Welders: Attach the shock mounted mounting plate to the front of the SAM electrical component panel to left of the relay case with 4 of the #10 self-tapping screws provided. Older models require the drilling of 4 5/32 dia. holes into the panel. Connect the adapter control cable to the SAM terminal strips per the proper connection diagram.

K-276 ENCLOSED 50lb. WIRE REEL SUPPORT Installation and loading instructions (M-13153) are supplied with the kit.

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

LN™-23P

B-1

SAFETY PRECAUTIONS

WARNING

OPERATION

The LN™-23P includes a voltage control which controls the power source output. Also included is an analog voltmeter which allows easy setting of the procedure arc voltage at the LN™-23P.

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ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• When inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before installation or changing drive roll and/or guide tubes.

• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

• Only qualified personnel should perform this installation.

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PRODUCT DESCRIPTION

The K316L-[ ] / LN™-23P is a lightweight, portable wire feed unit which includes calibrated wire speed control, voltage control, wire drive with enclosed 14 lb. Wire reel, analog voltmeter and various input control and electrode cable lengths.

The feeder is designed for welding with 14 pound coils of .068 and 5/64 Innershield self-shielding electrodes using a constant voltage type DC power Source. When shipped, it is internally connected for welding with electrode negative polarity (DC–). Depending upon which gun and cable is used, its rating is either 350 amps or 250 amps at 60% duty cycle.

The wire speed control has a calibrated dial plate with a range of 30 to 170 inches per minute and allows quick and easy setting of the procedure wire feed speed. The wire speed is not affected by changes in the arc voltage setting even though the wire feed circuit is powered by arc voltage. A two-position switch, which is mounted on the gun and a reduced speed circuit, allows selection of the preset wire speed or 83% of the preset speed.

A low voltage gun trigger circuit turns both the power source output and wire feed on and off. The gun trigger circuit is interlocked by a weld current sensing reed switch so that while welding, the gun trigger switch does not have to be held closed. The welding process is stopped by pulling the gun away from the work. The electrode remains cold until the gun trigger is operated.

LOADING THE WIRE REEL

(For machines that have code numbers Lower than 11383.)

• Lay the LN™-23P flat with the wire reel cover up, unclip the rubber retaining strap, and remove the cover.

• Remove the center clamping nut and the cover plate from the wire reel.

• Unpack the 14-pound coil of wire. Be sure not to bend the side tangs of the coil liner and straighten any tangs that may have been bent.

• Place the coil on the wire reel so the coil will unwind when it rotates in a clockwise direction.

• Remove the start end of the coil from its holding slot in the coil liner, cut off the bent end, straighten the first few inches and thread it through the wire feed conduit connected to the wire enclosure until several inches of electrode are exposed. Be careful not to release the electrode until it is through the wire feed conduit; otherwise, it may unwind and tangle.

• Be sure all the lower tangs of the coil liner are flush against the back half of the wire reel and that none of the upper tangs are bent in against the coil.

• Replace the reel cover plat and the center clamping nut.

• Replace the cover of the wire reel enclosure and clip the retaining strap in place.

• Pull about 2 feet of the exposed end of the electrode through the wire feed conduit. Slide the insulator all the way up on the wire feed conduit.

Make a single, free loop in the electrode and feed the end into the section of wire feed conduit connected to the gearbox. Press the gun trigger and push the electrode into the drive rolls. Release the electrode as soon as it is picked up by the drive rolls. Continue feeding electrode until the excess length is fed through the drive rolls. Watch the single loop and guide it if necessary to make certain it untwists without kinking. Do not feed electrode through cable at this time. Slide insulator down on wire feed conduit until it slips over section of conduit connected to gearbox.

• Set the unit upright on floor, straighten the gun

cable, press the gun trigger, and feed electrode though the gun and cable assembly.

LN™-23P

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