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: [phone] FAX: [phone] 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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LN-15

Section D-1 Section D-1

TABLE OF CONTENTS

- MAINTENANCE SECTION -

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

Routine Maintenance.....................................................................................................D-2

Periodic Maintenance....................................................................................................D-2

Calibration Specification ...............................................................................................D-2

Major Component Locations.........................................................................................D-3

D-2 D-2

LN-15

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MAINTENANCE

ELECTRIC SHOCK can kill.

• Do not operate with covers
removed.

•Turn off power source before
installing or servicing.

• Do not touch electrically hot
parts.

• Turn the input power to the welding power
source off at the fuse box before working in the
terminal strip.

• Only qualified personnel should install, use or
service this equipment.

WARNING

SAFETY PRECAUTIONS

ROUTINE MAINTENANCE

Routine maintenance consists of periodically blowing
out the machine, using a low pressure airstream, to
remove accumulated dust and dirt from inside the

feeder.

PERIODIC MAINTENANCE

• Replace the drive rolls and inner wire guide when
they are worn.

• Replace the pig tail if the insulation is cut, abraded or
damaged.

CALIBRATION SPECIFICATION

All calibration is factory set on the LN-15.
To verify the wire feed speed:

• Assemble a .045 (1.2mm) drive roll kit into the LN-

15.

• Load a spool of .045 (1.2mm) electrode and thread
the electrode through the wire drive.

• Adjust the wire feed speed to 300 in/min
(7.62m/min).

• Press the COLD FEED switch and measure the
actual wire feed speed with a calibrated wire feed
speed tachometer.

• The measured wire feed speed should be within 2%
of the set value.

To verify the voltage display:

• Set the welding power source and LN-15 to a CV
procedure that gives steady "spray" transfer in the
arc.

• While a weld is being made, measure the voltage
from the feed plate to work.

• The displayed voltage on the LN-15 should be with­in 2% of the measured value.

1

2

3

4

MAINTENANCE

D-3 D-3

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FIGURE D.1 – MAJOR COMPONENT LOCATIONS

1. Molded Case Assembly

2. Control Box Assembly

3. Control Box Cover Assembly

4. Wire Drive & Contactor Assembly

LN-15

LN-15

NOTES

D-4 D-4

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LN-15

Section E-1 Section E-1

Theory of Operation ...............................................................................................Section E

General Description ......................................................................................................E-2

Input Power...................................................................................................................E-2

Trigger & Control Circuits..............................................................................................E-3

Wirefeed Speed Control & Feedback...........................................................................E-4

Display Board ...............................................................................................................E-5

TABLE OF CONTENTS

- THEORY OF OPERATION SECTION -

CONTACTOR

ELECTRODE
INPUT VOLTAGE

TOROID
ASSEMBLY

FULL
WAVE
BRIDGE

WORK
SENSING
LEAD

ON/OFF
SWITCH

MOV

BOOST
POWER
SUPPLY
BOARD

FEED HEAD
BOARD SUPPLY

DRIVE MOTOR
SUPPLY

"WORK" VOLTAGE FEEDBACK #21

GAS
SOLENOID

"ELECTRODE"
FEEDBACK
VOLTAGE #67

FEED
PLATE

M
O
T
O
R

HALL
EFFECT
MODULE

RPM FEEDBACK

ARMATURE

WELDING

GUN

DISPLAY
BOARD

COLD
INCH
SWITCH

WIRE
FEED
SPEED
CONTROL

TRIGGER
INPUT &
PROCEDURE

TRIGGER
INTERLOCK
SWITCH

SPI COMMUNICATIONS
SHIELDED CABLE

FEED HEAD

CONTROL BOARD

LN-15 WIRE FEEDER
DISPLAY BOARD

FIGURE E.1 – LN-15 BLOCK LOGIC DIAGRAM

FIGURE E.2 – GENERAL DESCRIPTION & INPUT POWER

CONTACTOR

ELECTRODE
INPUT VOLTAGE

TOROID
ASSEMBLY

FULL
WAVE
BRIDGE

WORK
SENSING
LEAD

ON/OFF
SWITCH

MOV

BOOST
POWER
SUPPLY
BOARD

FEED HEAD
BOARD SUPPLY

DRIVE MOTOR
SUPPLY

"WORK" VOLTAGE FEEDBACK #21

GAS
SOLENOID

"ELECTRODE"
FEEDBACK
VOLTAGE #67

FEED
PLATE

M
O
T
O
R

HALL
EFFECT
MODULE

RPM FEEDBACK

ARMATURE

WELDING

GUN

DISPLAY
BOARD

COLD
INCH
SWITCH

WIRE
FEED
SPEED
CONTROL

TRIGGER
INPUT &
PROCEDURE

TRIGGER
INTERLOCK
SWITCH

SPI COMMUNICATIONS
SHIELDED CABLE

FEED HEAD

CONTROL BOARD

THEORY OF OPERATION

GENERAL DESCRIPTION

The LN-15 is a lightweight portable semi-automatic
wire feeder. The “Across the Arc” model is capable of
operating with Lincoln DC power sources supplying
between 15VDC to 110VDC. The LN-15 is designed
for semi-automatic use and has a 60% duty cycle rat­ing.

By attaching the work clip to the work piece and the
LN-15 electrode cable to the Lincoln power source the
LN-15 is ready to feed wire and weld. The LN-15 can
be connected for either welding polarity without any
changes to the LN-15. When the gun trigger is acti­vated and wire feeds and an internal contactor ener­gizes the electrode output.

The wire drive is capable of operating in either the con­stant voltage or the constant current mode. A con­stant current voltage power source is recommended
for flux-cored arc welding (FCAW) and gas metal arc
welding (GMAW) to obtain code quality results.

For non-critical quality applications a constant current
power source may be used.

The LN-15 comes factory equipped with a K1500-2
Tweco style #2-#4 gun bushing.

The “dual procedure” mode drops the wire feed speed
83% from the original set point. The voltage setting
remains the same.

INPUT POWER

The DC voltage supplied from the power source is
applied to the LN-15 through the electrode cable and
the work sensing lead. The voltage is applied to the
full wave bridge through a toroid assembly. When the
ON/OFF switch is put in the ON position the positive
DC voltage from the bridge is applied to the
Boost/Power Supply board through an M.O.V. assem­bly. This M.O.V. is needed to protect the Boost/Power
board from inductive energy stored in the welding
cables.

The Boost/Power Board takes the weld voltage and
boosts it to 80VDC or the actual arc voltage being
applied. (Whichever is greater). The outputs of the
Boost/Power board are two separate 80VDC+ supply
voltages. One of these is utilized and regulated by the
Feed Head Control board to power the wire drive
motor. The other 80VDC supply is regulated to create
several plus and minus regulated DC supplies. These
+/-15VDC and +/-5VDC supplies are used to power
the electronics within the Feed Head board and other
components in the LN-15 such as the gas solenoid.

E-2 E-2

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LN-15

LN-15

THEORY OF OPERATION

TRIGGER AND CONTROL CIRCUITS

When the gun trigger is closed (activated) the Feed
Head Board is “signaled” to apply armature voltage
to the drive motor, activate the gas solenoid and
close the LN-15 internal contactor. When the con­tactor is closed the welding current path from the
electrode cable to the conductor block is completed.
This sequence will supply electrode wire, arc voltage
and current to the welding gun.

The Cold Inch/Gas Purge Switch allows the user to
feed wire without closing the contactor. This feature
gives the operator an electrically “cold” electrode
even though the power source’s output terminals are
electrically “hot”. This switch also allows the user to
activate the gas solenoid without feeding wire or
closing the contactor.

When activated the Trigger Interlock Switch keeps
the gun trigger circuit closed even when the operator
releases the trigger. This is useful when making long
welds.

E-3 E-3

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

FIGURE E.3 – TRIGGER & CONTROL CIRCUITS

CONTACTOR

ELECTRODE
INPUT VOLTAGE

TOROID
ASSEMBLY

FULL
WAVE
BRIDGE

WORK
SENSING
LEAD

ON/OFF
SWITCH

MOV

BOOST
POWER
SUPPLY
BOARD

FEED HEAD
BOARD SUPPLY

DRIVE MOTOR
SUPPLY

"WORK" VOLTAGE FEEDBACK #21

GAS
SOLENOID

"ELECTRODE"
FEEDBACK
VOLTAGE #67

FEED
PLATE

M
O

T
O
R

HALL
EFFECT
MODULE

RPM FEEDBACK

ARMATURE

WELDING

GUN

DISPLAY
BOARD

COLD
INCH
SWITCH

WIRE
FEED
SPEED
CONTROL

TRIGGER
INPUT &
PROCEDURE

TRIGGER
INTERLOCK
SWITCH

SPI COMMUNICATIONS
SHIELDED CABLE

FEED HEAD

CONTROL BOARD

LN-15

.THEORY OF OPERATION

E-4 E-4

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FIGURE E.4 – WIRE FEED SPEED CONTROL & FEEDBACK

CONTACTOR

ELECTRODE
INPUT VOLTAGE

TOROID
ASSEMBLY

FULL
WAVE
BRIDGE

WORK
SENSING
LEAD

ON/OFF
SWITCH

MOV

BOOST
POWER
SUPPLY
BOARD

FEED HEAD
BOARD SUPPLY

DRIVE MOTOR
SUPPLY

"WORK" VOLTAGE FEEDBACK #21

GAS
SOLENOID

"ELECTRODE"
FEEDBACK
VOLTAGE #67

FEED
PLATE

M

O
T
O
R

HALL
EFFECT
MODULE

RPM FEEDBACK

ARMATURE

WELDING

GUN

DISPLAY
BOARD

COLD
INCH
SWITCH

WIRE
FEED
SPEED
CONTROL

TRIGGER
INPUT &
PROCEDURE

TRIGGER
INTERLOCK
SWITCH

SPI COMMUNICATIONS
SHIELDED CABLE

FEED HEAD

CONTROL BOARD

WIRE FEED SPEED CONTROL AND
FEEDBACK

The combination of the Procedure Switch and the Wire
Feed Speed control provide a command voltage for
the Feed Head Control Board. The Hall Effect module
(Tach) monitors the motor RPM and outputs a digital
voltage frequency “feed back” that is delivered to the
Feed Head Board.

When operating in the constant voltage (CV) mode the
Feed Head Board monitors the feedback signal and
compares it to the command voltage and delivers the
appropriate armature voltage to the wire feed motor.
In this manner a constant wire feed speed is main­tained.

When the LN-15 is connected to a constant current
(CC) power source a variable wire feed speed is desir­able to compensate for the varying arc voltages asso­ciated with the constant current process. To accom­plish this the Feed Head Board monitors the command
voltage, the feed back signal from the Hall Effect mod-

ule and the arc voltage. These three factors are com­pared and the appropriate armature voltage is applied
to the wire feed motor to compensate for the varying
arc lengths and associated arc voltages.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

THEORY OF OPERATION

DISPLAY BOARD

The Display Board provides information to the user
through digital displays and LED’s. The Display Board
communicates with the Feed Head Board via the SPI
Bus cable.

The wire feed speed display shows the rate that the
LN-15 will feed wire during the welding process. The
wire feed speed is calibrated to within +/-2%. It
always displays the preset WFS.

The arc voltage display shows the average actual arc
voltage during the welding process. When welding
ceases the average arc voltage will continue to be
shown for 5 seconds. When not welding the display
show “----“. The voltage is calibrated to +/-2% over a
range of 10 to 45VDC. A negative “-“ will be automat­ically displayed when the LN-15 is configured for elec­trode negative processes.

All of the LEDs will briefly light when the machine is
first turned on.

E-5 E-5

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FIGURE E.5 – DISPLAY BOARD

CONTACTOR

ELECTRODE
INPUT VOLTAGE

TOROID
ASSEMBLY

FULL
WAVE
BRIDGE

WORK
SENSING
LEAD

ON/OFF
SWITCH

MOV

BOOST
POWER
SUPPLY
BOARD

FEED HEAD
BOARD SUPPLY

DRIVE MOTOR
SUPPLY

"WORK" VOLTAGE FEEDBACK #21

GAS
SOLENOID

"ELECTRODE"
FEEDBACK
VOLTAGE #67

FEED
PLATE

M
O

T
O
R

HALL
EFFECT
MODULE

RPM FEEDBACK

ARMATURE

WELDING

GUN

DISPLAY
BOARD

COLD
INCH
SWITCH

WIRE
FEED
SPEED
CONTROL

TRIGGER
INPUT &
PROCEDURE

TRIGGER
INTERLOCK
SWITCH

SPI COMMUNICATIONS
SHIELDED CABLE

FEED HEAD

CONTROL BOARD

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

LN-15

LN-15

NOTES

E-6 E-6

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LN-15

Section F-1 Section F-1

TABLE OF CONTENTS

- TROUBLESHOOTING & REPAIR SECTION -

Troubleshooting & Repair Section ........................................................................Section F

How to Use Troubleshooting Guide..............................................................................F-2

PC Board Troubleshooting Procedures and Replacement...........................................F-3

Troubleshooting Guide..................................................................................................F-4

Test Procedures

Boost Power Board Test .................... .................................................................F-11

Gas Solenoid Valve Test .......................................................................................F-15

Contactor Test ......................................................................................................F-17

Drive Motor Test ...................................................................................................F-19

Hall Effect Module Test.........................................................................................F-21

Replacement Procedures

Contactor Removal and Replacement .................................................................F-23

Feedhead Control Board Removal and Replacement .........................................F-27

Boost Power Supply Board Removal and Replacement .....................................F-31

Wire Drive Assembly Removal and Replacement................................................F-35

Cover & Spindle Mount Removal and Replacement............................................F-37

Roll Cage Removal and Replacement .................................................................F-41

Retest After Repair ...............................................................................................F-43

HOW TO USE TROUBLESHOOTING GUIDE

Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.

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LN-15

TROUBLESHOOTING & REPAIR

F-2 F-2

CAUTION

This Troubleshooting Guide is provided to help
you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible
symptoms that the machine may exhibit. Find
the listing that best describes the symptom that
the machine is exhibiting. Symptoms are
grouped into three main categories: Feeding
Problems and Welding Problems.

Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be
conducted without removing the case
wrap-around cover.

Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the
subject component is either good or bad. If there
are a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.

All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced
electrical wiring diagrams and schematics. Refer
to the Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.

LN-15

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TROUBLESHOOTING & REPAIR

F-3 F-3

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.

2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.

3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:

PC board can be damaged by static electricity.

- Remove your body’s static
charge before opening the static­shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
to a grounded part of the
equipment frame.

- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.

- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

ELECTRIC SHOCK
can kill.

•

Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.

- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield­ing bag.

- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.

- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop­er failure analysis.

4. Test the machine to determine if the failure

symptom has been corrected by the
replacement PC board.

NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.

NOTE

: Allow the machine to heat up so that all

electrical components can reach their operating
temperature.

5. Remove the replacement PC board and

substitute it with the original PC board to
recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.

6. Always indicate that this procedure was

followed when warranty reports are to be
submitted.

NOTE

: Following this procedure and writing on the

warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.

PC BOARD TROUBLESHOOTING PROCEDURES

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

WARNING

CAUTION

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TROUBLESHOOTING & REPAIR

F-4 F-4

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FEEDING PROBLEMS

Major physical or electrical damage is evident when the sheet metal cover(s) are removed.

1. Contact your local authorized
Lincoln Electric Field Service
Facility for assistance.

1. Contact the Lincoln Electric
Service Department,

1-888-935-3877.

The LN-15 does not “power-up” when the on/off switch is turned to the ”ON”position.

1. Make sure the correct input volt­age is being applied (15 to
110VDC). See Specifications

Pages.

2. Make certain the “Work Clip” is

attached securely to the work
piece.

1. Check the on/off switch. See
the wiring diagram.

2. Check the input rectifier bridge.

See the wiring diagram.

3. Perform the Boost Power

Supply Board Test.

4. The control board may be faulty.

5. If the Display Board is not lit

check the input voltages to the
Display Board. See the Wiring
Diagram.

When the gun trigger is activated the wire drive runs and electrode wire feeds, but there is no welding output.

1. Make sure the contactor is func­tioning correctly.

2. Check the current carrying leads
at the contactor and between
the contactor and the feed plate
for loose or faulty connections.
See the Wiring Diagram.

3. Make sure the welding gun is
connected correctly and func­tioning correctly.

4. Make certain the DC power
source is functioning correctly.

1. Perform The Contactor Test.

2. The Control Board may be faulty.

LN-15

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

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TROUBLESHOOTING & REPAIR

F-5 F-5

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FEEDING PROBLEMS

When the gun trigger is activated there is no wire feed.

1. Check to see if the drive rolls
are turning when the gun trigger
is pulled. If the drive rolls are
turning, then check for a
mechanical restriction in the
wire feed path.

2. If the drive rolls do not turn
then check to make sure the
correct DC voltage is being
applied to the LN-15. (15­110VDC).

3. Make sure the gun trigger is
functioning correctly.

1. With the gun trigger circuit acti­vated (see the Wiring Diagram)
and the LN-15 set for constant
voltage operation, check the
presence of 2.6 to 27.4VDC at
leads 550+ to 551-. This is the
voltage that is applied to the
wire drive motor. This voltage
is dependent upon the wire
feed speed setting.

2. If the correct voltage is being
applied to the drive motor and
the motor does not run the
motor or motor brushes may be
faulty.

3. If the correct voltage is not

being applied to the drive
motor the Control Board may
be faulty.

The wire feeds for a short period of time but then stops feeding. When the gun trigger is released then re-activated the wire resumes feeding but soon stops again.

1. The drive motor may be over­loaded. Check the wire feed­ing path for mechanical restric­tions.

2. While welding make certain the

power source arc voltage is
staying above 15VDC. The
feeder will not function properly
on less than 15VDC.

1. Check the motor armature cur­rent through either of the arma­ture leads (550 or 551). It
should not exceed 3.5 amps
DC.

2. If more than 3.5 amps is indi­cated, then the motor is draw­ing too much current. Check or
replace the motor brushes.

3. If less than 3.5 amps is indicat­ed and the motor is being dis­abled by the Control Board,
then the Control Board may be
faulty. Replace.

4. The motor or gearbox may be
faulty. Replace.

LN-15

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.

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LN-15

TROUBLESHOOTING & REPAIR

F-6 F-6

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FEEDING PROBLEMS

The wire stops or stubs while welding.

1. If the LN-15 is connected to a
constant current power source
the arc voltage may be “dip­ping” below the 15VDC thresh­old that is essential for proper
operation.

2. Try connecting the LN-15 to a

constant voltage power
source.

3. Check for mechanical restric-

tions in the wire feeding path.

1. Monitor the motor armature
voltage (leads 550 to 551).
Normal voltage range is 2.6VDC
to 27.4VDC dependent upon
wire feed speed. If the armature
voltage is correct then check or
replace the motor brushes.

2. If the motor armature voltage is
not correct then the Control
Board may be faulty.

The wire feed speed range is only 50 to 374 IPM.(1.3 to 9.5m/min.

1. The 83%wire feed speed dual
procedure is activated with the
low speed gear.

1. Tu rn off the 83% procedure
switch to return to the full wire
feed speed range.

2. Check the wiring between the

procedure switch and the con­trol board. See the Wiring
Diagram.

3. The control board may be faulty.

Replace.

The wire feed speed range is only 50 to 600 IPM.(1.3 to 15.3 m/min)

1. The 83%wire feed speed dual
procedures switch is activated
with the high speed gear in
place.

1. Turn off the 83% procedure
switch to return to the full wire
feed speed range.

2. Check the wiring between the
procedure switch and the
Control Board. See the wiring
diagram.

3. The Control Board may be
faulty. Replace.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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LN-15

TROUBLESHOOTING & REPAIR

F-7 F-7

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FEEDING PROBLEMS

The wire feed motor runs very fast and there is no control.

1. Make sure the LN-15 is operat­ing in the CV mode.

2. Make sure the wire speed con­trol and procedure switch are
operating correctly. See the
wiring diagram

1. Perform the Wire Drive Motor

Test.

2. Perform the Hall Effect Module
Test.

3. The Control Board may be faulty.
Replace.

The wire feed speed varies during welding but the meter reading remains constant.

1. The drive rolls may be slipping
causing feeding problems.

2. The LN-15 may be in the
Constant Current mode. Verify
on power-up that the LN-15 is
set for Constant Voltage weld­ing.

3. Reduce the spindle brake resis­tance.

1. Perform the Wire Drive Motor

Test.

2. Perform the Hall Effect Module
Test.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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LN-15

TROUBLESHOOTING & REPAIR

F-8 F-8

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

WELDING PROBLEMS

No shielding gas. 1. Make sure the gas supply is ade-

quate and the gas hoses are not
loose or kinked.

1. If the gas solenoid is not operat-

ing perform the Gas Solenoid

Test.

2. The Control Board may be faulty.

The shielding gas turns on sporad­ically, or remains on all the time.

1. The pressure in the gas line may
have exceeded 80psi (5.5 bar)

1. Perform the Gas Solenoid Test.

2. The Control Board may be faulty.

The welding arc burns back to the tip.

1. Check the wire feeding path for

mechanical restrictions,

2. Make sure the polarity is correct

for the process.

3. The contact tip may be worn.

4. The welding voltage may be set

too high or the wire feed speed
set too low.

5. Check the wire drive tension.

1. Perform the Wire Drive Motor

Test.

2. Perform the Hall Effect Module
Test.

The Display board shows “POS” “PRE” or “BRN”.

1. The LN-15 is in the “Press and
Spin” set-up mode.

2. One of the dip switches on the
control board is set to “ON” for
the timer setting mode.

1. The Control board may be faulty.

2. The Display Board may be faulty.

There is porosity in the weld.

1. The part being welded may be
wet or very dirty.

2. The electrode being used may
be wet or rusty.

3. The shielding gas may be wrong
for the process.

4. There may not be enough shield­ing gas.

5. Make sure the wire feed speed
and arc voltage are correct for
the process.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

LN-15

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RESOLUTION

DESCRIPTION/

DEFINITION

0081

0082

0086

Average motor over cur­rent shutdown

Locked rotor condition
on the wire drive motor.

Trigger lockout.

TROUBLESHOOTING & REPAIR

F-9 F-9

FAULT CODES

NOTE: If more than one fault message is being displayed, perform all the checks for the faults

before replacing the printed circuit board

• The wire drive motor has overheated.

• Check to make sure the electrode
slides easily through the liner of the
gun.

• Reduce the spindle brake resistance.

• Reduce the amount of tension in the
wire drive tension arm.

• For the best results, use only Lincoln
electrodes.

•Wait 10 minutes for the wire feeder to
cool.

•Verify that nothing is jammed in the
wire drive or gears.

• The ripple of the power source OCV
is too high, greater than 110V.
(Across the Arc Models only)

• Verify that the power source is
reconnected for the proper input
voltage.

• Repair or replace the power source.
The power source does not conform
to NEMA.

LN-15

NOTES

F-10 F-10

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Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

LN-15

F-11 F-11

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WARNING

TROUBLESHOOTING & REPAIR

BOOST POWER BOARD TEST

TEST DESCRIPTION

This procedure will determine if the correct input voltage is being applied to the Boost
Power Board and if the correct output voltage is being produced by the Boost Power

Board.

MATERIALS NEEDED

Volt/Ohm Meter

DC Voltage Source (15 to 110 VDC)

LN-15

F-12 F-12

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TROUBLESHOOTING & REPAIR

TEST PROCEDURE

1. Remove input power to the LN-15.

2. Perform the Cover and Spindle Mount removal

procedure.

3. Locate the Boost Power Board. See Figure F.1.

4. Apply the correct DC voltage to the LN-15 (15-110
VDC).

5. Check for the correct input voltage to the Boost
Power Board at leads 526A (+) to 527A(-) (15-110
VDC). See Figure F.3. If the input voltage is not
present check the input rectifier bridge and associ­iated circuits. See the wiring diagram.

6. Check for approximately 80 VDC at leads 501(+) to
502(-) . See Figure F.3.

7. Check for approximately 80 VDC at leads labeled
POS to NEG. See Figure F.3.

8. If the correct input voltage is present in step 5 and
either of the voltages in steps 6 or 7 are not present
the Boost Power Board is faulty. Replace.

BOOST POWER BOARD

FIGURE F.1 – BOOST POWER BOARD LOCATION

BOOST POWER BOARD TEST (continued)

LN-15

F-13 F-13

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TROUBLESHOOTING & REPAIR

C9

C10

J47

+ -

+ -

R2

R1

R71

R72

R14

R15

R16

FIGURE F.2 – BOOST POWER BOARD

526A

Neg.

Pos.

501

502

527A

FIGURE F.3 – PLUG J47 LEAD LOCATIONS

BOOST POWER BOARD TEST (continued)

LN-15

NOTES

F-14 F-14

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LN-15

F-15 F-15

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TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

GAS SOLENOID VALVE TEST

TEST DESCRIPTION

This test will determine if the gas solenoid valve is functional.

MATERIALS NEEDED

12 VDC Supply
Volt/Ohmmeter
DC Voltage Source (15 to 110 VDC)

LN-15

F-16 F-16

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TROUBLESHOOTING AND REPAIR

GAS SOLENOID

LEADS 552 &553

GAS SOLENOID VALVE TEST

(continued)

FIGURE F.4 – LEADS 552 & 553

TEST PROCEDURE

1. Remove power to the LN-15 machine.

2. Perform the Cover and Spindle
Mount removal procedure.

3. Locate and remove the two solenoid
leads 552 & 553 from the solenoid
valve. See Figure F.4.

4. Make sure the gas supply for the
solenoid is hooked up, and then apply
12 VDC to the gas solenoid.

5. If the solenoid activates and allows
gas flow, then the solenoid valve is
good.

NOTE

: There should not be any gas flow

until the solenoid is activated.

6. If the solenoid does not activate and
allow gas to flow, then the solenoid is
faulty. Replace.

7. The normal solenoid resistance is
approximately 20 to 21 ohms.

8. Normal voltage (with gun trigger
activated) measured at the solenoid
is 6.5 VDC (leads 552 & 553).

9. If the voltage is not present at leads
552 & 553 the feed head control
board may be faulty.

LN-15

F-17 F-17

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TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

CONTACTOR TEST

TEST DESCRIPTION

This test will determine if the contactor is functional.

MATERIALS NEEDED

12 VDC Supply
Volt/Ohmmeter

LN-15

F-18 F-18

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TROUBLESHOOTING AND REPAIR

LARGE TERMINAL
STUDS

LEADS 507 & 578 (blue)

CONTACTOR TEST

(continued)

FIGURE F.5 – CONTACTOR

TEST PROCEDURE

1. Remove input power to the LN-15.

2. Perform the Wire Drive Assembly

removal procedure.

3. Locate the contactor and leads 507
and 578 (blue) and separate the two
in line connectors. See Figure F.5.

4. Apply 12 VDC to the contactor coil
leads.

Do not leave the 12 VDC applied to the
contactor coil for a prolonged period of
time (15 seconds maximum). Damage to
contactor may result.

5. If the contactor does not activate
when the 12 VDC is applied, the
contactor is faulty. Replace.

Note: The normal contactor coil resistance

is approximately 4.4 ohms.

6. If the contactor activates when the 12
VDC is applied, check the resistance
between the two large terminal studs
with the contactor activated. The
resistance should be very low (0 to
1 ohm).

7. If the resistance is “high” or “open”
between the two large terminal studs
when the contactor is activated, the
contactor is faulty. Replace.

8. If the contactor activates and the
resistance between the terminals is
low when the 12 VDC is applied, the
contactor is good.

NOTE

: When the contactor is not activated,

the resistance between the terminals
should be very high (infinite). If the
resistance is always low, the
contacts are “stuck” and the
contactor is faulty. Replace.

CAUTION

LN-15

F-19 F-19

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TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

DRIVE MOTOR TEST

TEST DESCRIPTION

This test will determine if the Wire Drive Motor is functioning properly.

MATERIALS NEEDED

Voltage Source (variable 3 to 26 VDC)
Volt/Ohmmeter

LN-15

F-20 F-20

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LEADS
550 & 551

TEST PROCEDURE

1. Remove the input power to the LN-15.

2. Perform the Wire Drive Assembly

Removal procedure.

3. Locate the Positive lead 550 (white)
and disconnect from motor. Note pin
location for reassembly. See Figure
F.6.

4. Locate the Negative lead 551 (gray)
and disconnect from motor. Note pin
location for reassembly. See
Figure F.6.

5. Apply a variable DC voltage to the

drive motor from lead 550(white)(+) to
lead 551(gray)(-).

6. When the supply voltage is varied
from 3 to 26 VDC, the drive motor
speed (RPM) should vary accordingly.
If the motor does not run or vary in
speed, the motor, gearbox or motor
brushes may be faulty. Check or
replace.

7. Check the resistance between each
of the motor leads and the motor
case. The resistance should be very
high (at least 500,000 ohms). If the
resistance is low, the motor is
grounded to the motor case and
should be replaced.

TROUBLESHOOTING AND REPAIR

DRIVE MOTOR TEST (Continued)

Figure F.6- Motor Leads

LN-15

F-21 F-21

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TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

HALL EFFECT MODULE TEST

TEST DESCRIPTION

This test will determine if the Hall Effect Module is functioning properly.

MATERIALS NEEDED

Voltage Source (variable 15 to 110 VDC)
Volt/Ohmmeter

Blue
(562)

Red
(563)

Black
(561)

LN-15

F-22 F-22

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TEST PROCEDURE

1. Remove the input power to the LN-15.

2. Perform the Wire Drive Assembly

Removal procedure.

3. Locate the three Hall Effect leads at
Plug J2. See Figure F7.

4. Apply at least 15VDC but no more
than 115VDC to the LN-15 from the
electrode cable to the work sensing
lead.

5. Check for the presence of 5VDC from
lead 563 (Red+) to lead 561 (Black-).
If the 5VDC is not present or low, the
feed head control board may be
faulty.

6. Activate the LN-15 trigger circuit,
make sure the drive motor is running
and check for the presence of
approximately 2.8VDC from lead 562
(Red+) to lead 561 (Black-). The
value of 2.8VDC represents the
correct feedback voltage from the Hall
Effect device to the control board.

This value can also be measured

using a frequency counter
50 in./min. = 120 HZ
700 in./min. = 1.6 KHZ

7. If the above voltage reading is not
correct, the Hall Effect device may be
faulty.

TROUBLESHOOTING AND REPAIR

HALL EFFECT MODULE TEST (Continued)

Figure F.7 - PLUG J2 LEAD LOCATION

LN-15

F-23 F-23

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TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the contactor.

MATERIALS NEEDED

7/16” Wrench
3/4” Wrench
11/16” Wrench
Screwdriver

LN-15

F-24 F-24

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REMOVAL PROCEDURE

1. Remove the input power to the LN-15.

2. Perform the Roll Cage Removal

Procedure.

3. Perform the Wire Drive Assembly

Removal procedure.

4. Remove the two rubber roll cage
mounts that hold the contactor
assembly to the case bottom.

5. Using the 3/4” wrench remove the
welding cable from the contactor
assembly stud. See Figure F.8. Also
leads 567 & 567A.

6. Disconnect the two coil leads at their
in line connectors.

7. Disconnect and clear ground leads
as necessary.

8. Using the 7/16” wrench remove the
two bolts mounting the contactor

assembly to the divider plate. See
Figure F.8.

9. Carefully remove the contactor
assembly from the LN-15.

10. Using the 11/16” wrench remove the
cable and copper bus bar from the
contactor.

11. The contactor may now be removed

by using the screwdriver to remove
the four screws mounting the
contactor to the mounting plate.

TROUBLESHOOTING AND REPAIR

CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.8 - CONTACTOR LEAD LOCATION

Leads 567 & 567A

3/4" Nut

Copper Bus Bar

Welding Cable

7/16" Bolts

Divider Plate

LN-15

F-25 F-25

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REPLACEMENT PROCEDURE

1. Install the new contactor using the
four screws previously removed.

2. Replace the copper bus bar and cable.

3. Install the the contactor assembly into
the case.

4. Using the 7/16” wrench mount the
contactor assembly to the divider
plate.

5. Install the two rubber mounts
previously removed.

6. Connect the two coil leads.

7. Connect all group leads previously
removed.

8. Using the 3/4” wrench replace the
welding cable and lead 567 and 567A.

9. Replace the wire drive assembly.

10. Replace the roll cage.

TROUBLESHOOTING AND REPAIR

CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (Continued)

LN-15

NOTES

F-26 F-26

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LN-15

F-27 F-27

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

FEED HEAD CONTROL BOARD

REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Feed head
Control Board.

MATERIALS NEEDED

3/8” Wrench

LN-15

F-28 F-28

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TROUBLESHOOTING AND REPAIR

FEED HEAD CONTROL BOARD

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.9 - FEED HEAD CONTROL BOARD LOCATION

REMOVAL PROCEDURE

1. Remove input power to the LN-15.

2. Perform the Cover and Spindle

Mount Removal Procedure.

3. Locate the Feed head Control Board.
and plugs J81, J82, J83, J84, J85, J86
and J88. See Figure F.9 & See Figure

F.10.

4. Remove the seven plugs from the
board taking note of placement for
reassembly.

5. Using the 3/8” wrench remove the four
nuts holding the board in place.

6. Carefully remove the Feed head
Control Board.

REPLACEMENT PROCEDURE

1. Set the new Feed head Control Board
on the four mounting studs.

2. Secure with the four nuts previously
removed.

3. Replace the seven plugs previously
removed. See Figure F.10.

4. Replace the Cover and Spindle mount.

FEEDHEAD CONTROL BOARD

LN-15

F-29 F-29

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TROUBLESHOOTING AND REPAIR

FEED HEAD CONTROL BOARD

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.10 - FEED HEAD CONTROL BOARD

J81

J82

J83

J84

J85 J86

J88

3/8" Mounting
Nuts

3/8" Mounting
Nuts

LN-15

NOTES

F-30 F-30

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LN-15

F-31 F-31

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

BOOST POWER SUPPLY BOARD

REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Boost Power
Supply Board.

MATERIALS NEEDED

3/8” Wrench

LN-15

F-32 F-32

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TROUBLESHOOTING AND REPAIR

BOOST POWER SUPPLY BOARD

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.11 - BOOST POWER BOARD LOCATION

REMOVAL PROCEDURE

1. Remove input power to the LN-15.

2. Perform the Cover and Spindle

Mount Removal Procedure.

3. Locate the Boost Power Supply Board.
See Figure F.11.

4. Disconnect plug J47. See Figure F.12.

5. Using the 3/8” wrench remove the
three nuts holding the board in place.

6. Carefully remove the Boost Power
Supply Board.

REPLACEMENT PROCEDURE

1. Set the new Board on the mounting
studs.

2. Secure with the three nuts previously
removed.

3. Replace plug J47 previously removed.

See Figure F.12.

4. Replace the Cover and Spindle mount.

BOOST POWER BOARD

LN-15

F-33 F-33

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TROUBLESHOOTING AND REPAIR

BOOST POWER SUPPLY BOARD

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.12 - BOOST POWER BOARD PLUG/MOUNT LOCATION

C9

C10

J47

+ -

+ -

R2

R1

R71

R72

R14

R15

R16

3/8" Mounting
Nuts

3/8" Mounting
Nut

LN-15

NOTES

F-34 F-34

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LN-15

F-35 F-35

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

WIRE DRIVE ASSEMBLY

REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Wire Drive
Assembly.

MATERIALS NEEDED

3/8” Wrench
3/4” Wrench
Screwdriver
Small Pliers

LN-15

F-36 F-36

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TROUBLESHOOTING AND REPAIR

WIRE DRIVE ASSEMBLY

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.13 - WIRE DRIVE MOUNTING SCREW LOCATION

REMOVAL PROCEDURE

1. Remove input power to the LN-15.

2. Open door.

3. Remove the four screws mounting the
wire drive assembly to the case. See
Figure F.13.

4. Using small pliers disconnect the gas
hose from the conductor block.

5. Carefully maneuver the drive assembly
out of the case.

6. Using the 3/4” wrench remove the
cable from the conductor block.

7. Remove lead 67 from the conductor
block. See Wiring Diagram.

8. Remove plug J2.

REPLACEMENT PROCEDURE

1. Connect previously removed plug J2
to the new conductor block.

2. Replace lead 67 into the conductor

block.

3. Replace the cable onto the conductor

block.

4. Replace the gas hose onto the

conductor block.

5. Carefully maneuver the Wire Drive

Assembly into the case.

6. Secure assembly to machine using the

four previously removed screws.

MOUNTING SCREWS

LN-15

F-37 F-37

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TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

COVER AND SPINDLE MOUNT

REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Cover and
Spindle Mount Assembly.

MATERIALS NEEDED

3/8” Wrench
1/2” Wrench
Large Pliers

LN-15

F-38 F-38

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TROUBLESHOOTING AND REPAIR

COVER AND SPINDLE MOUNT

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.14 - COVER AND SPINDLE MOUNT LOCATION

REMOVAL PROCEDURE

1. Remove input power to the LN-15.

2. Open door.

3. Locate the spindle mount and cover
assembly. See Figure F.14.

4. Using the 1/2” wrench remove the one
bolt from the top of the cover.

5. Using the 3/8” wrench remove the five
mounting screws. See Figure F.15.

6. Using the large pliers loosen and
remove the cord grip nut. See Figure
F.14.

7. Pull the electrode cable inward through
the rear case.

8. Disconnect the gas hose from the
conductor block on the Wire Drive
Assembly.

9. Carefully remove the cover and spindle
assembly from the case. Be careful
not to damage the switches, leads or
solenoid.

10. If complete removal is necessary
disconnect the leads from the
switches and solenoid. Be sure to
label for reassembly.

Cover

Spindle Mount

Cord Grip Nut

LN-15

F-39 F-39

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TROUBLESHOOTING AND REPAIR

COVER AND SPINDLE MOUNT

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

REPLACEMENT PROCEDURE

1. Replace all leads to switches and
solenoid.

2. Maneuver assembly into case.

3. Connect gas hose to conductor block.

4. Replace five mounting screws.

5. Replace bolt into top of case.

6. Replace the electrode cable into the
cord grip. Replace and tighten the nut.

Figure F.15 - COVER AND SPINDLE MOUNT SCREW LOCATION

1/2" Bolt

Screw

Screw

Screw

Screw

Screw

LN-15

F-40 F-40

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NOTES

LN-15

F-41 F-41

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

TROUBLESHOOTING AND REPAIR

Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty . For
your safety and to avoid electrical shock, please observe all safety notes and pre­cautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to per­form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

WARNING

ROLL CAGE

REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Roll Cage.

MATERIALS NEEDED

7/16” Wrench

LN-15

F-42 F-42

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TROUBLESHOOTING AND REPAIR

ROLL CAGE

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.16 - ROLL CAGE BOLT LOCATION

REMOVAL PROCEDURE

1. Remove input power to the LN-15.

2. Using a 7/16” Wrench remove the five
bolts securing the roll cage to the LN­15 case.

3. Carefully remove the roll cage.

1/2" Bolt

7/16" Bolts

LN-15

TROUBLESHOOTING AND REPAIR

F-43 F-43

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RETEST AFTER REPAIR

If a failed test indicates that any mechanical part that could affect the machine’s electri­cal characteristics must be replaced or if any electrical components are repaired of
replaced, the machine must be retested and meet the following standards.

Wire Feed Speed...................................... 50 thru 700 inches per minute

Gas Solenoid............................................. Must operate when gun trigger is activated

Contactor................................................... Must operate when gun trigger is activated

LN-15

NOTES

F-44 F-44

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LN-15

Section G-1 Section G-1

TABLE OF CONTENTS

- ELECTRICAL DIAGRAMS SECTION -

Electrical Diagrams ...............................................................................................Section G

Wiring Diagram (L11436-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2

Entire Machine Schematic (G4198-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3

Boost PC Board Schematic (L11818-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4

Boost PC Board Assembly (M19753-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*G-5

Feedhead PC Board Schematic (G3883-1E0/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6

Feedhead PC Board Schematic (G3883-1E0/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7

Feedhead PC Board Assembly (G3884-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*G-8

SPI Display PC Board Schematic (L11756-1E1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9

SPI Display PC Board Assembly (L11757-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10

* NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore consid­ered to be unserviceable. The Assembly drawings are provided for reference only.

ELECTRICAL DIAGRAMS

G-2

LN-15

WIRING DIAGRAM - ENTIRE MACHINE - (L11436-1)

G-2

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

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L11436-1

ENGINEERING CONTROLLED
MANUFACTURER:

J1,J86

PRINT TO 8.5 X 11.0

No

CHANGE DETAIL:

RELEASED A.02 FROM "X"

LN-15 ACROSS THE ARC MODEL

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

J81,J82

1

6

1

3

N.C.

2

J83,J88

4

5

10

ON / OFF SWITCH

1

4

J85,J87

3

6

J2,J47,J84

1

9

526B
526C

1

5

8

16

S3

BAFFLE
MOUNTED

21A

RECTIFIER
DIODE
BRIDGE

L1

-

21B

67

FEED
PLATE

N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.
N.C. TOGGLE SWITCHES AND POTENTIOMETERS SHOWN FROM CONNECTION SIDE OF SWITCH.

L2

GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537

4

8

W - WHITE

+

526C

567

21

527

COLOR CODE

MOV ASBLY

320V, 150J

B - BLACK
R - RED

U - BLUE

526

B

W

MOTOR /
GEARBOX

.0047/.005 mF,
1400VDC

1M W

MOV ASBLY

L3

TO

WORK

150V, 300J

TACH.

320V, 150J

N.A.

POWER SUPPLY P.C. BOARD

J47

NEG

8

5

6

7

3

4

501

J81

J82

J83

J84

5

7

4

587

559

558

512

S1

CONTROL P.C. BOARD

5

16

2

3

4

J85

9

12

11

8

10

13

14

15

1

589

N.C.

589

587

J88

J87

9

8

10

7

11

16

2

3

4

6

1

2

3

4

DISPLAY P.C. BOARD

2-STEP
TRIGGER
INTERLOCK

S2

1
2
3
4
5
6

12

14

13

15

6

1

J86

9

8

5

7

9

58

6

7

J1

N.C.

10

10

21A
KEYING PLUG

67

578

N.A.

SHIELDED CABLE
DRAIN LEAD

POS

1
2

3
4
5
6

7
8

527A

502

501

WIRE FEED

SPEED

CONTROL

POTENTIOMETER

J3

A
B
C

554A

D
E

L6

577

1
2

576

3

575

N.B.

556
554

555

J2

552

GAS

SOLENOID

553

CONTACTOR

507

GND-B

N.C.

GND-D

578

TRIGGER

INPUT

83%

PROCEDURE

567

INPUT

10K2W

GND-C

TRIGGER

CONNECTOR

502
501

NEG

POS

L5

550
551
552
553
507

563

561
575

576
562
577

16

2

556

554

555

COLD INCH/
GAS PURGE

558
512
559

1
2
3
4

1
2
3
4

1
2

3
4
5
6

1

2
3
4
5
6
7
8

3

1

2

526A

N.B.

B

W

R
U
B

L4

B

R

U

GND-A

567A

INPUT ELECTRODE

CABLE CONNECTION

A
L11436-1

CLEVELAND, OHIO U.S.A.

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

REFERENCE:

TJP/KJ

E. ENYEDY

EQUIPMENT TYPE:

L11436

SUBJECT:

SCALE:

MATERIAL

1:1

DISPOSITION:

NA

SEMI-AUTOMATIC WIRE FEEDER

LN-15 WIRING DIAGRAM ACROSS THE ARC

APPROVAL
DATE:

5/23/03

PROJECT
NUMBER:

CRM35166

DOCUMENT
NUMBER:

L11436-1

1

PAGE ___ OF ___

1

DOCUMENT
REVISION:

A

STRP

E
G
D
E

D

I

L
O
S

EN-168

PROPRIETARY & CONFIDENTIAL:

UNLESS OTHERWISE SPECIFIED TOLERANCE

MANUFACTURING TOLERANCE PER E2056

ON 2 PLACE DECIMALS IS ± .02

ON 3 PLACE DECIMALS IS ± .002

ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE

WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING

t

DESIGN INFORMATION
DRAWN BY:
ENGINEER:

APPROVED:

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ELECTRICAL DIAGRAMS

G-3

LN-15

SCHEMATIC - ENTIRE MACHINE - (G4198-1)

G-3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

G4198-1

ENGINEERING CONTROLLED

General Notes:

Codes 10864,11033 & 11035 do not support the high/low speed gear

x

change. Only the high speed (1.8" diameter) gear may be used.

Error
Code

Err 0081 Average

Err 0086 Trigger

MANUFACTURER:

Description Cause and Remedy

motor Over­current
shutdown

lockout

The wire drive has exceeded the current rating:

 10 amps for 0.5 seconds or
 3.5 amps for 10 seconds.

Wait 45 seconds for the error to reset.
Reduce the current load on the motor by:

 Verifying the electrode slides easily through the

liner of the gun.

 Reduce the spindle brake resistance.
 Reduce the amount of tension in the wire drive

pressure arm.
 Use only Lincoln electrodes.
The voltage into the feed head board exceeds 150
VDC.

Some inverters and choppers may have spikes on the
output that charge the capacitors inside the LN-15
beyond limits. If this error occurs, lower the OCV of
the power source. It may be likely that a different
power source is required.

WFS Display

Voltage Display

No

RELEASED A.03 FROM "X"

Voltage LED

SPI DISPLAY

YELLOW

RED

RED

RED RED

L11757-1

Not Used

The display board communicates to the feedhead board through the SPI
bus. Only the power supply signals can be monitored during servicing.

The WFS always shows the present WFS.
The voltage display shows the voltage while welding, plus holds the

voltage for 5 seconds after the weld. It shows "- - -" when idle. A negative
"-" sign will automatically be shown when welding with reverse polarity
procedures.

All the LEDs, including those not used, will briefly light on power up. The
LED's not used are visible behind the nameplate when lit.

15-110 VDC from
welding power
source

All LED’s light
briefly

Show CC/CV
mode and HI/LO
gear

LN-15 ACROSS THE ARC MODEL

Positive
Voltage
Feedback

ON/OFF
SWITCH

526B

526C

Input
Power
Circuit

Input
Voltage
Protection

N.A. CAVIT Y NUM B E RI N G SE QU E N CE A S VI E W E D FROM C OM P ON E NT SI D E OF B OA R D.
N.B. CAVIT Y NUM B E RI N G SE Q UE N C E AS VI E W E D FR OM LE A D SI D E OF CO N N ECTOR.
N.C. TOGGLE S WITCHES AND POTE NTI OMETERS SHOW N FR OM C ON N E CTI O N SID E OF SWITCH.

TOROID

67

FEEDPLATE

Boost Board

Schematic M19752

21A

WORK
CLIP

Located on the right
side of the control box.

Common

ISOLATION

to '-' input

SWITCH (FET)

enabling

circuit

COM

o

o

t

s

B

u

r

c

i

t

C

i

COM

BOOST BOARD

The boost board takes the weld voltage
and boosts it to 80V DC for the rest of
the LN-15. There are two s upplies on
the boost board, one f or t he motor and
the other for the feedhead board. With
two supplies, even if the motor supply
should droop because of heavy loads,
power to the feed head board is not
affected.

The rectifier allows the LN-15 to
be powered either electrode
positive or electrode negative
without any s witches for the
customer to set.

Located under the cover
in the control box ably.

BRIDGE
RECTIFIER

526B

-

21B

TOROID

21

INPUT ELECTRODE
CABLE CONNECTION

- INPUT

COM

+

567

J47

8
7

6

5

4

3

2

1

526C

Pigtail

502

501

P

OS

N

EG

+ INPUT

526A

This large MOV
absorbs the
inductive energy in
the weld cables and
power source when
the contactor
opens.

150V, 300J

526

MOV ASBLY

Located in the control box next
to the Feedhead board.

15- 110 VDC

527

567A

- INPUT

527A

Located behind the insulating
wire drive panel. Remove the
wire drive ably to gain access.

MOV ASBLY

Not a PC board; no schematic.

Located behind the wire drive

320V, 150J

.0047/.005 mfd,
1400VDC

COM

FEEDHEAD SUPPLY

MOTOR SUPPLY

COM

TOROID

B

W

MOTOR /
GEARBOX

2.6 VDC @ 50 in/min

27.4 VDC @ 700 in/min
8 sec average Current
limit = 3.5 Amps
(Limit is softw are set)

1M ohms

320V, 150J

WFS
Control
Circuit

Wire Drive
Circuit

80VDC or w eld voltage,
whichever is higher

J2

8
7

Measure B to U
120 Hz @ 50 in/min

1.6 kHz @ 700 in/min

TACH.

R
U

B

TOROID

Access this connector
by removing the wire
drive asbly.

GND-A

Bussbar from input
stud to contactor

1
2
3
4
5

6

Located on the case
front. Remove the wire
drive asbly to gain
access.

Contactor

TOROID

GAS

SOLENOID

CONTACTOR
300A 60%

250A 100%

Coil measures 4.4 ohms.
0 VDC Open

2.3 VDC Closed
12 VDC coil
PWM Controlled

Gas Solenoid
Circuit

Motor +

Motor -

578

10K Ohms
3-1/2 turns

507

1
2
3

Gas Solenoid +

Gas Solenoi d -

see power
supply section
molex

15 VDC Tach Supply

Tach Signal

Tach COM

N.C.

GND-C

552

6.5 VDC when gas flowing
Coil measures 21 ohms

Located under the cover at

553

the rear of the feeder

WIRE FEED SPEED
CONTROL
POTENTIOMETER

GND-B

The contactor is
located behind
the glastic panel
next to the motor.

502

501

POS

NEG

550
551
552
553

563

562
561

Wiper to COM
5 VDC at 700 ipm
0 VDC at 50 ipm

POT Supply

577

576
575

Wiper
COM

Vin

+

J81

1
2
3
4

J83

6

J82

3
4
1

2

+15V

5

512

559

15 VDC

J83

1

2

3
4
5

5

6

6

J84

1
2

3

7

4

J84

8
6

5

k2

OM

C

k57.4

9

8

7

558

Gas Purge

2 Step

2 Step

589

587

Cold Inch

Gas Purge
15 VDC when Purge OFF
0 VDC when Purge ON

Cold Inch
15 VDC when Inch OFF
0 VDC when Inch ON

4-18J
4-28J
5-38J

6-38J
3-18J
3-28J

+5V (TACH)

10

2 Step Trigger
15 VDC for 2 Step
0 VDC for Interlock

INPUT VOLTAGE MONITOR
(MOTOR FETS AREBO TH
OFFWHENINPUT VOLTAGE
DROPS BELOW 20V)

niV+

+ motor

1200uF

COM

+ MOTOR

DRIVE

BRAKE

COM

COM

2k

4.75k

11

+15V

COM

14

13

558 (BLK)

559 (RED)

TACH

WFS
ANALOG
INPUT

A=1

A=1

INTERNAL
SWITCH
INPUTS

k2

15

6

1

TRIGGER

INTERLOCK

589
587

512

PWM

MOTOR

CONTROL

INPUT

MOC

k57.4

12

2-STEP

COLD INCH/
GAS PURGE

+

-

COM

5

V

+

163

4

554

Trigger Supply

+MOTOR

REWOP

REWOP
YLPPUS

YLPPUS

niV

AVERAGE
CURRENT
LIMITING

PULSE BYPULSE
PEAK CURRENT
LIMIT (27 AMPS)

gas
solenoid
PWM control
ckts

V51+

005

k57.4

2

J85

555

556

Trigger
15 VDC when Trigger and 83%
Switch Open
9 VDC when Trigger Open, 83 %

Trigger Input

83% Input

Switch Closed
0 VDC when Trigger Closed

83% Procedur e Input
0 VDC Normal

S2

9 VDC 83% switch Closed
and Trigger Open

S1

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

J81,J82

1

J1,J86

6

YLPPUS

ROTOM

V5+

OMEGATLOV

+15V

-15V

-5V
)HC

+5V(TA

V

+5

COM

CPLD

4

3

ROTIN

6

4

5

J85,J87

10

3

1

1

2

J83,J88

1

J2,J47,J84

5

1

8

16

9

FEED HEAD CONTROL

P.C. BOARD

Schematic G3883

ARC VOLTAGE
FEEDBACK
INPUT

78k

+

­78k

niV+

PWM
CONTROL
FOR
CONTACTOR

MICRO
CONTROLLER

LANRETXE
HCTIWS
STUPNI

005

005

For programming at LECo factor y only.

k57.4

CONNECTOR

554A

Not field reprogra mmable.

J87

8

5

7

3612

4

+ 5V

TRIGGER

Located on the lower left
of the front of the case.

J3

GUN

A

TRIGGER

B

INPUT

C

D

PROCEDURE

E

INPUT

The 83% pr o cedure reduces the
WFS to 83% of the set point, but
no less than 50 in/min. It is used
most often when pipe welding.

16

2

14

15

6

1

COM

+ 15V

3

4

Chip Select 1

+ 15 VDC SPI

+ 5 VDC SPI

Slave Select

SHIELDED CABLE
DRAIN LEAD

16

2

3

4

DISPLAY P.C. BOARD

Schematic L11756-x

9

10

11

12

13

83%

k57.4

556

554

555

GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537

4

8

W - WHITE

1M

J88

4

k

40

1

1M

J83

J88

4.5 A PEAK
CURRENT
LIMIT

SPI
CKTS

J86

9

8

5

10

7

Serial Clock

Chip Select 2

Master Out Slave In

Chip Select 3

COM

Master In Slave Out

9

58

10

7

J1

5

5

COLOR CODE

67

Work

21A

B - BLACK
R - RED

U - BLUE

Electrode Voltage

N.A.

GAS PURGE

GAS PURGE SWITCH

DEPRESSED

Enter Press and
Spin Mode

Idle:
Display WFS, “---”
Wire Drive: OFF
Gas Solenoid: OFF

EN-170

SWITCH OFF

Model Ranger 8,9 Classic Ranger 250, 305

K1870-1,-2 Across
the A rc



Recommended



all CV operation.

Recommended for CV



operation. (Wire
Feed Module
Required)

Commander 300,400,500

Recommended for CV



(Common Anal og

Controls)

operation.

V350

(Common Digital

Control s)

Recommended for



CV operation.

DC-400, 600 Square W ave TIG

Recommended



for CV and CC
operation.

300/355

Not recommended



for CC opera t io n
because the
customer may
experience short
contactor life from
inductive nature of
the pow er source.

Miller Inve rters STT II

Recommende



d for CV
voltage sense
operation.

Not



recommen d ed
for STT
operation.

Note:
Most s emiautomatic
wire welding
processes perform
better using co nstan t
voltage power sources.
Be sure the p r oper
power source is used
for yo ur application.
Contactor life may be
shortened in
applications using CC
mach ines with high
OCV.

Interlock
Circuit

Inch/Pu rg e
Circuit

PROPRIETARY & CONFIDENTIAL:

UNLESS OTHERWISE SPECIFIED TOLERANCE

MANUFACTURING TOLERANCE PER E2056

ON 2 PLACE DECIMALS IS ± .02

ON 3 PLACE DECIMALS IS ± .002

ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE

WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING

DESIGN INFORMATION
DRAWN BY:
ENGINEER:

t

APPROVED:

Gun Trigger
Circuit

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

REFERENCE:

E. ENYEDY/KJ

E. ENYEDY

G4198

SCALE:

NONE

EQUIPMENT TYPE:
SUBJECT:

MATERIAL

NA

DISPOSITION:

LN-15 (ACROSS THE ARC)

MACHINE SCHEMATIC

APPROVAL

05/27/2003

DATE:

PROJECT
NUMBER:

Display
Board
Circuit

CRM35166

PAGE ___ OF ___

DOCUMENT
NUMBER:

G4198-1

1

1

DOCUMENT
REVISION:

A

E
G
D
E
D

I

L
O
S

ELECTRICAL DIAGRAMS

G-4

LN-15

SCHEMATIC - BOOST PC BOARD - (L11818-2)

G-4

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-

vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

ELECTRICAL DIAGRAMS

G-5

LN-15

PC BOARD ASSEMBLY - BOOST - (M19753-2)

G-5

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

M19753-2

ENGINEERING CONTROLLED
MANUFACTURER:

No

CHANGE DETAIL:

NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY.

SEE E2454 BEFORE HANDLING.
N.B. MODULE IDENTIFICATION LABEL TO BE PLACED IN THIS AREA.
N.C. MOLEX CAVITES AND AREA AROUND LOCKING TAB TO BE FREE OF POTTING MATERIAL. MASK PER

APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
N.D. TORQUE TO 3.0 in. lbs. +/-10%.
N.E. ENCAPSULATE TO WITHIN .10 OF TRAY TOP. WHILE APPLYING ENCAPSULATION, APPLY SOME

OVER THE TOP OF ITEM 11.
N.F. PRINT “M19753-[ ] “ (LATEST DASH NUMBER AND I.D. CODE) BOARD LABEL.
N.G. ASSEMBLE ITEMS 1 THROUGH ITEMS 4 AS SHOWN. TORQUE MODULE TO 15-20 IN. LBS.
N.H. ASSEMBLE P.C. BOARD WITH CAPACITORS LOCATED AS SHOWN.

P.C. BOARD BLANK INFORMATION

BUY COMPLETE AS M19753-K (4 LAYER BOARD PER E3281)

(MAKES 8 BOARDS PER PANEL. SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)

PANEL SIZE PER E1911

REVISED ITEM 4 WASHER

ITEM REQ'D PART NO. DES CRIPTION

C1,C11 2 S13490-173 CAPACITOR,PEMF,1.0,63V,10%
C3,C7,C14,C28 4 S16668-11 CAPACITOR,CEM O ,0.1, 50V,10%
C4 1S16668-2 CAP A CITOR,CEMO , 47P , 100V , 5%
C5,C62S16668-10 CAPA CITOR,CEMO , 4700P , 50V , 2%
C8,C12 2 S13490-197 CAPACITOR,ALEL,82,35V,20%,LOW-ESR
C9,C10 2 S13490-195 CAPACITOR,ALEL,1200,160V,20%
C21,C26,C29 3 S16668-5 CAPACITOR,CEMO,.022,50V,20%

R19

-

C1

R9

C7

DZ1

R70

BOOST SUPPLY

M19753­2

+

C9

R2 R1

D9

R20

X2

C14

R68

FTP8

R64

R69

C29

R63

L1

N.C.

R5

TP1

FTP6

J47

R8

DZ2

FTP4

C3

R10

R12

R11

R75
R73
R74

R51

R60

X1

C4

C5

R7

R6

D1

D6

C6

R61

FTP7

C8

DZ6

C12

R21

DZ8

Q6

C24

Q1

-

+

C10

R71

TP2

R62

C26

C28

D7

R52

C21

R40

R39

DZ7

R37

R18

R72

C11

R17

A1

D2

D8

DZ9

FTP5

R67

R65

R66

R55

Q7

R14 R15 R16

Q5

R38

10 11

N.G.

1

N.G.

4

C241T11577-38 CAPACIT OR,CD,.02,600V,+80/-20%
D1 1T12705-23 DIODE,SCHOTTKY,AXLDS,1A,30V,1N5818
D2,D6,D7,D8,D9 5 T12705-34 DIODE,AXLDS,1A,400V,FR,1N4936
DZ11T12702-58 ZENER DIODE,5W ,16V,5% 1N5353B
DZ2,DZ9 2 T12702-45 ZENER DIODE, 1W,18V,5% 1N4746A
DZ6,DZ8 2 T12702-29 ZENER DIODE, 1W,15V,5% 1N4744A
DZ71T12702-27 ZENER DIODE, 1W,10V,5% 1N4740A
FTP4,FTP5,FTP6,FTP7,FTP8 5 TESTPT_FUNTION F UNCTIONA L TES T POINT
J471S24020-8 CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
L1 1 T12218-14 CHOKE,470UH,10%,11.4A,RADIAL
Q1 1T12704-72K2 MOSFET/HEATSINK ASBLY,T12704-72&S20590-2(SS)

N.A.

Q5,Q6,Q7 3 T12704-68 TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
R1,R2,R71,R72 4 S25365-00R1 RESISTOR,STAND-UP,WW,5W,0.1,5%
R5,R10 2 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
R6 1S19400-9092 RESISTOR,MF,1/4W,90.9K,1%
R7,R52 2 S19400-1821 RESISTOR,MF,1/4W,1.82K,1%
R8 1S19400-20R0 RESISTOR,MF,1/4W,20.0,1%
R9,R20 2 S19400-2673 RESISTOR,MF,1/4W,267K,1%
R111S19400-4321 RESISTOR,MF,1/4W,4.32K,1%
R121S19400-2213 RESISTOR,MF,1/4W,221K,1%
R14,R15,R16 3 S25365-3300 RESISTOR,STAND-UP,WW,5W,330,5%
R17,R18,R19 3 S19400-8251 RESISTOR,MF,1/4W,8.25K,1%
R211S19400-5622 RESISTOR,MF,1/4W,56.2K,1%
R37,R38 2 S19400-3322 RESISTOR,MF,1/4W,33.2K,1%
R39,R40,R64,R65,R66,R67 6 S19400-1003 RESISTOR,MF,1/4W,100K,1%
R511S19400-1000 RESISTOR,MF,1/4W,100,1%
R551S19400-1503 RESISTOR,MF,1/4W,150K,1%
R601S19400-3321 RESISTOR,MF,1/4W,3.32K,1%
R61,R73,R74,R75 4 S19400-47R5 RESISTOR,MF,1/4W,47.5,1%
R621S19400-6810 RESISTOR,MF,1/4W,681,1%
R631S19400-2211 RESISTOR,MF,1/4W,2.21K,1%
R681S19400-1004 RESISTOR,MF,1/4W,1.00M,1%
R691S19400-7501 RESISTOR,MF,1/4W,7.50K,1%
R701S19400-4753 RESISTOR,MF,1/4W,475K,1%
TP1,TP2 2 T13640-24 MOV,175VRMS,120J,20MM
X1 1M15458-8 IC,PWM-CONTROLLER,IMODE,2843A
X2 1S15128-4 OP-A M P , Q UAD, GE N-P URPO S E , 224N

N.G.

N.B.

6

12

5

N.G.

3

2

ISO VIEW

REFERENCE ONLY

N.F.

N.H.

8

MANUFACTURED AS:

4

M19753-2K0

}

IDENTIFICATION CODE

7

N.D.

MAKE PER E1911& E3875
TEST PER E4036-BT

ENCAPSULATE WITH ITEM 9

SCHEMATIC REFERENCE : L11818-2K0

ITEM PART NO. DESCRIPTION QTY

1M19996 HEA T SINK 1
2S25347-1 THERMAL INTERFACE PAD 1

N.A. 3 M16100-57 ELECTRONIC MODULE ASBLY 1

N.B., N.F. 12 E3768-4 LABEL 2

CF000012 1/4-20X.50HHCS 2

4

T12735-3 SPRING WASHER 2

CF000017 1/4-20 HN 2
5S25346-1 GASKET 1
6M19436-8 POTTING TRAY 1
7S8025-96 SELF TAPPING SCREW 2
8SEE ABOVE BOOST PC BD BLANK 1

*9E2527 EPOXY ENCAPSULATING RESIN

10 S20590-2 HE A T SINK 1
11 S25253-1 HE A T SINK MO UNTING CLIP 1

* THESE ITEMS NOT SHOWN

PROPRIETARY & CONFIDENTIAL:

UNLESS OTHERWISE SPECIFIED TOLERANCE

MANUFACTURING TOLERANCE PER E2056

ON 2 PLACE DECIMALS IS ± .02

ON 3 PLACE DECIMALS IS ± .002

ON ALL ANGLES IS ± .5 OF A DEGREE

MATERIAL TOLERANCE (" ") TO AGREE

WITH PUBLISHED STANDARDS.

EN-170

DO NOT SCALE THIS DRAWING

t

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

DESIGN INFORMATION
DRAWN BY:
ENGINEER:

APPROVED:

REFERENCE:

M19753-1

SCALE:

1:1

EQUIPMENT TYPE:
SUBJECT:

MATERIAL
DISPOSITION:

APPROVAL

UF

DATE:

BOOST BD HEATSINK ASBLY

FEI

05/12/2003

LN-15

PROJECT
NUMBER:

CRM22115-EF

DOCUMENT
NUMBER:

M19753-2

1

PAGE ___ OF ___

1

DOCUMENT
REVISION:

C

E
G
D
E
D

I

L
O
S

ELECTRICAL DIAGRAMS

G-6

LN-15

SCHEMATIC - FEEDHEAD P.C. BOARD - (G3883-1E0/1)

G-6

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

ELECTRICAL DIAGRAMS

G-7

LN-15

SCHEMATIC - FEEDHEAD P.C. BOARD - (G3883-1E0/2)

G-7

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-

vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

ELECTRICAL DIAGRAMS

G-8

LN-15

PC BOARD ASSEMBLY - FEEDHEAD - (G3884-1)

G-8

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

ELECTRICAL DIAGRAMS

G-9

LN-15

SCHEMATIC - SPI DISPLAY P.C. BOARD - (L11756-1E1)

G-9

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-

vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

ELECTRICAL DIAGRAMS

G-10

LN-15

PC BOARD ASSEMBLY - SPI DISPLAY P.C. BOARD - (L11757-1)

G-10

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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SVM ERROR REPORTING FORM

We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.

If you discover new or different “Problems or Symptoms” that are not covered in the three col­umn troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.

Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199

FAX [phone]

SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________

Please give detailed description below:
___________________________________________________________________________

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

SD287 01/99

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