Lincoln Electric LN-8, SVM132-A User Manual
LN-8 SEMIAUTOMATIC WIRE FEEDER
SERVICE MANUAL
SVM132-A
May, 2002
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.
For use with code numbers: 9963, 9964
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
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LN-8
SAFETY
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.
ii
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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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LN-8
SAFETY
iiii
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
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LN-8
SAFETY
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, VA 22202.
iiiiii
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.
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LN-8
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
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.
Mar. ‘93
LN-8
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - LN-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Power Source Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Power Source Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
LN-8S and LN-8SE Continuous Flux Feed (Submerged Arc) . . . . . . . . . . A-18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Avoiding Ground Lead Protector (GLP) Activation . . . . . . . . . . . . . . . . . . B-4
Wire Feed Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Setting for CV or CC Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Welding with a Constant Voltage Power Source . . . . . . . . . . . . . . . . . . . . B-7
Welding with a Constant Current Power Source . . . . . . . . . . . . . . . . . . . . B-7
Wire Reel Loading - 50 and 60 lb. Coils (K303 Wire Reel Stand) . . . . . . . B-8
Wire Reel Loading (K1524-1 Unversal Wire Reel Stand) . . . . . . . . . . . . . . B-9
Slow Acceleration Starting (Code 7926 and Above) . . . . . . . . . . . . . . . . . B-12
Flux Tank Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Reel Mounting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Welding Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Welding Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Constant Current Conversion Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Power Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Gun Trigger and 1CR Relay Contact Control Circuits . . . . . . . . . . . . . . . . E-3
Variable Voltage Board, Meter Shunt, Wire Speed
and Remote Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
LN-8 Electrical Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . F-24
Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-40
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P293 Series
vv
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SECTION A-1
INSTALLATION
LN-8
SECTION A-1
TABLE OF CONTENTS
-INSTALLATION SECTION-
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - LN-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Power Source Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
LN-8N and LN-8NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
LN-8S and LN-8SE (and converted LN-8N and LN-8NE) . . . . . . . . . . . . . . . . . . . . . . A-4
Power Source Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Connection of the LN-8 to an Idealarc R3S-400, 600 or 800
(with LVC) (Discontinued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Connection of LN-8 to an Idealarc R3S-400, 600 or 800
(without LVC) (Discontinued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Connection of LN-8 to a Sam Motor-Generator or Engine Driven Welder. . . . . . . . . . A-8
Connection of LN-8 to R3S-250 and R3S-325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Connection of LN-8 to DC-600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Connection of LN-8 to DC-250, 400 and CV/CVI Power Sources . . . . . . . . . . . . . . . . A-11
K318 Dual Process Contactor Kit DC-400, CV-400 and CVI-500 Connection
to LN-8 for Same Polarity Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
K318 Dual Process Contactor Kit DC-400, CV-400 and CVI-500 Connection
to LN-8 for Opposite Polarity Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
For Power Sources Other Than Lincoln Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Input Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
LN-8N and LN-8S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
LN-8NE and LN-8SE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
Gun Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
LN-8S and LN-8SE Continuous Flux Feed (Submerged Arc) . . . . . . . . . . . . . . . . . . . . . . A-18
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ELECTRODE DIAMETER
SOLID 0.030 in. through 3/32 in. (0.76 through 2.36 mm)
CORED 0.062 in. through 0.120 in. (1.57 through 3.05 mm)
OPERATING -4˚F to 104˚F (-20˚C to 40˚C)
STORAGE -31˚F to 185˚F (-35˚C to 85˚C)
A-2
INSTALLATION
LN-8
A-2
TECHNICAL SPECIFICATIONS – LN-8
INPUT – VOLTAGE
WIRE FEED SPEED
WIRE DIAMETERS
WEIGHT WIRE TOTAL WEIGHT
LENGTH WIDTH HEIGHT DRIVE UNIT ONLY LESS ELECTRODE
LN-8 WITH K303 30.25 in. 9.75 in. 26.50 in. 36.0 lb (◊) 80.0 lb. (◊)
(50-60 lb wire reel stand (768 mm) (248 mm) (673 mm) (16.3 kg) (36.3 kg)
with dust cover over reel) * ** ***
LN-8 WITH K377 22.19 in. 9.44 in. 17.00 in. 36.0 lb 48.0 lb.
(small stand equipped for (564 mm) (240 mm) (432 mm) (16.3 kg) (21.8 kg)
Readi-Reel)
LN-8 WITH K378 25.68 in. 9.44 in. 17.00 in. 36.0 lb 48.0 lb.
(small stand equipped for (652 mm) (240 mm) (432 mm) (16.3 kg) (21.8 kg)
14 lb Innershield coil)
PHYSICAL DIMENSIONS
115 VAC, 50/60 Hz @ 4.5 amps
TEMPERATURE RATING
50 in. to 600 in. per minute (1.25 to 15.24 m/min)
* Add 1.00 in. (25.4 mm) to length if door kit is attached.
** Add 0.50 in. (12.7 mm) to width if door kit is attached.
*** Add 7.31 lbs (3.32 kg) to total weight if door kit is attached.
(
◊) Codes below 7926-33.5 lbs (15.2 kg) and 78.5 lbs (35.6 kg)
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A-3
INSTALLATION
LN-8
A-3
MOUNTING LOCATION
The LN-8 can be operated as a free-standing unit, or it
can be mounted to an undercarriage when portability
is required. Refer to Accessories Section for avail-
able under carriage, mounting platform, or wire reel
stands.
POWER SOURCE CONNECTIONS
Use the type of power source required for the specific
welding application.
Never operate a Lincoln Squirt welder wire feeder with
a power source that has a jumper from #2 to #4 on the
terminal strip, or with a power source without a
contactor. To do so would defeat the ground lead
protector circuit and could result in overheating of the
electrical ground circuit to the wire feeder.
____________________________________
A constant voltage power source is required for
Innershield electrode and other open arc welding. It is
often preferred for small, single pass submerged arc
welds at fast travel speeds.
Formerly, a constant current power source was recommended for most submerged arc welding. With the
innovation of the new DC power sources, a special
mode (CV Sub-Arc) is available and is preferred for
most submerged arc welding.
The LN-8N and LN-8NE, when shipped, can only be
used with a constant voltage power source. These
models can be converted to weld with a constant current power source with the installation of the proper
conversion parts.
The LN-8S and LN-8SE, when shipped, can weld with
either a constant voltage or constant current power
source. Be sure that both the power source and the
wire feeder are properly set for the required procedure.
Refer to the “Input Cable Connections” section
when connecting the LN-8 to a Lincoln power source.
LN-8N AND LN-8NE
Use a constant voltage type power source. If the LN-8
has been converted to weld with a constant current
power source, use the instructions for the LN-8S.
1. If using a multi-purpose power source, be sure it
is set for constant voltage welding per the
instructions in the power source operating
manual.
2. Connect the LN-8 input cable to the power source
exactly as specified on the appropriate
connection diagram, see Table A.2. Include any
jumpers on the terminal strips as shown in the
applicable diagram.
3. Connect a work lead of sufficient size and length
per Table A.1, between the appropriate output
terminal on the power source and the work.
Ensure the connection to the work makes tight
metal-to-metal contact.
TABLE A.1 – WORK LEAD SPECIFICATIONS
Copper Work Cable Length
Current Amps
60% Duty 25 ft 50 ft 100 ft
Cycle (7.5 m) (15 m) (45 m)
300 0 0 000
400 00 00 0000
500 00 000 0000
600 000 000 Two 000
CAUTION
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A-4
INSTALLATION
LN-8
A-4
LN-8S AND LN-8SE (AND CONVERTED
LN-8N AND LN-8NE)
1. Use either a constant voltage or constant current
type power source as required for the application.
Ensure the power source is properly set for
constant voltage or constant current welding, as
appropriate, per the instructions in the power
source operating manual.
2. Set the LN-8 wire feeder for a constant voltage or
constant current power source as appropriate per
the following:
a. There are two nameplates on the front of the
wire feeder, one mounted on top of the other.
Be sure the ‘Constant Current Power Source’
nameplate is on top when using a constant
current power source. When connected to a
constant voltage power source, be sure the
‘Constant Voltage Power Source’ nameplate is
on top.
b. Turn the power to the wire feeder off. Open the
door to the control section and switch the
power source selection switch to constant
current ‘CC’ or constant voltage ‘CV’ as
appropriate. See Figure A.1.
3. Connect the LN-8 input cable to the power source
exactly as specified in the wire connection
diagrams in Table A.2. Include any jumpers on
the terminal strips as shown in the connection
diagrams.
4. Connect a work lead of sufficient size and length,
per Table A.1, between the appropriate output
terminal on the power source and the work.
Ensure the connection to the work makes tight
metal-to-metal contact.
FIGURE A.1 – POWER SOURCE SELECTION
SWITCH
POWER SOURCE
SELECTION SWITCH
VARIABLE
VOLTAGE
PC BOARD
VARIABLE
VOLTAGE
PC BOARD
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A-5
INSTALLATION
LN-8
A-5
Figure No. Power Source
A.2 Connection of LN-8 to an Idealarc® R3S-400, 600 or 800 (with LVC) (Discontinued)
A.3 Connection of LN-8 to an Idealarc R3S-400, 600 or 800 (without LVC) (Discontinued)
A.4 Connection of LN-8 to a SAM Motor-Generator or Engine Driven Welder
A.5 Connection of LN-8 to R3S-250 and R3S-325
A.6 Connection of LN-8 to DC-600
A.7 Connection of LN-8 to DC-250, 400 and CV/CVI Power Sources
A.8 K318 Duel Process Contactor Kit
DC-400, CV-400, and CVI-500 Connection to LN-8 for Same Polarity Operation
A.9 K318 Duel Process Contactor Kit
DC-400, CV-400, and CVI-500 Connection to LN-8 for Opposite Polarity Operation
A.10 Power Sources other than Lincoln Electric
POWER SOURCE CONNECTION DIAGRAMS
Table A.2 – LN-8 Power Source Connection Diagrams
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A-6
INSTALLATION
A-6
LN-8
FIGURE A.2 – CONNECTION OF LN-8 TO AN IDEALARC R3S-400, 600 OR 800
(WITH LVC) (DISCONTINUED)
CLEVELAND, OHIO U.S.A.
N.A.
WARNING
ELECTRIC
SHOCK
CAN KILL
76 77
75
24 21
31 32
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
A
B
C
4
GND
32
31
2
21
TO OPTIONAL R3S
LINE VOLTAGE
COMPENSATOR
TO LN-8
INPUT CABLE PLUG
N.D.
LN-8 CONTROL
CABLE
N.B.
NEGATIVE
N.B.
POWER SOURCE
THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED FOR POSITIVE POLARITY. TO CHANGE POLARITY, TURN OFF THE POWER,
REVERSE THE ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND REVERSE THE "CONTROL SWITCH" AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. ON EARLIER R3S-400, -600, AND -800 MACHINES, TERMINALS #67 AND #1 WERE ALSO ON THE TERMINAL STRIP.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD
#21 SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.D. LN-8 LEADS A, B, AND C (#75, #76, AND #77 ON OLDER LN-8 CONTROL CABLES) ARE TAPED UP WHEN THE R3S LINE VOLTAGE
COMPENSATOR IS CONNECTED. ARC VOLTAGE IS CONTROLLED BY THE LINE VOLTAGE COMPENSATOR RHEOSTAT. THERE WILL BE NO
ADJUSTMENTS OF VOLTAGE BY THE LN-8 VOLTAGE CONTROL.
POSITIVE
TAPE UP BOLTED CONNECTION
ELECTRODE CABLE TO
WIRE FEED UNIT
N.C.
TO WORK
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A-7
INSTALLATION
A-7
LN-8
FIGURE A.3 – CONNECTION OF LN-8 TO AN IDEALARC R3S-400, 600 OR 800
(WITHOUT LVC) (DISCONTINUED)
CLEVELAND, OHIO U.S.A.
N.A.
WARNING
ELECTRIC
SHOCK
CAN KILL
76 77
75
24 21
31 32
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
N.E.
C
B
A
4
GND
32
31
2
21
TO LN-8
INPUT CABLE PLUG
N.D.
LN-8 CONTROL
CABLE
N.B.
NEGATIVE
N.B.
POWER SOURCE
THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED FOR POSITIVE POLARITY. TO CHANGE POLARITY, TURN OFF THE POWER,
REVERSE THE ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND REVERSE THE "CONTROL SWITCH" AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. ON EARLIER R3S-400, -600, AND -800 MACHINES, TERMINALS #67 AND #1 WERE ALSO ON THE TERMINAL STRIP.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD
#21 SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.D. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON THE TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON THE TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.
N.E. UPPER TERMINAL STRIP (#75, #76 AND #77) MAY NOT APPEAR ON OLDER R3S MACHINES. LEADS A, B, AND C SHOULD BE TAPED UP.
THERE WILL BE NO ADJUSTMENT OF VOLTAGE BY THE LN-8 VOLTAGE CONTROL.
POSITIVE
TAPE UP BOLTED CONNECTION
ELECTRODE CABLE TO
WIRE FEED UNIT
N.C.
TO WORK
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A-8
INSTALLATION
A-8
LN-8
FIGURE A.4 – CONNECTION OF LN-8 TO A SAM MOTOR-GENERATOR OR ENGINE DRIVEN WELDER
CLEVELAND, OHIO U.S.A.
WARNING
ELECTRIC
SHOCK
CAN KILL
REMOVE SAM PORTABLE FIELD CONTROL AND
CONNECT LEADS B AND C FROM LN-8 CONTROL CABLE.
DO NOT CONNECT LEAD A. LEAD MUST BE TAPED UP.
21
67
1
2
31
32
C4
77
76
75
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
CONNECTION
N.A.
TAPE UP
BOLTED
21
2
31
32
4
GND
C
B
A
TO LN-8 INPUT
CABLE PLUG
CONTROL CABLE
ELECTRODE CABLE TO
WIRE FEED UNIT
N.B.
AUTO
EQUIP.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.B. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #76 TO #76 ON TERMINAL
STRIP, CONNECT LEAD #77 TO #75 ON THE TERMINAL STRIP, AND TAPE UP LEAD #75.
STICK WORK
POWER
SOURCE
TAPE
UP
TO WORK
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A-9
INSTALLATION
A-9
LN-8
FIGURE A.5 – CONNECTION OF LN-8 TO R3S-250 AND R3S-325
CLEVELAND, OHIO U.S.A.
WARNING
ELECTRIC
SHOCK
CAN KILL
POWER SOURCE
21
4
31
32
77
76
75
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
TAPE UP
BOLTED
CONNECTION
N.B.
21
4
31
32
2
GND
C
B
A
TO LN-8 INPUT
CABLE PLUG
CONTROL CABLE
N.C.
NEGATIVE POSITIVE
ELECTRODE CABLE TO LN-8 OR
NA-3 AUTOMATIC SHUNT
N.A.
THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED FOR POSITIVE POLARITY. TO CHANGE POLARITY, TURN OFF THE POWER,
REVERSE THE ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND REVERSE THE 'CONTROL SWITCH' AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACKET.)
N.C. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING), CONNECT LEAD #75 TO #75 ON THE TERMINAL
STRIP, LEAD #76 TO #76 ON THE TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.
TO WORK
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A-10
INSTALLATION
A-10
LN-8
FIGURE A.6 – CONNECTION OF LN-8 TO DC-600
CLEVELAND, OHIO U.S.A.
WARNING
ELECTRIC
SHOCK
CAN KILL
POWER SOURCE
476
21 75
32 8127731 80
PNS
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
N.F.
N.D.
GND
N.B. AND N.C.
TO LN-8 INPUT
CABLE PLUG
C
N.E.
B
A
32
31
2
4
21
CONTROL
CABLE
NEGATIVE
THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN OFF THE POWER, REVERSE THE
ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND POSITION THE SWITCH ON THE POWER SOURCE TO PROPER
POLARITY.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ] REMOTE
VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK.)
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL
STRIP OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.E. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON TERMINAL STRIP.
N.F. FOR DC-600 CODES BELOW 8200, CONNECT A JUMPER FROM 'N' TO 'S' ON LN-8 ONLY. THERE IS NO NPS TERMINAL STRIP ON CODES
ABOVE 8200.
POSITIVE
ELECTRODE CABLE TO
WIRE FEED UNIT
N.A.
TO WORK
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A-11
INSTALLATION
A-11
LN-8
FIGURE A.7 – CONNECTION OF LN-8 TO DC-250, 400 AND CV/CVI POWER SOURCES
CLEVELAND, OHIO U.S.A.
WARNING
ELECTRIC
SHOCK
CAN KILL
POWER SOURCE
4
21
231
NEGATIVE POSITIVE
32
CV OUTPUT
TERMINALS ON
DC-250
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
76 77
75
C
B
A
32
31
2
4
GND
21
N.D.
N.B. AND N.C.
TO LN-8 INPUT
CABLE PLUG
N.E.
CONTROL CABLE
ELECTRODE CABLE TO
N.A.
THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN OFF THE POWER, REVERSE THE
ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND POSITION THE SWITCH ON THE POWER SOURCE AND WIRE FEEDER
(IF EQUIPPED) TO PROPER POLARITY. ALSO REFER TO THE FOLLOWING NOTE:
NOTE: IF LEAD #21 IS TO BE CONNECTED TO THE TERMINAL STRIP, CONNECT TO TERMINAL #21 THAT MATCHES WORK POLARITY. THIS
CONNECTION MUST BE CHANGED WHENEVER THE ELECTRODE POLARITY IS CHANGED. THIS DOES NOT APPLY TO DC-400 BELOW
CODE 9200 WITH POLARITY SWITCH.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (IF THE LENGTH OF THE WORK LEAD CIRCUIT IS SHORT, AND CONNECTIONS CAN BE
EXPECTED TO BE RELIABLE, THEN CONTROL CABLE LEAD #21 DOES NOT NEED TO BE EXTENDED AND CAN BE DIRECTLY CONNECTED
TO TERMINAL #21 ON THE TERMINAL STRIP. NOTE THAT THIS IS NOT THE PREFERRED CONNECTION BECAUSE IT ADDS ERROR TO THE
WIRE FEEDER VOLTMETER READING.)
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL
STRIP. THE POWER SOURCE GROUNDING TERMINAL STRIP (MARKED AND LOCATED NEAR THE POWER SOURCE INPUT POWER
CONNECTIONS) MUST BE PROPERLY CONNECTED TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL.
N.E. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.
WIRE FEED UNIT
TO WORK
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A-12
INSTALLATION
A-12
LN-8
FIGURE A.8 – K318 DUAL PROCESS CONTACTOR KIT DC-400, CV-400 AND CVI-500 CONNECTION TO
LN-8 FOR SAME POLARITY OPERATION
CLEVELAND, OHIO U.S.A.
231
4
21
TO NEGATIVE OUTPUT
STUD ON POWER
SOURCE
DC-400
75
32
N.A.A.
N.F.
TO POSITIVE OUTPUT
STUD ON POWER
SOURCE
WARNING
ELECTRIC
SHOCK
CAN KILL
N.B.B.
76 77
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
N.B.B.
GND
A
B
C
21
4
2
32
31
N.B.
21A
N.C.
WELDER
CONTROL
CABLE
21B
81
80
77
76
75
4
GND
2
31
32
WELDING LEAD STUD ON
BACK OF CONTACTOR KIT
A
75
76
77
4
2
32
31
A
75
76
77
4
2
32
31
N.E.
N.D.
DUAL PROCESS
CONTACTOR
GND
B
A
B
C
21
4
2
32
31
B
N.B.
FOR 50 HZ OPERATION, DISCONNECT BOTH BROWN LEADS FROM TERMINAL 31B AND TAPE UP EACH LEAD. UNTAPE BOTH RED LEADS AND
CONNECT TO 31B.
N.A.A. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL
STRIP OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.B.B. EXTEND LEAD #21A & #21B USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THESE EXTENDED #21A AND #21B
LEADS SHOULD BE TAPED TO THE WELDING WORK LEAD. EACH LEAD MUST BE CONNECTED DIRECTLY TO THE WORK AND LEADS MUST
NOT BE CONNECTED TOGETHER.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. BOLT AND TAPE CONNECTIONS.
N.C. TAPE UP SEPARATELY.
N.D. PUT TRANSFER SWITCH IN "SAME POLARITY ON FEEDERS" POSITION.
N.E. MODE SWITCHES ON CONTACTOR KIT ARE NOT FUNCTIONAL WHEN USED WITH THE POWER SOURCE.
N.F. CONNECTION SHOWN FOR NEGATIVE POLARITY. FOR POSITIVE POLARITY REVERSE ELECTRODE AND WORK CABLES CONNECTED TO
POWER SOURCE OUTPUT STUDS.
N.A.
TO WORK
WIRE FEEDER
CONTROL
CABLE
N.A.
TO "A" WIRE FEEDER TO "B" WIRE FEEDER
ELECTRODE
CABLES
WIRE FEEDER
CONTROL
CABLE
N.A.
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A-13
INSTALLATION
A-13
LN-8
FIGURE A.9 – K318 DUAL PROCESS CONTACTOR KIT DC-400, CV-400 AND CVI-500 CONNECTION TO
LN-8 FOR OPPOSITE POLARITY OPERATION
CLEVELAND, OHIO U.S.A.
231
4
21
TO NEGATIVE OUTPUT
STUD ON POWER
SOURCE
DC-400
75
32
N.A.A.
N.F.
TO POSITIVE OUTPUT
STUD ON POWER
SOURCE
WARNING
ELECTRIC
SHOCK
CAN KILL
76 77
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
N.B.B.
21A
N.C.
WELDER
CONTROL
CABLE
81
80
77
76
75
4
GND
2
31
32
N.B.B.
21B
GND
TO WORK
N.A.
WELDING LEAD STUD ON
BACK OF CONTACTOR KIT
A
A
B
C
21
4
2
32
31
N.B.
75
76
77
4
2
32
31
A
N.E.
N.D.
DUAL PROCESS
CONTACTOR
B
75
76
77
4
2
32
31
B
GND
A
B
C
21
4
2
32
31
N.B.
FOR 50 HZ OPERATION, DISCONNECT BOTH BROWN LEADS FROM TERMINAL 31B AND TAPE UP EACH LEAD. UNTAPE BOTH RED LEADS
AND CONNECT TO 31B.
N.A.A. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME MARKED NEAR THE POWER SOURCE TERMINAL STRIP OR
TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.B.B. EXTEND LEAD #21A AND #21B USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THESE EXTENDED #21A AND
#21B LEADS SHOULD BE TAPED TO THE WELDING WORK LEAD. EACH LEAD MUST BE CONNECTED DIRECTLY TO THE WORK AND LEADS
MUST NOT BE CONNECTED TOGETHER.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. BOLT AND TAPE CONNECTIONS.
N.C. TAPE UP SEPARATELY.
N.D. PUT TRANSFER SWITCH IN "OPPOSITE POLARITY ON FEEDERS" POSITION.
N.E. MODE SWITCHES ON CONTACTOR KIT ARE NOT FUNCTIONAL WHEN USED WITH THE POWER SOURCE.
N.F. TO MAKE "A" FEEDER POSITIVE POLARITY AND "B" FEEDER NEGATIVE POLARITY, REVERSE ELECTRODE CABLES CONNECTED TO
POWER SOURCE OUTPUT STUDS.
N.A.
TO "A" WIRE FEEDER
ELECTRODE NEGATIVE
WIRE FEEDER
CONTROL
CABLE
N.A.
ELECTRODE
CABLES
WIRE FEEDER
CONTROL
CABLE
N.A.
TO "B" WIRE FEEDER
ELECTRODE POSITIVE
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A-14
INSTALLATION
A-14
LN-8
FIGURE A.10 – FOR POWER SOURCES OTHER THAN LINCOLN ELECTRIC
CLEVELAND, OHIO U.S.A.
WARNING
ELECTRIC
SHOCK
CAN KILL
POWER SOURCE POWER SOURCE
INTERNALLY POWERED CONTACTOR EXTERNALLY POWERED CONTACTOR
OUTPUT CONTACTOR COIL
ELECTRODE
FOR POWER TO
OPERATE CONTACTOR
MAX. RATING OR LN-8
#2 TO #4 CIRCUIT IS
5 AMP 115 VAC OR
5 AMP 28 VDC
1/2 AMP 115 VDC
TO 115 VAC 350
VOLT-AMP CAPACITY
TAPE UP
EACH LEAD
TO LN-8 CIRCUIT TO LN-8 CIRCUIT
31 3132 322244
CONTROL
32 32
75 75
76 76
77 77
INPUT
CABLE
WORK WORK
GND GND
21 21
44
22
31 31
TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.
OUTPUT CONTACTOR COIL
MAX. RATING OF LN-8
#2 TO #4 CIRCUIT IS
5 AMP 115 VAC
5 AMP 28 VDC
1/2 AMP 115 VDC
TO 115 VAC 350 VOLT-AMP
FOR LN-8 PLUS
REQUIREMENTS
TO
WORK
(115 VAC)
CONTACTOR
TAPE UP
EACH LEAD
ELECTRODE
TO
WORK
INPUT
CONTROL
CABLE
LN-8 WIRE FEEDER LN-8 WIRE FEEDER
REFER TO THE POWER SOURCE WIRING DIAGRAM TO FIND THE TYPE OF CONTACTOR CIRCUIT.
ELECTRODE CABLE ELECTRODE CABLE
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A-15
INSTALLATION
LN-8
A-15
INPUT CABLE CONNECTIONS
For connecting an LN-8 to a specific Lincoln Electric
power source, use the appropriate steps in one of
these paragraphs and refer to the connection diagrams listed on Table A.2 for the applicable power
source. Table A.2 lists each figure number with its
corresponding power source.
LN-8N AND LN-8S
The input cable consists of an electrode cable and a
multi-conductor control cable. The control cable has a
polarized plug on the wire feeder end. To connect the
cables, refer to Figure A.11 and perform these steps:
1. Connect the polarized plug of the control cable to
the mating connector on the back of the wire
feeder.
FIGURE A.11 – INPUT CONTROL CABLE AND
ELECTRODE CABLE CONNECTIONS
2. Remove the screws holding the cable clamp
located near the rear of the wire reel base. Put
the control cable and electrode cable under the
clamp and install the screws. On cables with
more than one electrode cable, leave the junction
between the two or more cables and the single
4/0 stub behind the clamp so only the single
electrode lead is under the clamp.
3. Pass the single electrode cable through the holes
provided in the back corner of the control section
and fasten it to the tab on the conductor above
the rear brass block of the wire feeder.
LN-8NE AND LN-8SE
The extension unit consists of a wire reel mount with
a hand crank and either a 22-1/2 or 45 ft (6.9 or
13.7 m) extension cable assembly. The cable is rated
at 450 amps, 50% duty cycle. For higher currents
install a parallel length of 1/0 cable per step 10. The
extension cable can be used for 0.068 through
0.120 in. (1.7 through 3.0 mm) flux-cored electrode
and 5/64 through 3/32 in. (2.0 through 2.4 mm) solid
electrode. The 22-1/2 ft. (6.9 m) cables can also be
used for 1/16 in. (1.6 mm) solid electrodes. To connect the cables, perform these steps:
1. When shipped, the hand crank on the wire reel
mount is equipped to feed 1/16 through 0.120 in.
(1.6 through 3.0 mm) electrode.
CONDUCTOR
ELECTRODE
CABLE
WIRE
REEL
BASE
CABLE
CLAMP
CONTROL
CABLE
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A-16
INSTALLATION
LN-8
A-16
2. The standard cable setup consists of an electrode
cable and a control cable with a polarized plug on
the wire feeder end. Position the control cable
with the polarized plug at the wire reel base. Refer
to Figure A.12.
3. Connect the electrode cable to the brass block on
the hand crank assembly using the screw
provided.
4. Position the 22-1/2 or 45 ft (6.9 or 13.7 m) control
cable extension so the polarized connector with
the threads on its O.D. is at the wire reel base.
5. Connect the polarized connectors of the control
cable together.
6. Place both the control and electrode cables under
the clamp on the wire reel base and tighten the
screws.
7. Insert the connector on the electrode cable
extension into the brass block of the hand crank
assembly and tighten with a 3/16 in. Allen wrench.
8. At the wire feeder, connect the polarized plug of
the control cable extension into the mating
receptacle on the back of the wire feeder. Refer to
Figure A.13.
FIGURE A.13 – CABLE EXTENSION
CONNECTIONS TO WIRE FEEDER
FIGURE A.12 – INPUT CONTROL CABLE AND ELECTRODE CABLE EXTENSIONS
WIRE
DRIVE
UNIT
CONTROL
CABLE
EXTENSION
ELECTRODE
EXTENSION
CABLE
POLARIZED
PLUGS
BRASS
BLOCK
CONTROL
CABLE
ELECTRODE
CABLE
WIRE
HAND
CRANK
REEL
BASE
REAR
BRASS
BLOCK
ELECTRODE
CABLE
EXTENSION
CONNECTOR
LOCKING
SCREW
CONTROL
CABLE
EXTENSION
INGOING
GUIDE
TUBE
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A-17
INSTALLATION
LN-8
A-17
9. Remove the ingoing guide tube from the rear
brass block of the wire feeder and plug the
connector of the electrode cable extension into
the brass block. Tighten the locking screw with a
3/16 in. Allen wrench. The guide tube is not used
when the extension assembly is installed.
10. If using over 450 amperes, connect a length of
1/0 cable between the brass block on the wire reel
base and the tab on the rear brass block of the
wire feeder. Tape this cable to the extension
assembly. Proper cable lengths are:
• For a 22-1/2 ft (6.9 m) extension use 23-1/2 ft
(7.2 m) - order M5906-106
• For 45 ft (13.7 m) extension use 46 ft (14 m) order M5906-104
11. To mount the wire feeder handle provided with
the extension unit, remove the two self-tapping
screws that hold the hinge pin in the top of the
wire feeder. Push the hinge pin out, leaving the
covers intact. Place the handles into the slots
provided and push the hinge pin back into the
assembly making sure that the pin goes through
the holes in the handle. Put the two self-tapping
screws back into their respective positions. Refer
to Figure A.14.
12. If the extension is being used with a K306 Wire
Reel Flux Tank assembly, the hose attached to
the bottom of the flux tank may have to be
shortened. This hose is 64 ft (19.5 m) long, and is
the correct length for use with the 45 ft (13.7 m)
extension. If a 22-1/2 ft (6.9 m) extension is to be
used, cut 22-1/2 ft (6.9 m) off the flux hose to give
the correct length of 41-1/2 ft (12.6 m). (The
conductor cable is 22-1/2 ft (6.9 m) long, tip to tip,
and can be used to measure the length of hose
cut off.) If the flux hose is taped to the extension
cables or gun cable, it should be done in such a
manner as not to deform or collapse the hose.
FIGURE A.14 – WIRE FEEDER HANDLE
INSTALLATION
SELF-TAPPING
SCREW
HINGE
PIN
HANDLE
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A-18
INSTALLATION
LN-8
A-18
GUN AND CABLE ASSEMBLIES
GENERAL
The LN-8 is used with various guns. In all cases, the
gun is shipped connected to the cable and is ready to
weld. Use the gun recommended for the wire type
(solid or cored) and size to be used. See the paragraph on Welding Guns in the Accessories Section
for more information on the different types of guns.
GUN CABLE CONNECTIONS
Lay the cable out straight. Insert the male end of the
welding conductor cable into the brass block on the
front of the LN-8. Make sure it is in all the way and
tighten the locking screw with a 3/16 in. Allen wrench.
Keep this connection clean and bright. Connect the
control cable polarized plug into the receptacle next to
the coupling.
HANDLING PROCEDURES
1. Do not kink or pull the cable around sharp
corners.
2. Keep the electrode cable as straight as practical
when welding or starting the electrode through
the cable.
3. Do not allow dolly wheels or trucks to run over the
cables.
4. Keep the cable clean by following the
maintenance instructions.
5. Use only clean, rust-free electrode wire.
6. Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or
deformed.
LN-8S AND LN-8SE CONTINUOUS
FLUX FEED (SUBMERGED ARC)
Connect the loose end of the hose to the tube at the
back end of the welding gun. Tighten the hose clamp.
If the hose is taped to the gun cable, be sure it is not
collapsed or deformed as this could cause flux feeding problems.
The air for the automatic flux feeding system is
obtained from the regular plant compressed air system, providing the plant system pressure is between
60 and 120 psi (414 and 827 kPa). The tank is
equipped with a pressure regulator to reduce the input
pressure to the 30 psi (207 kPa) required for the flux
feeding system. This pressure is set at the factory
before the machine is shipped. When the LN-8SE
with the 22-1/2 or 45 ft. (6.9 or 13.7 m) extension is
used, and the flux hose is long, set the air pressure at
45 psi (310 kPa) for 1/2 in. (12 mm) I.D. hose, and 55
psi (379 kPa) for 3/8 in. (9.5 mm) I.D. hose. Exact
pressure is indicated on the pressure gage. Air consumption is normally less than 1.5 cubic feet
(4.2 cubic meters) per minute of welding.
Connect the input air hose to the street elbow located
at the right side of the flux tank. A quick disconnect
should be installed between the elbow and the input
hose.
The air tank is equipped with a water and dirt separator. Water separated from the input air feeds down
through the long flux filled tube located at the input
connection. It is exhausted from the system through
the coiled tube below the flux tank. There is always a
small amount of air and possibly water coming out of
the end of this tube.
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OPERATION
LN-8
SECTION B-1SECTION B-1
TABLE OF CONTENTS
-OPERATION SECTION-
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Controls and Their Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Constant Current Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Constant Voltage Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Avoiding Ground Lead Protector (GLP) Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Wire Feed Rolls and Guide Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Setting for CV or CC Power Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Welding with a Constant Voltage Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Welding with a Constant Current Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Wire Reel Loading - 50 and 60 lb Coils (K303 Wire Reel Stand). . . . . . . . . . . . . . . . . . . . B-8
Wire Reel Loading (K1524-1 Universal Wire Reel Stand) . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Feeding Electrode to the LN-8N or LN-8S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
Feeding Electrode to the LN-8NE or LN-8SE (With Extension) . . . . . . . . . . . . . . . . . . B-11
Slow Acceleration Starting (Code 7926 and Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
Flux Tank Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
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B-2
OPERATION
B-2
CONTROLS AND THEIR
FUNCTIONS
CONSTANT CURRENT CONTROLS
Operator controls for welding using a constant current
power source are illustrated in Figure B.1. Refer to the
figure and the following explanations of the controls.
FIGURE B.1 – CONSTANT CURRENT CONTROLS
LN-8
Read and understand this entire section before
operating your machine.
SAFETY INSTRUCTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
____________________________________
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
____________________________________
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge on containers
that have held combustibles.
____________________________________
ARC RAYS
can burn.
• Wear eye, ear and body protection.
____________________________________
Only qualified personnel should operate this equipment. Observe all safety information throughout this
manual.
WARNING
CURRENT
CONTROL
VOLTAGE
CONTROL
CIRCUIT
BREAKER
TRIGGER
INTERLOCK
WIRE FEED
DIRECTION
CONTROL
GROUND LEAD
PROTECTOR
RESET BUTTON
B-3
OPERATION
B-3
CURRENT CONTROL. Adjusts welding current by
controlling power source output.
VOLTAGE CONTROL. Adjusts arc voltage by control-
ling wire feed speed.
TRIGGER INTERLOCK. With the switch in the OFF
position, the wire feed motor runs and the welding circuit is energized only when the gun trigger is pressed.
The operator must hold the trigger in from the start to
the finish of the weld. To stop the arc, the operator
releases the trigger and raises the gun from the work.
With the switch in the ON position, the operator holds
the trigger until the arc is established, then the trigger
can be released. When the welding is completed, the
operator raises the gun from the work to break the
arc.
WIRE FEED DIRECTION CONTROL. The direction
the electrode passes through the wire feeder is controlled by this switch. The electrode is fed through the
wire feeder in the same direction that the switch is
pointing.
CIRCUIT BREAKER. Protects the circuit from severe
wire feed motor overloads and short circuits. Press to
reset.
GROUND LEAD PROTECTOR RESET BUTTON.
The ground lead protector guards the ground lead in
the control cable from damage that can occur when
the electrode circuit touches the wire feeder frame
while the gun trigger is pressed. This button resets the
ground lead protector circuit.
CONSTANT VOLTAGE CONTROLS
Operator controls for welding using a constant voltage
power source that differ from the constant current controls are illustrated in Figure B.2. Refer to the figure
and the following explanations of the controls.
VOLTAGE CONTROL. Adjusts arc voltage by controlling power source output voltage.
CURRENT CONTROL. Adjusts wire feed speed to
control welding current.
FIGURE B.2 – CONSTANT VOLTAGE CONTROLS
LN-8
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CURRENT
CONTROLS
VOLTAGE
CONTROLS
B-4
OPERATION
B-4
CIRCUIT PROTECTION
FIELD CIRCUIT FUSE. This 1/2 amp slow blow fuse,
located on the Relay PC board, protects the field circuit. It will blow if the field shorts or if one of the field
circuit components on the Relay PC board fails.
MOTOR THERMAL PROTECTION. The temperature
sensing thermal protector mounted in the motor opens
the relay circuit when the motor overheats because of
excessive loading or frequent triggering. This protects
the motor without nuisance tripping. The thermal protector automatically resets itself after the motor cools
sufficiently (may take 10-15 minutes). Reset time can
be shortened by cooling the motor with an air hose or
fan.
CIRCUIT BREAKER. The 5 amp circuit breaker located above the drive rolls normally trips only when an
overload occurs because of excessive loading in the
wire feed cable, or a defective motor or control component. After allowing a minute for cooling, push the
reset button and weld. If it trips again, be sure the wire
feed cable is clean and the proper size for the wire
diameter being fed. If it still trips, look for a defective
electrical component.
AVOIDING GROUND LEAD
PROTECTOR (GLP) ACTIVATION
The frame of the LN-8 wire feed unit and the drive
motor are grounded to the frame of the power source
by a lead in the control cable. An overload protector
prevents welding current from damaging this lead if
the electrode circuit touches the wire feeder frame
while the gun trigger is pressed.
When the protector is tripped, the welding contactor in
the power source will not close when the gun trigger is
pressed.
DO NOT allow the electrode to contact the case of the
wire feeder or the uninsulated part of the wire reel
stand when the gun trigger is activated.
Be sure that all work lead connections to the work
make tight metal-to-metal contact.
DO NOT allow excess input cable or work cable to be
placed closer than three feet from the wire feeder.
DO NOT coil excess input cable assembly or use a
coiled assembly as shipped from the factory. Instead,
loop the excess cable length back and forth in three to
six foot straight lengths. Coiling the input cable results
in a transformer action between the electrode
conductor cable and the ground lead in the
multiconductor control cable. This transformer action
can cause a current to flow in the ground lead which
will falsely activate the GLP circuit.
To reset the GLP circuit, press the white button above
the drive motor and to the right of the circuit breaker.
LN-8
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B-5
OPERATION
B-5
WIRE FEED ROLLS AND GUIDE
TUBES
The drive rolls and guide tube kits are ordered separately. Refer to Figure B.3 and install these parts per
the following instructions:
1. Loosen the idle roll spring pressure screw.
2. Remove the drive roll screw and clamping collar
from the drive shaft.
3. Install the drive roll and replace the clamping collar. Tighten the drive roll screw.
4. Remove idle roll shaft screw. Install the idle roll
and idle roll shaft screw.
5. Remove the large ingoing guide from the rear
brass block by loosening the locking screw.
6. Loosen the ingoing guide tube clamping screw.
Install the ingoing guide tube (which is stenciled
“in”) through the rear brass block. Tighten the
clamping screw.
LN-8
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FIGURE B.3 – WIRE FEED ROLLS AND GUIDE TUBE INSTALLATION
INGOING
GUIDE
TUBE
DRIVE
CLAMPING
COLLAR
DRIVE
ROLL
ROLL
SCREW
OUTGOING
GUIDE TUBE
LOCKING
SCREW
IDLE ROLL
SHAFT SCREW
IDLE
ROLL
LOCKING
SCREW
SPRING PRESSURE
IDLE ROLL
SCREW
CLAMPING
SCREW
LARGE
INGOING
GUIDE
B-6
OPERATION
B-6
7. Install the large ingoing guide into the rear brass
block and tighten the locking screw.
8. Install the outgoing guide tube with its plastic
insert through the front brass block. Tighten the
locking screw so the dog point goes into the
groove on the O.D. of the guide tube.
9. Set the drive roll spring pressure:
a. For wire sizes from 0.030 thru 0.052 in. (0.8
thru 1.3 mm) – With wire in the system, the
idle roll pressure indicator should be set to the
wire size shown on the “solid” side of the
nameplate. (For 0.030 in. (0.8 mm) solid wire,
set the pressure indicator to slightly less than
the 0.035 in. (0.9 mm) marking.) This setting
is a starting point and may have to be
changed depending upon the type of wire,
surface condition, lubrication, and hardness.
The optimum idle roll setting can be determined when there are wire stoppages. If the
wire “bird nests” between the drive roll and
the guide tube, the idle roll spring pressure is
too high. When properly set, the drive rolls will
slip during a stoppage. If the electrode is
removed from the cable, there will be a slight
waviness in the electrode for about a foot
beyond the slip marks on the electrode. If
there is no waviness, the pressure is set too
low.
b. For 1/16 in. (1.6 mm) solid or 0.062 in.
(1.6 mm) cored wire (using the 1/16 in. drive
roll) The idle roll pressure should be set with
wire in the system. For 1/16 in. (1.6 mm)
solid wire, the indicator should be lined up
with the “solid” 1/16 in. mark. For 0.062 in.
(1.6 mm) cored wire, adjust the idle roll pressure so that the indicator is lined up with the
“cored” 3/32 in. mark.
NOTE: These indicator settings are accurate enough
so that there is no need to readjust unless the electrode is unusually soft.
c. For wire sizes from 0.068 thru 0.120 in. (1.7
thru 3.0 mm) Idle roll pressure should be set
with wire in the system. For solid wire, the
indicator should be lined up with the “solid”
wire settings. For cored wire, the indicator
should be lined up with the “cored” wire settings. When using 7/64 in. (2.8 mm) diameter
‘Innershield’ wire, adjust the idle roll pressure
so that the indicator is between the 0.120 and
3/32 in. “cored” wire setting.
NOTE: The indicator settings for these larger wire
sizes are accurate enough so that there is no need to
readjust, unless the electrode is unusually soft.
The drive rolls are stamped with the wire size for
which they are designed. If a wire size is used
that is not stamped on the drive roll, the drive
rolls and guide tubes will have to be changed.
SETTING FOR CV OR CC POWER
SOURCES
The LN-8N and LN-8NE weld only with a constant
voltage (CV) power source. These machines can be
converted for constant current (CC) welding by
installing the proper parts.
The LN-8S and LN-8SE weld with either a CV or CC
power source. Set the equipment for either “CV” or
“CC” as appropriate per the following:
1. If using a multi-process power source, set it up
per the instructions in the operating manual
shipped with the power source.
2. Turn the input power off and open the left panel.
Set the “CV-CC” switch located on the variable
voltage PC board inside the control box as
shown in Figure B.4.
3. There are two nameplates on top of each other
on the front of the wire feeder control box. Make
sure the correct nameplate for the power source
being used is on top.
LN-8
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