Lincoln Electric LN-15 User's Manual
Contents
1. AIX ALUM al gll e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo e B emRMB ox 71 Sol 55576 43 y dee de A y vas Gi sai daaag READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res Mantenga la fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur o2. WARNING Service and Repair should only be performed by 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 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 SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Faci
3. LINCOLN 5 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO 2 Chinese Korean Do not touch electrically live parts electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja d a del trabajo y de la tierra Ne laissez la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se e terra RRPORABA el amp T4eP ADo5 Stiigs ATUSRELTFEL A AER etti B omm eri Syza FY sE au ong e HIE uA JUI uil el jad CHE T aal J9 dus ule Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos emaiovtosoosfconstTER e 1 59 9 155 3 135 E
4. e Turn the input power to the welding power source off at the fuse box before working in the terminal strip e Only qualified personnel should install use or service this equipment 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 e Replace the drive rolls and inner wire guide when they are worn e 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 045 1 2mm drive roll kit into the LN 15 e Load a spool of 045 1 2mm electrode and thread the electrode through the wire drive e Adjust the wire feed speed to 300 in min 7 62m min Press the COLD INCH 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 procedure that gives steady spray transfer in the arc While a weld is being made measure the voltage from the feedplate to work The displayed voltage on the LN 15 should be with in 2 of the measured value LN 15 CONTROL CABLE MODEL CE LINCOLN 5 D 1 E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE
5. FIGURE B 4 CC WIRE SPEED SETTING bee b Referring to the graph located above the Mode switch also shown in Figure B 4 1 Select the horizontal line representing the DE SIRED 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 24 26 CC Speed Setting Desired IPM x 35 Arc Volts LN 15 CONTROL CABLE MODEL CE LINCOLN 5 B 10 OPERATION MAKING WELD The serviceability of a product or structure utilizing the LN 15 wire feeder is and must be the sole responsibil ity of the builder user Many variables beyond the con trol of The Linco
6. 1 Routine Maintenance re D 1 NE Lone eed D 1 Calibration semis D 1 Troubleshooting in Section E Safety ee EE 1 How to Use Troubleshooting Guide eene emen E 1 Troubleshooting Gilde iita tente E 2 thru E 4 Wiring Diagram amp Dimension Prints nine Section F 5 cc P 544 viii 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS LN 15 1871 3 INPUT VOLTAGE 42 VAC 1 50 60 5 Amps Maximum CONTROL CABLE MODEL RATED CURRENT 500 Amps 60 Duty Cycle 350 Amps 100 Duty Cycle ELECTRODE DIAMETERS and SPEED RANGE Electrode Size Speed Range Solid Electrode 0 023 0 052 150 700 in min Steel 0 6 1 3 mm 1 3 17 8 m min Flux Cored 0 035 5 64 50 400 in min Electrode 0 9 2 3 mm 1 3 10 1 m min PHYSICAL DIMENSIONS 8 200mm Dia x 4 100mm 12 7 Inches 8 7 Inches 23 Inches Wide Spools including 323 mm 221mm 584 mm AWS 8 DIA 10 15105 JIS 5 3 200mm 5 7 kg DIN 200 5 kg TEMPERATURE RANGE OPERATION 20 C to 50 C 4 F to 122 F STORAGE 40 C to 70 C 40 F to 158 F LN 15 CONTROL CABLE MODEL CE LINCOLN 5 A 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL 9 ONLY QUALIFIED PERSONNEL SH
7. 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 5 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the
8. HALANOILN3LOd Lee AOW M313AOl1N3LOd Sie 09945 334 ON tes GIONS10S Svo dva 299 108 N HOLIMS 330 NO 19 2 1e O d IOHINOO ama 7 a ser cer 3005 40109 MONITE 40 301S NOLLVINHONI ENEE 3ON3nO3S ALIAVO 19801 3 18 VO SI N 1 LN 15 CONTROL CABLE MODEL CE LINCOLN F 2 DIMENSION PRINT F 2 G4053 7 SCH d 1 ES EG T 6 E BN KL 5 LN 15 CONTROL CABLE MODEL CE LINCOLN 5 NOTES LN 15 CONTROL CABLE MODEL CE
9. 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 4 Rotate the triangular shaped drive roll retaining mechanism to unlock the drive rolls and remove the drive rolls LOCKED POSITION UNLOCKED POSITION 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 N Install a drive roll on each hub assembly and lock by rotating the triangular drive roll retaining mecha nism 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 0 m 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 COLD FEED GAS PURGE SWITCH BRAKE THUMB SCREW SPOOL ELECTRODE Turn the reel or spool until the free end of the elec trode is accessible 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 elect
10. may be difficult to achieve required weld metal properties or to achieve the required quality of welds needed to pass nonde structive tests when such welds are made under con stant current operation FIGURE B 3 Current Welding Cable Electrode Constant Current Power Source 1 Current Welding Cable LN 15 Wire Feeder GUN AND CABLE ASSEMBLY CTWD LN 15 CONTROL CABLE MODEL CE LINCOLN 5 B 9 OPERATION B 9 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 con stant 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 pm DESIRED IN MIN ARC VOLTS USED SEN CDI GI PE SEE EEE IM Aen AAA A PAIE 220 Ed GAT HHH y A CITIITITTI 50 50 100 150 200 250 300 350 400 450 500 550 600 650 700
11. 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 Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 LINCOLN 5 li 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 e Semiautomatic DC Constant Voltage Wire Welder e DC Manual Stick We
12. pin recepta cle on the front panel of the wire feeder ELECTRODE POLARITY The LN 15 automatically adjusts for positive and neg ative polarity When welding with negative polarity procedures the voltmeter will display a sign exam ple 23 6 Volts cable assembly CONTROL CABLE CONNECTIONS For Control Cable model attach the control cable from the LN 15 to power source Do not use more than 150 ft 45 m of cable Table A 2 Trigger Connector J1 5 Pin PIN Lead amp Function B Notused Procedure ground 8396 Procedure Trigger 8396 Procedure ground 554 _ PIT Table A 3 Control Cable Receptacle 8 Pin PIN Lead Function 42 VAC c 2 2 Output Control trigger Output Control trigger _21 5 76_____ pem Voltage Control Remote Voltage Control LN 15 CONTROL CABLE MODEL CE LINCOLN 5 A 5 PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING INSTALLATION FEEDING WIRE ELECTRODE WARNING A 5 ELECTRIC SHOCK CAN KILL ELECTRIC SHOCK CAN KILL Turn off input power at the welding power source before installation or changing drive roll and or wire guides Do not touch electrically live parts such as the wire drive or internal wiring When feeding with the gun trigger the electrode and wire drive mechanism are hot to work and ground and could remain energized several sec onds after the
13. 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 short ening the contact tip to work distance lowers the volt age If the contact tip to work distance is properly main tained 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 dis tance 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 prop erties may not be achieved Constant voltage power sources deliver large current surges to stabilize the arc when the electrode is short ed or the arc length is very short However a constant current power source does not provide such a response to stabilize the arc It
14. shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Wher
15. 6 Remove the outer wire guide and push the gun bushing out of the wire drive Because of the pre cision 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 COLD FEED To activate Cold Feeding hold the switch in the UP position wire drive will feed electrode but neither the power source nor the gas solenoid will be energized Adjust the speed of cold feeding by rotat ing the WFS knob Cold feeding or cold inching the electrode is useful for thread ing the electrode through the gun GAS PURGE FIGURE B 2b CONNECTOR BLOCK OUTER WIRE GUIDE SOCKET _ 7 CAP SCREW LOOSEN TIGHTEN LN 15 CONTROL CABLE MODEL CE LINCOLN 5 B 7 OPERATION B 7 Hold with toggle switch in the DOWN position to acti vate Gas Purge and let the shielding gas flow The gas solenoid valve will energize but neither t
16. IM910 LN 15 WIRE FEEDER For use with machines having Code Number 11372 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 thoughtful opera tion on your part DO NOT INSTALL OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful ISO 9001 CVE Designe eia nd Manufa See ne to ISO 9001 Requirements CERTIFICATE NUMBER 30273 N80 IEC 60974 5 EN 60974 5 OPERATOR S MANUAL LINCOLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products 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 A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS 1 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOU
17. ONTROL CABLE MODEL CE LINCOLN 5 B 3 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 dur ing 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 the welding A minus 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 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 FIGURE B 1a IDLE a es 25 25 ELECTRODE POSITIVE WELDING ELECTRODE NEGATIVE WELDING AFTER ELECTRODE POSITIVE WELDING OPERATION B 3 4 VOLTAGE KNOB The voltage knob is present only on control cable models A
18. OULD 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 on Do not connect the LN 15 to a non Lincoln TIG power source a SQUARE WAVE TIG power source or a PLASMA CUTTING power source LOCATION The LN 15 should be positioned upright on a horizontal surface Do not submerge the LN 15 in water The best practice is to keep the wire feeder in a dry environment When working outdoors in severe wet weather place the LN 15 with the door facing up HIGH FREQUENCY PROTECTION WARNING 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 machin ery 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 INSTALLATION WELD CABLE CONNECTIONS A WARNING ELECTRIC SHOCK CAN KILL Only a qualified electrician should connect the electrode leads to the LN 15 Connections should be made i
19. S 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 amp Cutting ANSI Standard 249 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 FOR ENGINE A 11 To avoid scalding do not remove the powered equipment RA 2 radiator pressure when the engine is hot 1 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 vaporiz ing 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 eli
20. 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 LN 15 CONTROL CABLE MODEL CE LINCOLN 5 B 8 OPERATION B 8 CONSTANT CURRENT OPERATION See Figure B 3 CAUTION 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
21. and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc
22. ariables include but are not limited to welding proce dure plate chemistry and temperature weld ment design fabrication methods and service requirements The available range of the LN 15 wire feeder may not be suitable for all applica tions and the builder user is and must be sole ly responsible for welding settings e FUMES AND GASSES be 9 dangerous Keep your head out of fumes 0 Use ventilation exhaust at the arc or both to remove fumes and gases from breathing zone and general area 7 WELDING SPARKS can cause Tle x D fire or explosion Keep flammable material away ARC RAYS can burn B Wear eye ear and body protec AZ tion SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL O F 4 po U 02 l4 l2 AN B 1 GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL 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 LN 15 CONTROL CABLE MODEL CE LINCOLN B B 2 OPERATION B 2 GENERAL DESCRIPTION The LN 15 is light weight portable durable semi automatic wire feeder The LN 15 accommodates spools 8 200mm diame ter up to 4 100mm wide The domestic feeders comes fac
23. c Symbols that appear on this Machine or in this B 1 General da ceste rere B 2 Bey ERROR B 2 Recommended Processes rettet ce aestate te B 2 Process Limitations ii MH B 2 Equipment Limitations B 2 Operational Features and Controls 2 B 2 Case EE B 3 8396 I B 3 LN 15 POWER UP SEQUENCE B 4 B 5 Internal GOBIFols err OE 5 Spring TO NSION MEUM 5 Wire Drive Conftouration ss B 6 Cold Feed Gas Purge Switch sise B 6 2 Step Trigger 7 gio AL hei ei 7 Spindle Braker AR AN eR Aen Rie 7 shielding Gas Connection oce ode t OE E FERE B 7 Constant Current OperatiOn B 8 Setting Arc Sensing wire Feed Speed For Constant Current Operation B 9 Making a RII B 10 E eee eenenenenennnse Section C Factory EE Me IT 1 elle ER TEE 1 Electrode K Kit used C 1 Maintenant PP rene Section D Safety Precautions 3 eo eres ea eres D
24. can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d 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 e Read and understand the manufacturer s instructions for this DI LINCOLN 5 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 Also see item 1 b Jan 09 gt SPARKS 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 WELDING and CUTTING 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 249 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating an
25. d create a fire hazard 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 welding area 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA
26. d is set to ON for timer setting mode Cycle power to the LN 15 or wait 45 seconds If all recommended possible areas of The LN 15 is an old ALPHA unit misadjustment have been checked and a DIP switch is in the wrong and the problem persists Contact position your local Lincoln Authorized The voltage display reads 0 0 volts 1 The power source meter polarity Field Service Facility during welding switch is in the wrong position Set the power source meter polar ity switch to match the welding process WELDING PROBLEMS Porosity in the weld he part being welded is wet dirty Variable or hunting arc or rusty The electrode being used is wet dirty or rusty There is insufficient shielding gas flow from possible cuts in the gas hose There is moisture or water in the shielding gas line There is too much shielding gas There is too much wind or drafts The arc voltage is set too high If all recommended possible areas of The wrong shielding gas is being misadjustment have been checked used and the problem persists Contact Variable or hunting arc Worn and or melted contact tip Your local Lincoln Authorized 2 Worn work cable or poor work Field Service Facility connection Loose electrode connection Wrong electrode polarity for the process being used The arc burns back to the tip The spool of electrode is tangled The electrode and work leads are reversed welding with the wrong po
27. ding wire 1 after about 10 seconds The drive rolls are slipping because of feeding problems The LN 15 is in CC mode instead If all recommended possible areas of CV mode of misadjustment have been Reduce the spindle brake resis checked and the problem persists tance Contact your local Lincoln Increase the amount of tension in Authorized Field Service Facility the wire drive pressure arm For best results use only Lincoln electrodes Verify on power up that the LN 15 is set for CV welding welding but the meter reading remains constant The Wire Feed Speed Range is only 1 The 8396 wire feed speed dual 50 601 in min 1 3 15 3 m min procedure is activated with the high speed gear Check dual proce dure switch in gun CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 15 CONTROL CABLE MODEL CE LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual The Wire Feed Speed Range is only 1 The 83 wire feed speed dual 50 374 in min 1 3 9 5 m min procedure is activated with the low speed gear Check dual procedure switch in gun DISPLAY PROBLEMS POS PRE or BRN show on the 1 display Spin set up mode One of the DIP switches on the feed head boar
28. disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 i SAFETY PR CAUTIONS DE SURETE 6 Eloigner les mat riaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machi
29. djusting the voltage knob varies the power source volt age to the LN 15 The value displayed is not a preset voltage Only actual average arc voltage is shown on the voltage display For codes 10864 10865 The voltage knob controls the output of the power source through a 3 3 4 turn 10K ohm potentiometer For codes 11033 and above The voltage knob controls the output of the power source through a turn 10K ohm potentiometer 5 TRIGGER CONNECTOR 5 Pin Receptacle is used to activate the Magnum Gun Switch 6 CONNECTOR BUSHING This connection is for weld ing conductor cable assembly 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 8396 of the set value but no less than 50 inch es minute 1 27 m min The 8396 procedure is most commonly used during pipe and out of position weld ing Requires Magnum 400 Dual Procedure Gun Equivalent FIGURE B 1 LN 15 CONTROL CABLE MODEL CE LINCOLN 5 B 4 OPERATION B 4 LN 15 POWER UP SEQUENCE E E F L l Normal Power Up Display Preflow When power is first applied to the LN 15 the display H 5 Lim will momentarily show set up information For exam Postflow ple it may show CV a
30. e the GAS PURGE switch to select the timer The time will then display in the right hand side of the display HEIN 4 Rotate the WEG knob to adjust the time to the new setting IP rj A WFS 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 LN 15 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 inch es 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 COLD FEED 1115 mes PURGE The LN 15 is now in the Press Spin set up mode If aft
31. e the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in 60974 10 Electromagnetic Compatibility product standard for Idi D arc welding equipment 3 1 96H L10093 LINCOLN 5 vii vii for selecting a QUALITY product by Lincoln Electric We want you Tha ou to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutti
32. er When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equip
33. er 15 seconds no other action is taken the LN 15 will then revert to normal operation LN 15 CONTROL CABLE MODEL CE LINCOLN B B 5 OPERATION B 5 Rotate the WFS knob until the desired parameter is displayed CV CC Mode lu EVE its E Ci 11 WFS Units uis EI Ok 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 set ting gum wm A WFS 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 LN 15 will enter normal operation INTERNAL CONTROLS Figure B 2 COLD FEED 2 STEP TRIGGER d ge INTERLOCK SPRING TENSION a SPINDLE ARM Tw BRAKE FLOWMETER SPRING TENSION ARM The pressure arm controls the amount of force the drive rolls exert on the wire Proper adjustment of both pres sure arm gives the best welding p
34. erformance 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 CORED WIRES SOLID WRES ALUMINUM OUTERSHIELD METAL SHIELD INNERS HIELD loe DJANI STAINLE SS LN 15 CONTROL CABLE MODEL CE LINCOLN 5 B 6 WIRE DRIVE CONFIGURATION See Figure B 2b Changing the Gun Receiver Bushing ELECTRIC SHOCK can kill 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 mainte nance work Tools required 1 4 hex key wrench Note Some gun bushings do not require the use of the thumb screw Turn power off at the welding power source Remove the welding wire from the wire drive Remove the thumb screw from the wire drive Remove the welding gun from the wire drive 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 E D OPERATION B 6
35. he 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 CONTROL CABLE MODEL CE LINCOLN 5 B 10 1 ACCESSORIES OPTIONAL EQUIPMENT e K1797 control cable extensions K1798 Adapter Cable for Control Cable to Terminal Strip Power Sources K1500 1 2 8 5 Gun Receiver Bushings Drive Roll Kits Include drive rolls and guide tube necessary to feed the identified wire size and type Steel Wires 023 030 0 6 0 8mm Including stainless steel 035 0 9mm KP1696 030S KP1696 035S 040 045 1 0 1 2mm 052 1 4 035 045 0 9 1 2mm 040 1 0 Cored Wires 030 035 0 8 0 9mm 040 045 1 0 1 2mm 052 1 16 068 5 64 Aluminum Wires LN 15 CONTROL CABLE MODEL CE LINCOLN 5 1696 0455 1696 0525 1696 1 1696 2 KP1697 035C KP1697 045C KP1697 052C KP1697 1 16C KP1697 068 KP1697 5 64 KP1695 035A KP1695 040A KP1695 3 64A C 1 D 1 MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill e Do not operate with covers removed Turn off power source before installing or servicing e Do not touch electrically hot parts
36. he level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must followed to avoid minor personal injury or damage to this equipment viii TABLE OF CONTENTS Page ARR M Section A Technical SPSCHICALIONS 1 rivi cct ERES A 2 LOCATION eiie cites en ILI LL ILLU A 2 High Frequency Protection ss A 2 Weld Cable Connections erre 2 Electrode Connection An eee 3 Work annee 3 Power Source Connection eg 3 Engine Drive Power Source Connection A 3 Connection Diagram es isc savant A 3 Wine Gables 4 Electrode Polarity ues D 4 Control 4 Procedure to Install Drive Rolls and Wire Guides A 5 Feeding Wire deck 5 ecu naar Section Safety ET E 1 Graphi
37. he 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 2 Step trigger operation turns welding on and off in direct response to the trigger Trigger Interlock operation allows weld ing to continue when the trigger is released for comfort on long welds m Place the toggle switch in the UP posi re tion for 2 Step operation or in the DOWN TRIGGER INTERLOCK 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 com fort 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 out put turns off and the wire feeder stops feeding wire CAUTION If the arc goes out whi
38. ing assistance before you proceed LN 15 CONTROL CABLE MODEL CE LINCOLN 5 DIAGRAMS Jequunu juewuidinbe 5 104 juewyedeg 201S eui M s sjeued y jo euo uo y paysed s epoo 10 siu 104 eq jou 1 Ajuo 10 S SIUL 310 1 2891 HT HOLIMS 40 3015 NOLLO3NNOO WOH NMOHS SHALANOILNA10d ON S3HOLIMS 319901 HOLOANNO 40 3015 WOY4 GAMAIA SY 5 ONINSENNN ALIAVO OO 40 5 LNINOdNOD WOHL AMAIA SV SONINDAS ONHIENNN ALIAVO V N vr KEEN TOHLNOD indino zer sl pre 45 3ounos svo Ve ut es IHONI 0109 Vo OVAZV Quvos 1 51 4399 41 1 pes ostez 1NdNI sss a O m T VE sss Jo ae MaoohiL NOLLO3NNOO amer av gr 300819513 9 0931 318 2 aaa alHs sus d as Post A0zE Post A0zE us
39. larity The liner is clogged The contact tip is worn The wire drive tension is improp erly set CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 15 CONTROL CABLE MODEL CE LINCOLN 5 E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual ERRORS ON THE DISPLAY Fault Code Description Possible Adjustments ____ Average motor over current shutdown The wire drive motor has overheated Check to make sure the electrode slides easily through the liner of the gun Reduce the amount of tension in the wire drive tension arm Verify that the spindle brake is not set too tight For best results use only Lincoln elec trodes Wait 10 minutes for the wire feeder to cool Trigger lockout The ripple of the power source OCV is too high greater than 110V Across the Arc Models only Verify the power source is reconnect ed for the proper input voltage Repair or replace the power source The power source does not conform to NEMA CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshoot
40. lder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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
41. le welding with trigger inter lock 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 mid dle 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 Ball Valve 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 A WARNING 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 WARNING 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
42. lectrical contact Poor work lead connec tions can result in poor welding performance POWER SOURCE CONNECTION The LN 15 can be used with any DC welding power source constant voltage power source is mend 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 CAUTION To prevent possible damage to the LN 15 do not connect the LN 15 to non Lincoln TIG or square wave power sources TIG high frequency should never be applied to the LN 15 ENGINE DRIVE POWER SOURCE CONNECTION The LN 15 sends a control signal to the engine drive 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 Set the MODE switch on the engine drive to CV WIRE 4 Set the WELD TERMINALS switch to WELD TER MINALS OFF 5 Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polarity being used 6 Set the ARC CONTROL knob to 0 initially and adjust to suit 7 Set the IDLE switch to the AUTO po
43. lity for technical troubleshooting assistance before you proceed LN 15 CONTROL CABLE MODEL CE LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Major physical or electrical damagel1 is evident when the sheet metal cov ers are removed The wire drive turns off periodically 1 while operating on an engine drive No shielding gas flow OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Field Service facil ity for technical assistance The supply voltage for the LN 15 is too low The gas bottle empty The gas hose is cut or clogged The flow meter valve is closed The gas solenoid has failed If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility The feed head board has failed The shielding gas turns on sporadi 1 cally or remains on all the time The pressure in the gas line is exceeding 80 psi 5 5 bar The gas solenoid has failed FEEDING PROBLEM The motor has exceeded the cur rent rating Check to make sure the electrode slides easily through the liner of the gun Verify that the spindle brake is not set too tight For best results use only Lincoln electrodes Wait 10 minutes for the wire feed er to cool The wire drive stops fee
44. ln Electric Company affect the results obtained in using the LN 15 wire feeder These vari ables include but are not limited to welding proce dure 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 t
45. ment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures the time of day that welding or other activities are to be carried out L10093 LINCOLN 5 SAFETY vi ELECTROMAGNETIC COMPATIBILITY EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to
46. minated 49 ELECTRIC AND MAGNETIC FIELDS 353 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running 2 d 3 Do
47. n 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 wm TABLE A 1 Total Cable Length 50 100 100 150 150 200 15 30 m 30 46 61m 61m 76m 200 Amps 2AWG 2AWG TAWG 300 Amps __ 1AWG 1 AWG 400 Amps 2 0 LN 15 CONTROL CABLE MODEL CE LINCOLN 5 3 INSTALLATION 3 ELECTRODE CONNECTION Route the electrode cable through the strain relief in the rear of the case Connect the electrode cable to the LN 15 connection block using the mounting hard ware provided Secure the cable by tightening the strain relief domestic models are supplied with an optional pig tail for customers that prefer to make a taped and bolt ed 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 e
48. nd HI indicating operation L1 from a CV power source and the wire drive is config Burnback h urn h H ured for the high speed gear Because of limitations in the display will appear as CLIE WOO After a brief moment the LN 15 will then display the WFS and No voltage is displayed until the trigger is pressed JE 5j d 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 25 0 sec onds The postflow time is adjustable from 0 0 to 25 0 sec onds 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 COLD FEED GAS PURGE 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 EJS Sl Pl Li 2 2 Rotate the WFS knob until the desired timer is dis played 3 Activate and then releas
49. ne souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr
50. ng equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipmen
51. paineis abertos ou guardas removidas NRMRAN ERWALKEE CRRBTFELEWUTEFSU ARAL see Gals 13 jlgall lla ye Age All Al 5 DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese x Korean LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR EL TRHO RARE FEU E gt RMR PBN XA A OHRBEE lt BRA EFBRLTR SEL EA EE MO DD DUAE TE A NOG A HE Gt Ao EH BA LA D HE SSE AUAAMS SAA HAY HA SHE EFM Jall yakal Ah d Gala Sc yhaa Jub al gll gl allai agil LINCOLN amp ELECTRIC World s Leader in Welding and Cutting Products 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
52. rode is not properly straightened it may not feed or may jam Insert the free end through the incoming guide bushing Press the Cold Feed switch and push the electrode into the drive roll Feed the electrode through the gun Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overrun when the wire feeding stops Do not overtighten LN 15 CONTROL CABLE MODEL CE LINCOLN 5 B 1 OPERATION SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE WARNING ELECTRIC SHOCK CAN KILL Unless using COLD FEED ture when feeding with gun trig ger the electrode and drive mechanism are always electri cally energized and could remain energized several sec onds after the welding ceases Do not attach the work clip to the roll cage 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 uti lizing 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 v
53. s lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place ELECTROMAGNETIC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitt
54. sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc de se prot ger les yeux du ray onnement de et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter de
55. sition Important Some older engine drives may the IDLE switch to be in the HIGH position for proper LN 15 operation LN 15 CONTROL CABLE MODEL CE LINCOLN 5 4 CONNECTION DIAGRAM CONTROL CABLE MODELS See Figure A 1 INSTALLATION ES CV305 LN 15 serruautomatic n H hvert 1 14 Pn wie J 1871 3 model T A i wist Mate f 2 Mugnum gun and Cable assembty LN 15 sermiautomatk wire tooder 2 1871 3 model I Magnum gun and cable assermmbh LN 15 sermautomabe E wre leeder K1871 3 model Magnum gun and GUNS AND CABLES ASSEMBLIES A variety of Lincoln 10 3 0m or 15 4 6m gun and cable assemblies are available for use with the LN 15 including the Magnum models for GMAW K126 or K115 models for Innershield and more The LN 15 comes factory equipped with a K1500 2 gun 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 sur faces clean Make sure it is fully seated and tighten the thumb screw Connect the control cable plug into the 5
56. t For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection T
57. tory equipped with a K1500 2 Magnum Tweco compatible style 2 4 gun bushing Other K1500 series gun bushings are avail able 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 constant 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 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 25 0 sec onds with a default of 0 00 seconds postflow time is adjustable from 0 0 to 25 0 sec onds with a default setting of 0 0 seconds The Control Cable Model features remote voltage control with a potentiometer on the front of the feeder The operation of the voltage control is similar to other feeders having remote control kits such as the LN 25 While welding the voltage may be adjusted as desired The voltage setting is not a preset value Electrode output is energized in response to the gun trigger by signals sent to the power source via the control cable DUTY CYCLE The LN 15
58. u un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaga Use ventila o exhaust o remover fumo da zona respirat ria eta LAb55 tM 22 T KA Dab CTPA ZE OF RE GE FE 802 e SA7I28 S EXACE E 25748 HHSHP 9184 7 5471214 ESIE ASSHAIR Bes OF aa 4 1 4 e E AA Qd Bic js M ox uu Aal ge glial us Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarheiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas X7TTLA Y4 UACRUSD PORK EFRRALY FE AUS CHAR SY pit gS juil all e Do not operate with panel open or guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os
59. wire feeders are intended for semi auto matic use The maximum rating of the LN 15 is based upon a 60 duty cycle 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 defined below in Table B 1 The Control Cable Model is suitable for GMAW GMAW Pulse GMAW STT and FCAW semi auto matic applications within the rated duty cycle PROCESS LIMITATIONS The control cable model 15 not recommended for SAW SMAW GTAW or CAG The control cable model works only with power sources having remote control output EQUIPMENT LIMITATIONS Codes 11033 and higher The LN 15 cannot be used with the K1500 4 gun adapter bushing OPERATIONAL FEATURES AND CONTROLS Remote voltage control at the LN 15 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 TABLE B 1 Process 1 16 5 64 GMAW FCAW 0 045 0 052 1 2 1 3 FCAW Wire Diameter Range 0 023 0 052 0 6 1 3 mm 1 6 2 0 mm Wire Feed Speed Range 50 700 ipm 1 3 17 8 m minute 50 700 1 3 17 8 m minute 50 400 ipm 1 3 10 2 m minute LN 15 C
Download Pdf Manuals
Related Search