Lincoln Electric LN-15, SVM166-A User Manual
LN-15 WIRE FEEDER
SVM166-A
April, 2006
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.
SERVICE MANUAL
For use with machines having Code Number : 11033, 11035
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• 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
• World's Leader in Welding and Cutting Products •
Copyright © 2006 Lincoln Global Inc.
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i
SAFETY
i
LN-15
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.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.
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. AFree 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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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 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 Diesel Engines
The Above For Gasoline Engines
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ii
SAFETY
ii
LN-15
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.
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.
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
LN-15
SAFETY
iii iii
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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.
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, VA22202.
Mar ‘95
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.
LN-15
SAFETY
iv iv
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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.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
LN-15
vv
MASTER TABLE OF CONTENTS FOR ALL
SECTIONS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P482 Series
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LN-15
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation ..............................................................................................................Section A
Technical Specifications...............................................................................................A-2
Safety Precautions .......................................................................................................A-3
High Frequency Protection ..........................................................................................A-3
Connections .................................................................................................................A-4
Gun & Cable Assembly ................................................................................................A-6
Feeding Wire Electrode................................................................................................A-7
LN-15
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A-2
INSTALLATION
A-2
15-110 VDC (5 Amps Maximum)
Across the Arc Model
300 Amps 60% Duty Cycle
250 Amps 100% Duty Cycle
TEMPERATURE RANGE
OPERATION: - 40oC to +50oC (- 40oF to +104oF)
STORAGE: - 40oC to +70oC (- 40oF to +185oF)
RATED CURRENT
INPUT VOLTAGE
TECHNICAL SPECIFICATIONS – LN-15 (K1870-1), (K1870-2 CE)
HEIGHT WIDTH DEPTH WEIGHT
12.7 Inches 8.7 Inches 23 Inches 30lbs
(323 mm) (221mm) (584 mm) (14kg)
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)
ELECTRODE DIAMETERS and SPEED RANGE
PHYSICAL DIMENSIONS
Electrode Size Speed Range
0.023 - 0.052" 50 - 700 in/min
(0.6 - 1.3 mm) (1.3 - 17.8 m/min)
0.0345 - 5/64" 50 - 400 in/min
(0.9 - 2.3 mm) (1.3 - 10.1 m/min)
Solid Electrode
Steel
Flux Cored
Electrode
A-3 A-3
LN-15
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INSTALLATION
SAFETY PRECAUTIONS
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.
-------------------------------------------------------------------
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
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.
-------------------------------------------------------------------
** The work clip lead is present only on Across-the-
Arc models.
The work clip lead attached to the front of the LN15 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 Max. Length
#14 25 ft (7.6m)
#12 50 ft (15.2m)
#10 100 ft (30.5m)
#6 200 ft (61.0m)
CORRECT WORK CLIP ATTACHED TO WORK
INCORRECT WORK CLIP ATTACHED TO ROLL CAGE
HIGH FREQUENCY PROTECTION
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
total.
WARNING
WARNING
CAUTION
INSTALLATION
LN-15
A-4 A-4
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WELD CABLE CONNECTIONS
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)
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.
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.
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
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.
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.
------------------------------------------------------------------------------------------
WARNING
CAUTION
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
TABLE A.1
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.
2. For electrode Positive polarity welding, connect the
electrode cable to the "+" terminal of the welder and
work cable to the "-" terminal of the welder. For
Electrode Negative welding, connect the electrode
cable to the "-" terminal of the welder and work
cable to the "+" terminal of the welder.
3. 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.
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.
7. Set the ARC CONTROL knob to "0" initially and
adjust to suit.
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.
LN-15
INSTALLATION
A-5 A-5
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Work
Clamp
Electrode Cable
Electrode Cable
Electrode Cable
Work
Clamp
Work
Clamp
wire feeder
K1870-1
wire feeder
K1870-1
RANGER 8
SAE 400 WITH CV ADAPTER
ENGINE DRIVEN WELDERS
WITH WIRE FEED MODULE
(LOCAL MODE AND CV ADAPTER)
CV250
CV300
CV400
CC POWER SOURCE
Output
Output
Terminals
erminals
Always Hot.
Output
Output
Terminals
erminals
Always Hot.
Always Hot.
Output
Output
Terminals
erminals
Always Hot.
Order K484 Jumper
Order K484 Jumper
Plug Kit.
Electrode Cable
Work
Clamp
semiautomatic
semiautomatic
semiautomatic
semiautomatic
wire feeder
K1870-1
wire feeder
K1870-1
wire feeder
K1870-1
CV655, DC400, DC600,
DC655, V350-PRO,
RANGER 9, RANGER 300 DLX
COMMANDER 300
COMMANDER 500
RANGER 250
RANGER 305G
Output
Output
Terminals
erminals
Always Hot.
Always Hot.
Power source contactor
Power source contactor
switch must be in the
switch must be in the
"ON" position or use a
"ON" position or use a
K848 Junper Plug Kit.
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
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
INSTALLATION
A-6 A-6
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GUN AND CABLE 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®.
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.
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 556 Trigger
B-Not used
C 554 Trigger/ 83%
Procedure ground
D 555 83% Procedure
E 554 Trigger/ 83%
Procedure ground
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
• 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.
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.
WARNING
LN-15
INSTALLATION
A-7 A-7
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FEEDING WIRE ELECTRODE
• 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.
-----------------------------------------------------------------------
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.
WARNING
COLD FEED/
GAS PURGE
2 STEP/TRIGGER
INTERLOCK
SWITCH
LN-15
NOTES
A-8 A-8
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LN-15
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation ................................................................................................................Section B
Safety Precautions .......................................................................................................B-2
General Description ...............................................................................................B-3
Duty Cycle..............................................................................................................B-3
Operational Features and Controls ..............................................................................B-3
Case Front Controls .....................................................................................................B-4
Power-up Sequence.....................................................................................................B-5
CV/CC Mode ................................................................................................................B-6
WFS Units.....................................................................................................................B-6
Internal Controls ...........................................................................................................B-6
Cold/Feed/Gas Purge Switch.......................................................................................B-7
Two Step Trigger Interlock............................................................................................B-8
Constant Current Operation.........................................................................................B-9
Setting Wire Feed Speed ...........................................................................................B-10
Making a Weld............................................................................................................B-11
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B-2 B-2
LN-15
OPERATION
• 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.
---------------------------------------------------------------------ARC RAYS can burn.
• Wear eye, ear and body protec-
tion.
---------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MANUAL.
WARNING
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
INPUT POWER
ON
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
INPUT POWER
DIRECT CURRENT
OPEN CIRCUIT
VOLTAGE
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVE
GROUND
WARNING OR
CAUTION
U
0
U
1
U
2
I
1
I
2
--------------------------------------------------------------------
GRAPHIC SYMBOLS THAT APPEAR ON THIS
MACHINE OR IN THIS MANUAL
LN-15
OPERATION
B-3 B-3
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GENERAL DESCRIPTION
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 domestic feeders comes factory equipped with a
K1500-2 Magnum Tweco-compatible style #2-#4 gun
bushing. Other K1500 series gun bushings are available as field installed options. European models are
factory equipped with a Fast-Mate adapter.
The wire drive is capable of operating in either a "CV"
or "CC" mode. Aconstant voltage (CV) power source is
recommended for flux-cored arc welding (FCAW) and
gas metal arc welding (GMAW) to obtain code quality
results. However, the LN-15 may also be used with a
constant current (CC) power source to obtain passable
results for non-critical quality applications.
The “dual procedure” mode drops the WFS to 83% of
the original set point. The voltage setting remains the
same.
• Burn-back is adjustable from 0.0 to 0.25 seconds,
with a default of 0.00 seconds.
• The preflow time is adjustable from 0.00 to 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.
An internal contactor in Across the Arc Models energizes the electrode output in response to the gun trigger.
DUTY CYCLE
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.
RECOMMENDED PROCESSES
The LN-15 wire drive feeds electrode for various
processes as follows:(See Table B.1)
The Across the Arc Model is suitable for GMAW,
GMAW-Pulse and FCAW semi-automatic applications
within the rated duty cycle.
PROCESS LIMITATIONS
• 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
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
• 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.)
Process Wire Diameter Range Wire Feed Speed Range
GMAW 0.023 - 0.052" (0.6 - 1.3 mm) 50 - 700 ipm (1.3 - 17.8 m/minute)
FCAW 0.045 - 0.052" (1.2 - 1.3 mm) 50 - 700 ipm (1.3 - 17.8 m/minute)
FCAW 1/16 - 5/64" (1.6 - 2.0 mm) 50 - 400 ipm (1.3 - 10.2 m/minute)
TABLE B.1
OPERATION
LN-15
B-4 B-4
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1
2
3
4
5
6
7
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)
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.
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
CASE FRONT CONTROLS
(See Figure B.1)
ACROSS THE ARC MODEL
1. WIRE FEED SPEED DISPLAY-The Wire Feed
Speed display shows the rate the LN-15 will feed
electrode during welding. The default WFS units for
domestic models are inches/minute and can be
changed to meters/minute through the configuration
menu. The default WFS units for the European
models are m/min. The wire feed speed is calibrated to within ±2%.
2. VOLTAGE DISPLAY
-
The voltage display shows the
average arc voltage during welding. Aminus 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
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OPERATION
B-5 B-5
LN-15
LN-15 POWER-UP SEQUENCE
NORMAL POWER-UP DISPLAY
When power is first applied to the LN-15, the display
will momentarily show set-up information. For example, it may show "CV" and "HI", indicating operation
from a CV power source and the wire drive is configured for the high speed gear. Because of limitations in
the display, "CV" will appear as "Cu".
After a brief moment, the LN-15 will then display the
WFS and "---". No voltage is displayed until the trigger
is pressed.
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
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.
Preflow:
Postflow:
Burnback:
3. Activate and then release the GAS PURGE switch
to select the timer. The time will then display in the
right hand side of the display. Example:
4. Rotate the WFS knob to adjust the time to the new
setting.
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 LN15 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.
WFS
COLD
FEED
GAS PURGE
COLD
FEED
GAS PURGE
LN-15
OPERATION
B-6 B-6
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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
FLOWMETER
SPRING
TENSION
ARM
COLD FEED/
GAS PURGE
SWITCH
2 STEP/TRIGGER
INTERLOCK
SWITCH
SPINDLE
BRAKE
INTERNAL CONTROLS
(Figure B.2)
Rotate the WFS knob until the desired parameter is
displayed.
CV/CC Mode:
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.
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 LN15 will enter normal operation.
WFS
ALUMINUM
OUTERS HIELD
METALSHIELD
INNERSHIELD
STEEL
STAIN L ESS
COR ED W I RES
SOLID WIRES
6
1
3
2
5
4
LN-15
OPERATION
B-7 B-7
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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.
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.
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.
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.
GUN RECEIVER BUSHING
LOOSEN TIGHTEN
THUMB SCREW
OUTER WIRE GUIDE
SOCKET HEAD
CAP SCREW
CONNECTOR BLOCK
FIGURE B.2b
LN-15
OPERATION
B-8 B-8
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SCFH Liter/Min.
10 4.7
20 9.4
30 14.2
40 18.9
50 23.6
60 28.3
70 33.1
80 37.8
SPINDLE BRAKE
Adjust the spindle brake tension to allow the spool to
spin freely, yet have enough resistance for little or no
overrun when wire feeding is stopped.
SHIELDING GAS CONNECTION
CYLINDER may explode if
damaged.
• Keep cylinder upright and
chained to support.
• Keep cylinder away from areas where it may be
damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live
electrical circuits.
-----------------------------------------------------------------------
• BUILD UP OF SHIELDING GAS MAY HARM
HEALTH OR KILL.
• Shut off shielding gas supply when not in use.
• See American National Standard Z-49.1, "Safety
in Welding and Cutting” Published by the
American Welding Society.
------------------------------------------------------------------------
Customer must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve and a hose
from the flow valve to the gas inlet fitting of the LN-15.
Connect a supply hose from the gas cylinder flow valve
outlet to the 5/8-18 female inert gas fitting on the back
of the LN-15.
WARNING
WARNING
Hold with toggle switch in the DOWN position to activate Gas Purge and let the shielding gas flow. The gas
solenoid valve will energize but neither the power
source output nor the drive motor will be turned on.
The Gas Purge switch is useful for setting the proper
flow rate of shielding gas. Flow meters should always
be adjusted while the shielding gas is flowing.
2 STEP - TRIGGER INTERLOCK SWITCH
The 2 Step - Trigger Interlock switch
changes the function of the gun trigger. 2
Step trigger operation turns welding on
and off in direct response to the trigger.
Trigger Interlock operation allows welding to continue when the trigger is
released for comfort on long welds.
Place the toggle switch in the UP position
for 2 Step operation or in the DOWN
position for Trigger Interlock operation.
2 Step Trigger
2 Step trigger operation is the most common. When
the gun trigger is pulled, the welding power source
energizes the electrode output and the wire feeder
feeds wire for welding. The power source and wire
feeder continue welding until the trigger is released.
Trigger Interlock
Trigger Interlock operation provides for operator comfort when making long welds. When the gun trigger is
first pulled, the welding power source energizes the
output and the wire feeder feeds wire for welding. The
gun trigger is then released while the weld is made. To
stop welding, the gun trigger is pulled again, and when
it is released the welding power source output turns off
and the wire feeder stops feeding wire.
If the arc goes out while welding with trigger interlock operation, the electrode output from the welding power source remains energized and the wire
feeder will continue to feed wire until the gun trigger is again pulled and then released.
------------------------------------------------------------------------
FLOW METER
The flowmeter shows the flow rate of shielding gas and
has a valve to adjust the flow. The flow meter is calibrated for CO2, Ar, and CO2/Ar blends. The middle of
the ball indicates the flow rate of shielding gas.
Adjust the flow rate by turning the valve at the bottom
of the meter. Most weld procedures require 25-40 scfh
(11.8 - 18.9 lpm) for sufficient shielding gas coverage.
Gun angle, nozzle diameter, joint configuration and
wind conditions may effect the amount of shielding gas
required.
CAUTION
LN-15
OPERATION
B-9 B-9
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CONSTANT CURRENT OPERATION
( See Figure B.3)
Lincoln Electric does NOT recommend constant
current semiautomatic welding for applications
which need to meet specified weld metal chemical
or mechanical property requirements or weld quality requirements.
------------------------------------------------------------------------
Most semiautomatic welding processes perform better
using constant voltage power sources.
Welding codes usually do not address the power source
selection or specifically , whether the welding process is to
be operated in the constant voltage or constant current
mode. Instead, codes typically specify limitations on the
current, voltage, heat input and preheat temperature
based on the material to be welded. The intention is to
assure that proper weld material properties will develop.
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.
CAUTION
If the contact tip to work distance is properly maintained, a satisfactory operating voltage range may be
achieved, and a sound weld may result. However,
when a welder uses a longer contact tip to work distance, an arc-sensing wire feeder compensates by
increasing the wire feed speed to regulate the voltage.
Even if the voltage and current remain unchanged, the
increased wire feed speed may result in a deposition
rate well beyond the specified range of the electrode.
Under these conditions, the specified weld metal properties may not be achieved.
Constant voltage power sources deliver large current
surges to stabilize the arc when the electrode is shorted or the arc length is very short. However, a constant
current power source does not provide such a
response to stabilize the arc. It may be difficult to
achieve required weld metal properties, or to achieve
the required quality of welds needed to pass nondestructive tests, when such welds are made under constant current operation.
Constant Current
Power Source
Current
Current
Wire
Feeder
WFS
CTWD
Welding Cable
(Electrode)
Welding Cable
(
Work
)
LN-15
GUN AND CABLE
ASSEMBLY
+
-
FIGURE B.3
LN-15
OPERATION
B-10 B-10
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SETTING ARC SENSING WIRE FEED SPEED FOR
CONSTANT CURRENT OPERATION
When using a constant current (formerly variable voltage)
power source, welding performance is improved using arc
sensing wire feed speed (CC operation). In this wire feed
mode the wire speed increases if arc voltage increases, and
decreases if arc voltage decreases, but remains constant at
any specific voltage level.
The LN-15 permits accurate presetting of the desired
wire feed speed, for the desired arc voltage to be used,
by setting the Wire Feed Speed in the following manner
before welding:
a. Activate press and spin during power up and change
to the CC mode. See “Changing the CV/CC mode
or WFS units” in this Operation Section.
FIGURE B.4 CC WIRE SPEED SETTING
b. Referring to the graph located above the Mode switch
(also shown in Figure B.4):
1. Select the horizontal line representing the DESIRED 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.)
c. Adjust the WFS display to the value determined in
Step (3) above (450 for example used).
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:
TABLE B.1 CC WIRE SPEED SETTING
Arc Volts Used
Desired
In/Min 16 18 20 22 24 26 28 30 32 34
50 109 97 88 80 73 67 63 58 55 51
60 131 117 105 95 88 81 75 70 66 62
70 153 136 123 111 102 94 88 82 77 72
80 175 156 140 127 117 108 100 93 88 82
90 197 175 158 143 131 121 113 105 98 93
100 219 194 175 159 146 135 125 117 109 103
110 241 214 193 175 160 148 138 128 120 113
120 263 233 210 191 175 162 150 140 131 124
130 284 253 228 207 190 175 163 152 142 134
140 306 272 245 223 204 188 175 163 153 144
150 328 292 263 239 219 202 188 175 164 154
160 350 311 280 255 233 215 200 187 175 165
170 372 331 298 270 248 229 213 198 186 175
180 394 350 315 286 263 242 225 210 197 185
190 416 369 333 302 277 256 238 222 208 196
200 438 389 350 318 292 269 250 233 219 206
210 459 408 368 334 306 283 263 245 230 216
220 481 428 385 350 321 296 275 257 241 226
230 503 447 403 366 335 310 288 268 252 237
240 525 467 420 382 350 323 300 280 263 247
250 547 486 438 398 365 337 313 292 273 257
260 569 506 455 414 379 350 325 303 284 268
270 591 525 473 430 394 365 338 315 295 278
280 613 544 490 445 408 377 350 327 306 288
290 634 564 508 461 423 390 363 338 317 299
300 656 583 525 477 438 404 375 350 328 309
310 678 603 543 493 452 417 388 362 339 319
320 700 622 560 509 467 431 400 373 350 329
330 642 578 525 481 444 413 385 361 340
340 661 595 541 496 458 425 397 372 350
350 681 613 557 510 471 438 408 383 360
360 700 630 572 526 484 450 420 394 370
380 666 604 554 512 472 444 416 392
400 700 636 584 538 500 466 438 412
420 668 612 566 526 490 460 432
440 700 642 592 550 514 482 452
460 670 620 576 536 504 472
480 700 646 600 560 526 494
500 674 626 584 546 514
520 700 650 606 568 536
540 676 630 590 556
560 700 654 612 576
580 676 634 598
600 700 656 618
620 678 638
640 700 658
660 680
680 700
700
CC Speed Setting =
Desired IPM
X 35
Arc Volts
LN-15
OPERATION
B-11 B-11
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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
NOTES
B-12 B-12
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LN-15
Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories ............................................................................................................Section C
Factory Installed Equipment.........................................................................................C-2
Optional Equipment......................................................................................................C-2
LN-15
ACCESSORIES
C-2 C-2
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FACTORY INSTALLED EQUIPMENT
• K1500-2 Gun Receiver Bushing.
WIRE TYPE ELECTRODE SIZE KP KIT
Steel Wires: .023-.030" (0.6-0.8mm) KP1696-030S
(Including stainless steel) .035" (0.9mm) KP1696-035S
.040-.045" (1.0-1.2mm) KP1696-045S
.052" (1.4mm) KP1696-052S
Cored Wires: .030-.035" (0.8-0.9mm) KP1697-035C
.040-.045" (1.0-1.2mm) KP1697-045C
.052" (1.4mm) KP1697-052C
1/16" (1.6mm) KP1697-1/16C
.068" (1.7mm) KP1697-068
5/64" (2.0mm) KP1697-5/64
Aluminum Wires: .035" (0.9mm) KP1695-035A
.040" (1.0mm) KP1695-040A
3/64" (1.2mm) KP1695-3/64A
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.
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