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Lincoln Electric LN-8 SVM132-A User's Manual

1. 18913 H3d STOGWAS WOIHLO313 JUNLVHSdNAL HOLON d3lVnlOV X QHVOG O d YOYANYNA OLNI 55 4399114 SI 9 ANY SI HOLO3NNOO TWNINYSL SONOS H3MOd OL ce ANY 16 OVASGIL gt we 310v1d3038 9 B S2 9 Ly 9 NNN YN nN 4 amp LIN YS lal 58 899 2 5 S Lvs 198 z 5 5 5 HOLON erg 5 85 0334 8 35 929 409 5 MERE S 805 526 jg LG 4 ve I 3 Ige a HO103NNOO INTERNA AE 04 e 1vWHSHL ES 85 g YNOILdO O8 2 4 SOVITOA 38V vA Be sis E3dihnf 9 900 1090 12 25 D 3010 LON 300 ONY 1900 ao 2485 08 08 JOWLIOA 318 8s 18 08 30805 969 0 196 e ud 3 H3MOd 3OVLIOA 3 18 TYNOILdO m F alo OLNI G399Md HOLOINNOD 7 de T ONY Q3AONN3H SI HO103NNOO YANN ue 1 3 9 8 Sg tc Wee 9 09 109 j 689 5 8 lt 1081800 55 03345
2. B 2 cc Constant Voltage Controls B 3 Circu Protections Pr B 4 Avoiding Ground Lead Protector GLP B 4 Wire Feed Rolls and Guide B 5 Setting for CV 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 Ib Coils K303 Wire Reel Stand B 8 T Wire Reel Loading K1524 1 Universal Wire Reel Stand B 9 Feeding Electrode to the LN 8N or 1 85 B 11 Feeding Electrode to the LN 8NE or LN 8SE With Extension B 11 8 Slow Acceleration Starting Code 7926 and Above B 12 Flux Tank Loading ov aa OE 12 B E 2 o o 1 B E 2 O p B E 2 cc LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo 27 a 5 9 9 2 Return to Section TOC Return to Master TOC Read and understand this entire section be
3. tc pu TROUBLESHOOTING AND REPAIR dns INTERNAL VOLTAGE TEST continued FIGURE F 3 VOLTAGE TEST POINTS INPUT RECEPTACLE 32 32A SL B A 115 VAC INPUT APPLIED CIRCUIT 12 CONTROL D BREAKER 524 BORED CONNECTOR PLUG 2 7 CONTROL BOARD 1 4 32 531 6261 TT 2 OHM A D 7 32A 525 GUN TRIGGER A 31 RESISTOR R4 531 RECEPTACLE S RELAY BOARD TEST DESCRIPTION 4 Apply 115VAC to the input receptacle at pins C and D 1 Remove input power to the LN 8 5 Using the voltmeter carefully 2 Using the 5 16 in nutdriver test the voltages per Table F 1 remove the screws from the left at the test points shown in side cover assembly Figure F 3 3 Lift the left side cover 6 When testing is complete install the screws that secure the left side cover assembly LN 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv tc F 16 INTERNAL VOLTAGE TEST continued TABLE F 1 VOLTAGE TEST POINTS TROUBLESHOOTING AND REPAIR CHECKPOINT LOCATIONS Input Circuit Breaker and Resistor R4 Input Circuit Breaker and Resistor
4. LARGE IDLE ROLL IDLE LOCKING INGOING SHAFT SCREW ROLL SCREW pLEROLL GUIDE SPRING PRESSURE SCREW Return to Section TOC Return to Master TOC LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio F CIS a 5 tC Return to Section TOC Return to Master TOC 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 Setthe 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 deter mined 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 electrod
5. N B NEGATIVE POSITIVE ELECTRODE CABLE TO WIRE FEED UNIT WORK BOLTED CONNECTION THE DIAGRAM SHOWS THE ELECTRODE CONNECTED FOR POSITIVE POLARITY CHANGE POLARITY TURN OFF THE POWER REVERSE THE ELECTRODE AND 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 77 NEAR THE POWER SOURCE TERMINAL STRIP OR TO AN UNPAINTED FRAME SCREW THE POWER SOURCE MUST BE PROPERLY GROUNDED 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 CONN
6. CONTROL BOARD ARMATURE WIRE THERMAL FEED CIRCUIT MOTOR BREAKER 531 CONTROL GUN 1 RECEPTACLE OPTIONAL BURNBACK BOARD SWITCH TRANS SWITCH VARIABLE VOLTAGE operator The control board adjusts the armature voltage applied to the wire BOARD METER SHUNT feed motor to change the motor speed WIRE SPEED AND power souice cental fom CONTROLS The optional variable voltage board enables the LN 8 to be used with a con stant current power source The vari able voltage board monitors the arc voltage via leads 21 and 567 and modifies the wire feed speed according to arc voltage variations and require ments The wire speed control dictates to the control board the directives of the unit The remote control is coupled to the welding power source via leads 75 76 and 77 through the input receptacle The electrode meter shunt which is connected to and also in series with the gun connector block senses the weld ing current and arc voltage This infor mation is used by the variable voltage board and also the optional meter kit NOTE Unshaded areas of block logic diagrams are the subject of discussion LN 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio O o Fle CIS a 5 818 EIS 2
7. A 4 Power Source Connection 1 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 Discontinued 7 Connection of LN 8 to a Sam Motor Generator or Engine Driven Welder A 8 T Connection of LN 8 to R3S 250 and R3S 325 A 9 Connection of 8 to 600 A 10 Connection of 8 to DC 250 400 CV CVI Power Sources A 11 8 K318 Dual Process Contactor DC 400 CV 400 and CVI 500 Connection to LN 8 for Same Polarity A 12 K318 Dual Process Contactor DC 400 CV 400 and CVI 500 Connection m to LN 8 for Opposite Polarity Operation 13 8 For Power Sources Other Than Lincoln Electric A 14 Input Cable Connections 1 A 15 ENS8N and ENSSS NS deta nds caen end A 15 and LN 8SE orcum v eer Te ed 15 Gun and Cable Assemblies A 18 General 3t ios eue qos eue Sag dat A 18 Gun Ca
8. E 4 SCR AA RSR ccd eee dat eines E 5 Troubleshooting and Repair Section 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 csse 455 metre 12 Component Replacement Procedures F 24 Retest After Repair F 40 Electrical Diagrams 42 2 RR RI RR ERA ERES ERE Rn Section G Parts Manual i x ee ee RA ENTE NE P293 Series LN 8 LINCOLN SECTION 1 INSTALLATION SECTION A 1 5 5 INSTALLATION 8 Installation os facies oss sa dee cain aig ceed erga a Sed sia ee Section A 9 Technical Specifications 8 2 Mounting Location ere ker on e Yogi 3 2 Power Source 3 EN 8N arid I co e aer m dre Ra A 3 LN 8S and LN 8SE and converted LN 8N and LN 8NE
9. tc F 37 WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT continued TROUBLESHOOTING AND REPAIR FIGURE F 12 REED SWITCH REMOVAL AND SHUNT ELECTRICAL CONNECTIONS REED SWITCH BRACKET HEX HEAD SCREWS 7 Disconnect two leads 567 blue and lead 568 blue from the shunt using the 11 32 in wrench See Figure F 12 Note the lead placement on the shunt for reassembly Using a 7 16 in wrench loosen the two hex head screws that secure the reed switch bracket to LN 8 LINCOLN 5 the front of the wire drive assem bly Slide the bracket off the front of the wire drive assembly Using an offset flat blade screw driver remove the two mounting screws below the shunt and the one mounting screw below the wire drive motor Remove the wire drive assembly through the wire drive side of the case Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 5 Return to Section Return to Master TOC O 7 iv tc F 38 TROUBLESHOOTING AND REPAIR WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT continued FIGURE F 13 WIRE DRIVE ASSEMBLY REMOVAL 10 Using a 1 2 in wrench remove the four hex head screws lockwash ers and flat washers that hold the mounting plate to the gear box assembly
10. 5 5 10 1 5 2 B 1 Return to Section Return to Master TOC Return to Master TOC F 17 TROUBLESHOOTING AND REPAIR 1CR RELAY TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION This test will determine if the control relay is functioning properly by measuring the resistance across the contacts when the relay is energized and de energized This procedure takes approximately 15 minutes to perform MATERIALS NEEDED Volt Ohmmeter 24VDC power supply 5 16 in nutdriver LN 8 LINCOLN 5 F 17 ae TROUBLESHOOTING AND REPAIR Ee 1CR RELAY TEST continued FIGURE F 4 1CR RELAY TEST POINTS NORMALLY CLOSED Return to Section TOC Return to Master TOC NORMALLY OPEN 4 4 1CR RELAY o gt 2 o Return to M
11. 2002 LN 8 SEMIAUTOMATIC WIRE FEEDER For use with code numbers 9963 9964 Return to Master TOC View Safety Info 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 thought ful 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 Return to Master TOC View Safety Info Fg E 9 2 5 EL SERVICE MANUAL View Safety Info LINCOLN Copyright 2002 Lincoln Global Inc e 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 Return to Master TOC Return to Master Return to Master TOC 2 5 Return to Master SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A 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 defe
12. 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 e VARIABLE 4 Connect a work lead of sufficient size and length VOLTAGE per Table 1 between the appropriate output PC BOARD terminal on the power source and the work Ensure the connection to the work makes tight metal to metal contact oio o F CIS a g 2 5 tc Return to Section TOC Return to Master TOC LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo O10 Fle 5 a 2 tc Return to Section TOC Return to Master TOC INSTALLATION 23 POWER SOURCE CONNECTION DIAGRAMS Table 2 LN 8 Power Source Connection Diagrams Connection of LN 8 to an Idealarc amp R3S 400 600 or 800 with LVC Discontinued Connection of LN 8 to Idealarc R3S 400 600 or 800 without LVC Discontinued Connection of LN 8 to a SAM Motor Generator or Engine Driven Welder Connection of LN 8 to R3S 250 and 835 325 Connection of LN 8 to DC 600 7 Connection of LN 8 to DC 250 400 Power Sources 8 K318 Duel Process Contactor Kit AQ K318 Duel Process Contactor Kit DC 400 CV 400 and CVI 500 Connection to LN 8 for Opposite Polarity O
13. CONNECT THE LN 8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 77 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 amp 21B USING 14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 516586 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 218 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 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 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 LINCOLN ELECTRIC CLEVELAND OHIO U S A LN 8 13 13 INSTALLATION FIGURE 9 K318 DUAL PROCESS CONTACTOR KIT DC 400 CV 400 AND CVI 500 CONNECTION LN 8 FOR OPPOSITE POLARITY OPERATION WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITC
14. O 7 iv tc 2 TROUBLESHOOTING REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories function problems feeding prob lems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists
15. tc Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE E 4 SILICON CONTROLLED RECTIFIER OPERATION CATHODE OUTPUT A ANODE if if NOTE AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED SCR OPERATION silicon controlled rectifier SCR is a three terminal semi conductor device used to control currents to a load Refer to Figure E 4 An SCR acts very much like a switch When a gate signal is applied to the SCR it is turned ON and there is current flow from anode to cath ode In the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow thus the device acts like an open switch As the name suggests the SCR is a rectifier so it passes current only during positive half cycles of the AC supply The posi tive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state The amount of time spent in the ON state is controlled by the gate LN 8 LINCOLN An SCR is fired by a short burst of cur rent into the gate This gate pulse must be more positive than the cathode volt age Since there is a standard PN junc ti
16. The interlock switch is in the off position With the interlock switch S2 in the 1 postion the wire feed stops when the gun trigger is released 1 Check the welding cables for loose or faulty connections 2 jumper wire from 2 to 4 on the power source terminal strip machines with 14 pin amphenols pin C to pin D If the arc voltage is not present at the output terminals the power source is faulty If the arc volt age IS present the problem is in the wire feeder or control cable Check the continuity of leads 2 and 4 through the control cable Replace if open The welding gun may be faulty Check or replace Disconnect the gun trigger cable If the problem is solved the gun trigger or cable is faulty Repair or replace Check leads 529 and 528 for loose or faulty connections between the 2CR reed switch and the control board and motor thermal circuit breaker See wiring diagram 1 The 1CR relay located on the power board may be faulty Check or replace Note The relay may operate but the indi vidual contacts may not be func tioning properly If a burnback kit is installed remove and install the jumper plug If the problem is solved the burnback kit is faulty Check the 2 and 4 leads in the LN 8 wiring harness for loose or faulty connections See wiring diagram The 1CR relay may be stuck closed Perform the 1CR Re
17. a tacts are closed An infinite resis 9 Re install relay into the relay eg tance indicates that the contacts board E E ale 2 2 olo 5 5 10 1 5 2 B 1 Return to Section Return to Master TOC LN 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 20 TROUBLESHOOTING AND REPAIR DRIVE MOTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the drive motor is functioning correctly This procedure takes approximately 20 minutes to perform MATERIALS NEEDED 5 16 in nutdriver Volt Ohmmeter
18. LN 8 Electrical Sequence of Operation F 10 Test F 12 Trigger Transformer F 12 Internal Voltage Test F 14 ICR Relay D st gua retmen ian 9 4 6 j F 17 Drive Motor F 20 Component Replacement Procedures F 24 Potentiometer Replacement F 24 Circuit Breaker Replacement F 26 e Ground Lead Protector Push Button Switch F 28 Trigger Transformer F 30 5 Board Replacement 32 3 Wire Drive Assembly and Component Replacement F 35 Retest After Repair nad der fuk c RR UR ox gat ac dolia dee OR x F 40 2 re O 0 d g E O 0 g E re LN 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC
19. Return to Section Return to Master TOC TM TROUBLESHOOTING AND REPAIR 0 LN 8 ELECTRICAL OPERATION FIGURE 1 LN 8 ELECTRICAL OF OPERATION TURN ON POWER SOURCE PRESS GUN TRIGGER CLOSES 524 528 ENERGIZES 1 CR CLOSES 2 4 CIRCUIT OPENS 682 683 CLOSES 683 32A CIRCUIT ENERGIZES POWER SOURCE PILOT RELAY CLOSES 531 7 REVERSES WIRE ENERGIZES FEED MOTOR POWER SOURCE ENERGIZES FIELD CONTACTOR CONTROL CIRCUIT AND AUX EQUIPMENT HOT TO GROUND WIRE FEEDS DOWN ARC STARTS ENERGIZES 2 CR REED SWITCH MOTOR ACCELERATES INTERLOCKS 1 CR IF TO WELDING SPEED INTERLOCK SWITCH IS CLOSED WELDING LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv tc Ju TROUBLESHOOTING AND REPAIR EH FIGURE F 1 LN 8 ELECTRICAL SEQUENCE OF OPERATION continued WELDING RELEASE BREAK GUN TRIGGER WELDING ARC OPENS 2 8 NOTE 1 DE ENERGIZES 2 CR REED SWITCH OPENS INTERLOCK ON 1 CR NOTE 2 DE ENERGIZES 1 CR OPENS 2 4 CIRCUIT OPENS 531 7 OPENS 683 32A CIRCUIT CLOSES 682 683 DE ENERGIZES 2 E DISCONNECTS MOTOR ARMATURE AND CONTROL CIRCUIT FROM INPUT AC LINE DE ENERGIZES DE ENERGIZES AUX EQUIPMENT IF CONNECTE
20. lectrodes connect s deux machines soud er 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 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie 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
21. 1 Return to Section Return to Master TOC Return to Master TOC F 32 TROUBLESHOOTING AND REPAIR PC BOARD REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD MATERIALS NEEDED 5 16 in nutdriver Phillips screwdriver The Variable Voltage board takes approximately 5 minutes to replace The Relay board takes approximately 5 minutes to replace The Control board takes approximately 5 minutes to replace LN 8 LINCOLN 5 F 32 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv tc F 33 TROUBLESHOOTING AND REPAIR F 33 PC BOARD REPLACEMENT continued FIGURE F 10 PC BOARD LOCATIONS CONTROL
22. 8 0334 UM HOLIMS 0324 5 a 30 5 9 NOLLO3UIQ 52 ONLLVE 97 a 289 09 891 0 m O GHE o 5 JO NOLLO3NNOO 803 08708 0870825 d TT 0 STYNINYSL 103NNOO AT B8 5 SE TEE IPAE 726 4448 58 FEES THEE 995 EFE 85 ONIANNOUD 3599 HANLOISNYEL 5399141 m 242235 22 NOILD3NNOD 39vLIOA MOT D 5 31108 440 2 HE P Ez os M3Y9S 9NIONnOUD 929 22 O 8855 88 3970 JHL OL ALIIO EC m 228585 28 S DEN puit 0606 3408Y 53002 404 4399181 NNO T EEIE MOT38 ONY 0606 ux d 285242 54009 NO HI 80151538 801231044 0131 E SERI 5828 55 m 58 8 ge H0193NNO9 div 6 25 4 cf TOHLNO9 118110 p 709 y 209 Z LES vee 398005 u3MOd N T 80103NNOO rod 0901 iz Yaan Lo d li 25 5 o 9 p z 9 So us Lu pos 7 20 d y 5 D 5 o 1vNOLLdO QuvO8 O d HOLOWINOO 318340 OL 58 328005 83 04 OL 2 E d 5 2 O DOL Je1Se A 0 Unjo4 DOL 491Se N 0 DOL DOL 491Se N 0 DOL uonoes uumeg DOL uonoes uumeg DOL uonoes DOL 5 uumeg a4 ELECTRICAL DIAGRAMS OPER
23. from the LN 8 Locate and remove leads 539 and 541 from the control board Locate and remove leads 626 and 627 from the relay board Using the ohmmeter measure the resistances per Table 3 If the motor resistance test is good proceed to the Motor Applied Voltage Test MOTOR APPLIED VOLTAGE TEST 1 2 Carefully connect the isolated 120VDC supply supply turned off to motor leads 626 and 627 see Carefully connect the variable 0 to 120VDC supply supply turned off to motor leads 539 and 541 Apply field voltage first leads 626 and 627 to the motor Then slowly apply the armature voltage at leads 539 and 541 The motor should run and the speed should vary with changes to the armature voltage If the motor does NOT run and change speed correctly the motor or gear box may be faulty To stop the motor remove the armature voltage first leads 539 and 541 AFTER TESTING 1 2 Replace motor leads Install the screws that secure the left side cover assembly If disengaged engage the drive rolls If removed feed the electrode back into the wire drive unit TABLE F 3 DRIVE MOTOR TEST POINTS TEST POINTS RESISTANCE DC VOLTAGE Lead 539 to 541 Armature Lead 626 to 627 Field Winding All leads to motor shell min LN 8 LINCOLN 5 750 to 950 ohms 90 to 120VDC 500 000 ohms N A F 23 Return to Section Return to Master TO
24. install the K161 mechanized travel power pack CONSTANT CURRENT CONVERSION PARTS To convert the LN 8N or LN 8NE for welding with a constant current power source purchase a variable voltage PC board L5039 and constant current dial plate M12230 for LN 8N and LN 8S models M13148 for LN 8F models above code 7580 LN 8 LINCOLN amp 6 o ig g Z DOL Je1Se N 0 DOL Je1Se N 0 DOL Je1Se N 0 DOL Je1Se N 0 DOL uonoeg 0 DOL uonoes 0 DOL uonoes 0 DOL uonoes 0 SECTION D 1 MAINTENANCE SECTION D 1 TABLE OF CONTENTS MAINTENANCE SECTION Maintenance dk a aa line as Section D Routine Maintenance D 2 Drive Rolls and Guide D 2 Wire Reel Mounting D 2 Periodic D 2 Control 3 ane data a etat mo D 2 Wire Drive Motor and D 2 Gun and Cable Maintenance D 2 Return to Master TOC Return to Master TOC D 5 Return to Master LN 8 LINCOLN Return to Section Return to Master TOC R
25. mount is equipped to feed 1 16 through 0 120 in 1 6 through 3 0 mm electrode LINCOLN amp INSTALLATION 9 9 FIGURE 12 INPUT CONTROL CABLE AND ELECTRODE CABLE EXTENSIONS EE WIRE 3 3 pieds POLARIZED CONTROL CONTROL PLUGS CABLE 9 EIE EXTENSION 9 9 a ELECTRODE 7 EXTENSION WIRE with the polarized plug at the wire reel base Refer to Figure A 12 olo CABLE 2 HAND REEL ats CRANK BASE to 2 The standard cable setup consists of an electrode 8 cable and a control cable with polarized plug FIGURE 13 CABLE EXTENSION 9 the wire end Position the control cable CONNECTIONS TO WIRE FEEDER JE dc 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 LOCKING SCREW 5 Connect the polarized connectors of the control CONTROL cable together CABLE EXTENSION 6 Place both the control and electrode cables under the clamp on the wire reel base and tighten the screws oio Fle 5 a 5 9 9 2 7 Insert the connector the electrode cable extension into the brass block of the hand crank assembly and tighten with a 3 16 in A
26. 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 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 forte ment 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 PR CAUTIONS DE S RET POUR 3 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER TRANSFORMATEUR a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 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 pantalons sans revers et chaussures montantes LN 8 LINCOLN amp Relier la terre le chassis du poste
27. set of contacts control the motor field circuit polarity which along with the wire feed switch dictate the wire feed direction The third set of contacts control the 2 and 4 contactor circuit which enables the power source weld ing output The 2 and 4 contactor circuit is passed through the optional burnback board which delays the opening of the circuit and prevents the electrode from sticking in the weld puddle The interlock switch reed switch ground lead protector GLP and ther mal circuit breaker are all incorporated in the gun trigger circuit In case of a fault condition the GLP or thermal cir cuit breaker will disable the trigger cir cuit The interlock switch and reed switch enhance the gun trigger circuitry by allowing the operator to release the trigger button and continue welding NOTE Unshaded areas of block logic diagrams are the subject of discussion LN 8 LINCOLN 5 E 3 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo O10 5 a gt EIE i tc Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE E 3 VARIABLE VOLTAGE BOARD METER SHUNT WIRE SPEED AND REMOTE OUTPUT CONTROLS REMOTE OUTPUT CONTROL Eat DOAOSAZOO 21 WIRE FEED VARIABLE VOLTAGE BOARD 567 ELECTRODE METER SHUNT SPEED CONTROL CIRCUIT BREAKER
28. the addition of the proper spindle and Readi Reel adapters it can accomodate various sizes of coils spools and Readi Reels ACCESSORIES K363P 30 lb Readi Reel Adapter K435 Spindle Adapter for 14 Ib coils K468 Spindle Kit K1504 1 60 Ib Wire Reel K438 60 Ib Readi Reel Adapter K162 SPINDLE FOR MOUNTING READI REELS AND 10 THRU 30 Ib 4 5 THRU 13 5 kg SPOOLS For use with the K303 wire reel stand To mount this spindle kit remove the shaft from the standard 50 to 60 Ib 22 5 to 27 2 kg wire coils from the mounting framework Install the spindle per the instructions shipped with the kit K377 SMALL MOUNTING STAND FOR READI REEL COILS OR 10 THRU 30 Ib 4 5 THRU 13 5 kg SPOOLS WITH 2 in 50 mm I D This assembly includes a wire reel spindle similar to the K162 spindle attached to a small frame The unit is supplied with the K363 Readi Reel Adapter for using the Lincoln Readi Reel Electrode Coils Without the adapter the unit is capable of handling spools with a 2 in I D 12 in maximum O D and a 4 in width The spindle has an adjustable breaking system K378 SMALL MOUNTING STAND FOR 13 14 Ib 6 0 6 4 kg INNERSHIELD COILS This assembly includes the smaller frame as used in the K377 and the fully enclosed canister system for derailing of the 14 coil This system has a fixed brake for the 14 Ib coil M11514 WIRE REEL DUST SHIELD DOOR FOR K303 In extremely dusty and dirty locations t
29. 1K PT301 1 1 1 PULSE TRANSFORMER S 0109 110 7509 R124 1KOTRIMMER F201 1 2 125V 250V TP301 TRANSIENT PROTECTION SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT E SLOW BLOW FUSE BOARD MAY CHANGE WITHOUT AFFECTING THE INTER 0110 R111 50K TRIMMER R125 4 7K4W Sis 1 4 SCR201 4A 4001 ELECTRICAL SYMBOLS LEAD COLOR CODING CHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM 5 9 0112 113 39K Bs 150 TP201 TRANSIENT PROTECTION PER E1537 B BLACK R RED MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY U BLUE W WHITE amp 5 BA R os CONTROLS HAVING COMMON CODE NUMBER ele 0114 1A 115 68K R129 15K 12 3 92 cle DZ101 20V M14680 2 1 NOTE Lincoln Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided LELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LN 8 Return to Section Return to Section TOC Return to Master TOC o 2 5 2 c 3 Return to Section Return
30. 2 tc Return to Section TOC Return to Master TOC Return to Master TOC E 2 THEORY OF OPERATION FIGURE E 1 POWER INPUT CIRCUITS REMOTE OUTPUT CONTROL 20402 44200 21 VARIABLE VOLTAGE BOARD WIRE FEED SPEED CONTROL ELECTRODE METER SHUNT CIRCUIT BREAKER L 32A CONTROL BOARD ARMATURE WIRE THERMAL FEED CIRCUIT MOTOR BREAKER 531 CONTROL OPTIONAL BURNBACK BOARD GENERAL DESCRIPTION receptacle through the circuit breaker The LN 8 is a semiautomatic wire feeder designed for Innershield FCAW and gas metal arc processes with the appro priate accessories is also suitable for constant voltage CV submerged arc welding processes With the optional variable voltage board installed the LN 8 can be used with constant current CC procedures The wire feed speed and welding power source output can be controlled from the LN 8 POWER INPUT CIRCUITS The 115VAC is applied usually from the welding power source via the input LN 8 LINCOLN 5 and 2 ohm resistor to the control board the relay board and the trigger trans former The 24VAC developed at the trigger transformer is rectified on the relay board and applied to the gun trigger cir cuit which controls the 1CR relay The 115VAC that is applied to the
31. 7925 come equipped with a factory calibrated Speedmeter Trimmer PC board and meter kit receptacle prepared to accept the optional K261 speed ammeter voltmeter analog kit LN 8 wire feed units no 7926 and above come with the speedmeter trimmers incorporated into the Control PC board K202 BURNBACK KIT This kit is useful to help prevent the electrode from sticking in the crater at the end of the weld in two types of welding applications 1 Welding with small diameter wire 0 035 thru 1 16 in 0 9 thru 1 6 mm at fast wire feed speed when there is a tendency to overrun the wire 2 When the semiautomatic gun is mounted in a fix ture or on the K62 Squirtmobile in such a manner that it cannot be lifted from the work at the end of the weld The kit delays the dropout of the contactor allowing the electrode to burnback from the crater at the end of the weld The delay time is adjustable for optimum burnback for different sizes processes and proce dures Installation instructions are shipped with the kit ACCESSORIES dia K58 MAGNETIC SEPARATOR Useful with any submerged arc equipment The unit removes foreign magnetic particles from reused sub merged arc welding flux Operating instructions are included with the kit K119 GRAVITY FEED FLUX CONE The flux cone is manual feed attachment for the K112 and K113 sub arc guns that is used instead of the continuous feed flux system The flux cone attaches to the gun using the s
32. Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 8 LN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC F CIS a gle 5 2 1 Return to Section Return to Master TOC SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below 50287 01 99 LINCOLN
33. R4 Input Circuit Breaker and Resistor R4 Gun trigger receptacle pins A and C Terminals 7 and 2 located on relay board Terminals 626 and 627 located on relay board Terminals 539 and 541 located on control board Control board connector plug Relay board connector plug TEST DESCRIPTION Input voltage before the circuit breaker and 2 ohm resistor R4 Input voltage after the circuit breaker Input voltage after the circuit breaker and 2 ohm resistor R4 Check voltage across gun trigger trigger open Auxiliary terminals gas solenoid Note Gun trigger must be activated Drive motor field voltage Drive motor armature voltage Note Gun trigger must be activated and armature voltage will be dependent upon wire speed setting Check that 115VAC is being applied to control board when gun trigger is activated Check that 115VAC is being applied to the control board LEAD NO 31 and 32 31 2 16 ACCEPTABLE VOLTAGE READING 103 to 126VAC 103 to 126VAC 531 and 32A 103 to 126VAC 524 pin and 528 pin C 7 and 32A 34 to 42VDC 103 to 126VAC 626 and 627 102 to 125VDC 539 and 541 32A pin 12 and 7 pin 2 32A pin 1 and 531 pin 4 LN 8 LINCOLN 5 4VDC min 90VDC max 103 to 126VAC 103 to 126VAC Return to Section Return to Master TOC Return to Section TOC olo
34. THE MOLDED PLASTIC the grooves in the molded adapter cle K363 P READI REEL ADAPTER 2 8 Slide the cage all the way onto the adapter until oye The spindle should be located in the LOWER mount the retaining spring pops up fully ing hole 1 Depress the Release Bar on the Retaining Collar CAUTION and remove it from the spindle See Figure 6 Check to be sure the Retaining Spring has fully returned 2 Place the Adapter on the spindle to the locking position and has SECURELY locked the Readi Reel cage in place The Retaining Spring must 3 Re install the Retaining Collar Make sure that rest the cage not the welding electrode 5 Position the Readi Reel so that when it rotates the wire is de reeled from the bottom of the coil O e o the Release Bar pops up and that the collar cls retainers fully engage the retaining groove on the E spindle 9 To remove the Readi Reel from the Adapter 4 depress the retaining spring tab with thumb o lo 4 Rotate the spindle and adapter so the retaining while pulling the Readi Reel cage from the molded pn spring is the 12 o clock position adapter with both hands Do not remove the Ble Adapter from the spindle FIGURE B 6 READI REEL MOUNTING ADAPTER 2 IN O D SPINDLE RETAINING SPRING oio Fle 5 a 5 9 9 2 HOLDING PIN RETAINING COLLAR GROOVES READI REEL INSIDE C
35. 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 516586 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 75 ON THE TERMINAL STRIP LEAD 76 76 ON THE TERMINAL STRIP AND CONNECT LEAD 77 TO 77 ON THE TERMINAL STRIP O10 Fle 515 lo gt 8 Sis 2 tc LINCOLN jo ELECTRIC CLEVELAND OHIO U S A LN 8 Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio Fle 515 lo gt elg
36. THE POWER SOURCE AND WIRE FEEDER IF EQUIPPED 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 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 777 NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE GROUNDING TERMINAL STRIP MARKED 777 AND LOCATED NEAR THE POWER SOURCE INPUT POWER CONNECTIONS MUST BE PROPERLY CONNECT
37. Variable DC voltage supply 0 to 90VDC Isolated DC voltage supply 120VDC LN 8 LINCOLN 5 F 20 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle S 0 PEN a gt 818 cic 515 2 1 Return to Section Return to Master TOC F 21 TROUBLESHOOTING AND REPAIR DRIVE MOTOR TEST continued FIGURE F 5 DRIVE MOTOR TEST POINTS TEST PROCEDURE 1 Remove input power to LN 8 2 Remove the electrode wire or dis engage drive rolls LN 8 LINCOLN 5 Using the 5 16 in nutdriver remove the screws from the left side cover assembly Lift the left side cover Locate leads 539 and 541 at the control board See Figure F 5 F 21 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv tc F 22 TROUBLESHOOTING AND REPAIR DRIVE MOTOR TEST continued FIGURE F 6 GUN TERMINAL JUMPER LOCATIONS 2 m r gt lt Locate leads 626 and 627 at the relay board If a variable voltage board is installed in the LN 8 make cer tain the mode switch is in the CV position Apply 115VAC to the input recep tacle at pins C and D With the gun trig
38. be faulty Check or replace The gun contact tip may be worn Check or replace The welding power supply may be faulty Check or replace Make sure the welding parame ters and techniques are correct for the welding procedure being used Check the welding cables for loose or faulty connections The gun cable may be faulty Check or replace The gun contact tip may be worn Check or replace The welding power source may be faulty Check or replace 1 Put the power POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION Put the power source in Machine Control and check if the welding performance improves If the problem is resolved check or replace the control cable and or check the output control in the LN 8 Perform the Drive Motor Test source in Machine Control and check if welding performance improves If the problem is resolved check or replace the control cable and or check the output control in the LN 8 CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo 5 5 10 1 5 2 B 1
39. con trol board is rectified and controlled by SCRs See and applied to the armature of the wire feed motor The relay board rectifies the 115VAC and applies it to the field winding of the wire feed motor NOTE Unshaded areas of block logic diagrams are the subject of discussion E 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo O10 5 a gt EIE ple tc Return to Section TOC Return to Master TOC E 3 THEORY OF OPERATION FIGURE E 2 GUN TRIGGER AND 1CR CONTACT CONTROL CIRCUITS REMOTE OUTPUT CONTROL 21 VARIABLE VOLTAGE BOARD WIRE FEED SPEED CONTROL ELECTRODE METER SHUNT CIRCUIT BREAKER d 2 2 amp 4 2 OHMS BOARD CONTROL ARMATURE WIRE THERMAL FEED CIRCUIT MOTOR BREAKER 531 FUSE DOAHOrPAZOO CONTROL FIELD GUN CABLE RECEPTACLE 2 OPTIONAL BURNBACK BOARD REED TRIGGER GEP SWITCH TRANS GUN TRIGGER AND 1CR RELAY CONTACT CONTROL CIRCUITS When the gun trigger switch is activat ed closed the 1CR relay is energized Three sets of isolated contacts incor porated within the 1CR relay perform several functions One set of contacts completes the circuit to energize the wire feed motor armature and also the auxiliary circuit 7 and 32A Another
40. conformement au code de l lectricit et aux recommendations du fabricant Le dis positif 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 debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 RETURN MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ER ER ee i iv DIRS OND Ti nase E yea Section A Technical Specifications 8 A 2 Mounting Location 1 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 ec RR __ __ Section B Safety Instructions 2 Controls and Their B 2 Circuit Protection dau ua sets de n B 4 Avoiding Ground Lead Protector GLP Activation B 4 Wire Feed Rolls and Guide Tubes B 5 Setting for C
41. 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 LINCOLN ES OPERATION ads 9 9 WIRE FEED ROLLS AND GUIDE 3 Install the drive roll and replace the clamping col lar Tighten the drive roll screw TUBES 9 4 Remove idle roll shaft screw Install the idle roll glz The drive rolls and guide tube kits are ordered sepa and idle roll shaft screw o 9 rately Refer to Figure B 3 and install these parts per cle the following instructions 5 Remove the large ingoing guide from the rear 2 brass block by loosening the locking screw amp c 1 Loosen the idle roll spring pressure screw 6 Loosen the ingoing guide tube clamping screw 2 Remove the drive roll screw and clamping collar Install the ingoing guide tube which is stenciled from the drive shaft through the rear brass block Tighten the clamping screw FIGURE B 3 WIRE FEED ROLLS AND GUIDE TUBE INSTALLATION 8 INGOING 515 GUIDE 9 gle DRIVE 5 CLAMPING DRIVE ROLL eic COLLAR ROLL SCREW OUTGOING GUIDE TUBE LOCKING SCREW CLAMPING SCREW Q 2 O o 3 tc
42. 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 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 or 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 LINCOLN amp LN 8 VE Also see item 1 b ARC RAYS can burn 4 Use a shield with the proper filter and cover plates to protect your e
43. the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either good or bad there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chap ter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical trou bleshooting assistance before you proceed call 1 800 833 9353 LN 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC ojo 5 5 min a 2 2 B Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING N ELECTRIC SHOCK kill Have an electrician install and
44. tighten hand tight Reconnect the incoming air supply There will always be a small amount of air and possi bly drops of water coming out of the end of the tube coiled under the tank This is an automatic disposal system in case the plant air has water and dirt in it LN 8 LINCOLN SECTION 1 ACCESSORIES SECTION C 1 9 TABLE OF CONTENTS 5 ACCESSORIES SECTION 0 Section Q erc C 2 K163 Undercarriage Requires K303 K377 K378 C 3 2 K178 Mounting Platform sis C 3 261 Meter TER C 3 K202 BurnbackKIKIt Pec C 3 K58 Magnetic Separator sunset hihi aia Ni oie C 3 K119 Gravity Feed Flux Cone iii C 3 SCEGGh 3 CL IV SME Ia EL C 3 K161 Mechanized Travel Power Pack C 3 K240 Contactor Ege ren M leon nee C 4 T K317 Dual Process Kit No Polarity Change C 4 K318 Dual Process Contactor Kit With Polarity C 4 pa Reel Mounting ACCesSOries niinc esitare tna anre atra FEL dra REL C 4 8 K303 50 to 60 Ib 22 7 to 27 2 kg Wire Reel C 4 K1524 1 Universal Reel Stand and Assembly C 4 K162
45. to Master TOC Return to Master TOC Q D E oS ELECTRICAL DIAGRAMS os CONTROL BOARD L5767 SCHEMATIC W RECEPTACLE D3 1N4007 1N4007 TO CV W SWITCH ON VARIABLE VOLTAGE PCB 2N6397 FROM VARIABLE 7 gt 637 VOLTAGE PCB GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 1 022 50 UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 44 UNLESS OTHERWISE SPECIFIED LABELS NOTES DIODES 1A 40 V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM POWER SUPPLY SOURCE POINT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 57 COMMON CONNECTION NUMBER FRAME CONNECTION TO OPERATE THE LN8 WITH VARIABLE VOLTAGE POINTS amp ARE JUMPERED TOGETHER EARTH GROUND CONNECTION E I ET pur LN 8 CONTROL PER THE LINCOLN ELECTRIC TYPE OM ALL RES I OF A DECREE CLEVELAND OHIO U S A SCHEMATIC MATERIAL TOLERANCE Ft AGREE SCALE AUSTRALIA _______ WITH PUBLISHED STANDARDS DR FM SHT pate 11 25 31 cm J supsme No M 16802 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubles
46. until the free end of the electrode is accessible 2 While tightly holding the electrode cut off the bent end and straighten the first six inches Cut off the first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a birdnest 3 Insert the free end through the incoming guide tube 4 Press the gun trigger and push the electrode into the drive roll WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals internal wiring When inching with the gun trigger electrode and drive mechanism are hot to work and ground 5 Inch the electrode through the gun FEEDING ELECTRODE TO THE LN 8NE OR LN 8SE WITH EXTENSION 1 Slide the ingoing guide tube of the hand crank to the forward position 2 Remove start end of coil from the hole in the wire reel cover straighten the first six inches of the wire and then insert this end into the ingoing guide tube Push at least one foot of wire through 3 Pull the ingoing guide tube back to the rear posi tion and rotate 90 so that it will remain in this position during the cranking operation LN 8 B 11 OPERATION B 11 Pull the plastic hand crank handle to the out posi tion in the arm 5 Pull the shaft and drive roll assembly to the out position 6 Apply downward pressure to the idler roll pres sure arm Maintain this pressure and
47. wire feeding 6 Put the cover plate on the reel so the four arms of the cover plate straddle and are in line with the spring loaded arms of the reel 7 Tighten the cover as much as possible by hand DO NOT hammer on the spinner nut arms A CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in back lashing of the coil which may tangle the wire A tangled coil will not feed It must be untan gled or discarded LN 8 si OPERATION EX FIGURE B 5 LOADING A 50 OR 60 Ib COIL SPINNER NUT E Ey COVER PLATE CARDBOARD COIL LINER REEL SPRING LOADED ARM 8 Cut and remove only the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires 9 Replace the reel on the wire reel stand Grasp the shaft knob pull it out and swing it across the reel hub locking the reel in place LINCOLN p OPERATION ER E 9 WIRE REEL LOADING K1 524 1 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 15 UNIVERSAL WIRE REEL STAND 9 7 Lower the Readi Reel to depress the retaining iz TO MOUNT A 30 Ib 14 kg READI REEL spring and align the other inside cage wires with 2 USING
48. 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right Do not put your hands near the engine fan Do not attempt side the work cable should also be on your right side to override the governor or idler by pushing on the throttle control rods while the engine is running 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 LN 8 LINCOLN amp Return to Master Return to Master TOC Q 2 E Return to Master SAFETY ELECTRIC SHOCK can kill 8 a The electrode and work or ground circuits are electrically hot when the welder is 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
49. 2 mm 240 mm 432 mm a Ib Innershield coil 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 Ibs 3 32 kg to total weight if door kit is attached 0 Codes below 7926 33 5 Ibs 15 2 kg and 78 5 lbs 35 6 kg LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio O o Fle 5 a 9 8 EIS 2 tc Return to Section TOC Return to Master TOC 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 CAUTION 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 rec ommended fo
50. 203 50MFD C301 2MFD R301 6 8K 0 R4 2950W 8 2 C104 4 7MFD 0103 2 5815 C204 005MFD 0302 R302 5 6 290 RO 5 2 C205 50MFD C303 01MFD 8303 1K 2 R20 10K92W POT C105 10MFD 00101 2N6027 2 C206 005MFD C304 047MFD 304 3 9K 2 Ti 110 24V TRANSFORMER cle C106 C110 0111 Go TP101 TRANSIENT PROTECTION ss C 1CR 24V D C C305 01MFD R305 3 3K 208 REED SWITCH ACTUATED BY WELDING CURRENT 5 9 0107 C108 047MFD SCR102 12A 400V C900 CSOP 740 4CR GROUNDING LEAD PROTECTOR c C109 005MFD PT101 1 1 1 PULSE TRANSFORMER 0902 D301 R307 1000 81 SPST GUN SWITCH i 0203 0302 2 R308 TRIMMER S2 SPDT INTERLOCK SWITCH 0101 1A R101 68 R116 10K 0204 0303 8309 150 S3 SPDT DIRECTION SWITCH D102 1A R102 2KOTRIMMER R117 22K D D304 4 R310 470 FOR CONTROL BOARDS L5767 1 AND HIGHER USE D103 1A R103 10K R118 4 7Ko4W 201 409201 02301 62V R311 680 M16802 SCHEMATIC FOR VALUES AND 0104 R105 4 7K R119 27K R202 100 DZ302 10V 5304 SOURCE CIRCUIT CONNECTIONS D105 16A R106 47K R120 15K0 203 100 2 0301 243398 SELECTOR SWITCH FOR VARIABLE VOLTAGE BOARD L5039 1 OR HIGHER RT ORC R204 27 Q302 2N4125 QU301 UJT USE M16441 SCHEMATIC FOR COMPONENT VALUES AND Dior OE 8205 4 7K0 CIRCUIT CONNECTIONS aKO R206
51. 524 7529 T 3 ia EE cv VV 5 221501 Is 8 la 541 9230 S av oO LN 8 6x a D 8 8 Z ZA SHUNT 12 101 PT101 5 e gg olo 683 AA i Q Q ojo SOURCE TO 682 Pga m L 5 E OPERATE amp m m SCRI01 SCR102 54 dx ms E a 8 54 5 TE 7 U 2 Y 0204 x 5 0110 A 9 aati L S C109 A w 0102 VOLTAGE ele _ 504 1CR Lig 1108 EH Bas _ 1631 E GND LEAD 8 Fa 5 one gt ul tc 4 SCR 626 FEED x olm amp 5 5 R AK SOURCE 201 MOTOR vy E E E aT GND D E 5 FIELD 2 8 3 le 2 1 7 9 a 5 eg UE e tib 8 C307 E at joc rio 44 5 BEEE nB mo NI Ea l 5 87 18811 al m 4 L La 531 CASE GROUNDING gt VARIABLE VOLTAGE CONTROL CIRCUIT TO RIGHT OF THIS LINE olo OPERATE LN 8 WHEN THIS CIRCUIT IS NOT INSTALLED IN UNIT CONTROL CIRCUIT BOARD 1 cm RET BOARD 82 POINT A TO B IS JUMPERED sls D E zh Ai C202 02MED VARIABLE VOLTAGE CIRCUIT BOARD 3 COMPONENTS NOT ON P C BOARD 1222 0
52. AC 350 31 4 32 VOLT AMP CAPACITY 75 TAPE UP 4 76 EACH LEAD 477 INPUT LN 8 CIRCUIT CONTROL gt gt 31 32 2 4 RATING LN 8 2 TO 4 CIRCUIT 15 5 AMP 115 VAC 5 AMP 28 VDC 1 2 AMP 115 VDC TO 115 VAC 350 VOLT AMP FOR LN 8 PLUS CONTACTOR REQUIREMENTS EACH LEAD WORK TO LN 8 CIRCUIT Rok 31 32 2 4 LN 8 WIRE FEEDER TO WORK ELECTRODE CABLE LN 8 WIRE FEEDER REFER TO THE POWER SOURCE WIRING DIAGRAM TO FIND THE TYPE OF CONTACTOR CIRCUIT LINCOLN ELECTRIC CLEVELAND U S A LN 8 ELECTRODE CABLE Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio E tz a g 2 5 tc Return to Section TOC Return to Master TOC 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 dia grams 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 t
53. AGE WIRES RELEASE BAR Return to Section TOC Return to Master TOC LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 o E a 2 2 5 2 Return to Section Return to Master TOC B 10 TO MOUNT 10 TO 44 Ib 4 5 to 20 kg SPOOLS 12 in 300 mm DIAMETER OR 14 Ib 6 kg INNERSHIELD COILS The spindle should be located in the lower mounting hole For 8 in 200 mm spools a K468 spindle adapter must first be slipped onto the spindle For 13 to 14 lb 6 kg Innershield coils a K435 Coil Adapter must be used 1 Depress the Release Bar on the Retaining Collar and remove it from the spindle 2 Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the backside of the spool Be certain the wire comes off the reel in a direction so as to de reel from the bottom of the coil 3 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle TO MOUNT A 50 to 60 Ib 22 7 to 27 2 kg COIL USING K1504 1 COIL REEL FOR 50 to 60 Ib READI REELS A K438 READI REEL ADAPTER MUST BE USED The spindle should be located in the UPPER mount ing hole 1 With the K 1504 1 Coil Reel mounted on the 2 in 51 mm spindle or with reel laying flat on the floor loosen th
54. ATING SCHEMATIC O10 E o HE ois 78 CASE METER KIT RECEPTACLE JUMPER PLUG IS REMOVED AND CONNECTOR B IS PLUGGED INTO cle o GROUNDING X OPTIONAL BURNBACK BOARD SEE 515123 FOR OPERATING 5 76 SCREW GND 5411543 1217 25677 1568 5 2 x N B RESISTOR USED ON CODES 9090 AND BELOW ONLY FOR CODES THERMAL amp lt pce GND LEAD CIRCUIT 1 5 34 ABOVE 9090 THE GROUNDING LEAD PROTECTOR CONNECTS PROTECTOR 0103 D104 a DIRECTLY TO THE CASE GROUNDING SCREW SWITCH AK 18126 4 182A 32 568 go Lots a Ns 127 124 125 05 __ 528 5 B LB E 18306 Ber 32A 5 L jack l E Inn e A E Z a old a
55. BLESHOOTING AND REPAIR dd TRIGGER TRANSFORMER REPLACEMENT continued FIGURE F 9 TRIGGER TRANSFORMER REMOVAL o 2 o 3 Return to Master e 9 ROUNDHEAD SCREW E E 5 RELAY T 9 PC BOARD a 29 d gt INSULATION SHEET TRIGGER e TRANSFORMER i 0 c5 8 3 NUT a 21 REPAIR PROCEDURE 5 Place the insulation sheet and new 5 trigger transformer into the case t 9 1 Using the 5 16 in nutdriver and install the screws and nuts m remove the screws from the left that secure the transformer in place side cover assembly 2 Remove the Relay PC board as 6 Install the Relay PC board as described in the Board described in the PC Board Replacement procedure Replacement procedure 7 Attach the trigger transformer Molex plug to the bottom of the relay board 3 Disconnect the Molex plug for the trigger transformer from the bottom of the relay board Refer to Figure 9 8 Install the screws that secure the 4 Using a flat blade screwdriver and left side cover assembly needlenose pliers remove the trig ger transformer and insulation sheet from the case Return to Section TOC Return to Master TOC LN 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC olo 5 5 10 1 5 2 B
56. BOARD REPAIR PROCEDURE 1 Observe the static precautions detailed the PC Board Troubleshooting Procedures at the beginning of this section Using the 5 16 in nutdriver remove the screws from the left side cover assembly CAUTION Label all wires and connec tors prior to removal All wires and con nectors must be reconnected to the same terminals from where they were removed Improper connection may lead to component damage or machine malfunction VARIABLE VOLTAGE BOARD REMOVAL AND REPLACEMENT 1 Disconnect all plugs and connec tors that can be reached without removing the variable voltage PC board Refer to Figure F 10 LN 8 LINCOLN 5 TT VARIABLE VOLTAGE PC BOARD RELAY PC BOARD 2 Using a Phillips screwdriver remove the screws that secure the variable voltage PC board to the case NOTE The screws that secure the Variable Voltage PC board are on the wire drive assembly side of the unit 3 Carefully move the PC board away from the case checking to ensure that all plugs and connectors have been removed Disconnect any connectors that have been missed or that could not be reached while the PC board was installed 4 Place the new PC board into the case and install the mounting screws 5 Connect all plugs and connectors to the PC board in the same loca tion they were removed from 6 Install the screws that secure the
57. C Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 24 TROUBLESHOOTING AND REPAIR POTENTIOMETER REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD MATERIALS NEEDED 5 16 in nutdriver 1 2 in wrench 5 64 in Allen wrench Small slothead screwdriver Soldering iron and solder This procedure takes approximately 10 minutes to perform LN 8 LINCOLN 5 F 24 Return to Section Return to Master TOC Return to Section TOC ojo O o Fle S 0 PEN a gt 9 8 cic 515 2 1 Return to Section Return to Master TOC Return to Master TOC F 25 TROUBLESHOOTING AND REPAIR F 25 POTENTIOMETER REPLACEMENT continued
58. CIFIED RESISTORS Ohms 1 48 UNLESS OTHERWISE SPECIFIED LABELS DIODES 14 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT VV COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION THE LINCOLN ELECTRIC CO LN 8 CLEVELAND OHIO U S A suBJEcr VARIABLE VOLTAGE BOARD SCHEMATIC SCALE __ ___ HT or DB ____ 8718 92 M 16441 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 6 LN 8 CONTROL BOARD 15767 LAYOUT ELECTRICAL DIAGRAMS olo E 5 5 REQ D PART N
59. D TEST DESCRIPTION This test will aid the technician in determining if the Trigger Transformer is functioning properly This procedure takes approximately 8 minutes to perform MATERIALS NEEDED 115 VAC power supply 5 16 in nutdriver Volt Ohmmeter Multimeter LN 8 LINCOLN 5 F 12 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o Fle S 0 PEN a gt 9 8 cic 515 2 1 Return to Section Return to Master TOC js TROUBLESHOOTING AND REPAIR TRIGGER TRANSFORMER TEST continued FIGURE F 2 TRIGGER TRANSFORMER TEST POINTS BLACK BLACK BOARD TEST PROCEDURE 5 1 Remove input power to the LN 8 2 Using the 5 16 in nutdriver 6 remove the screws holding the left side cover assembly 3 Disconnect the Molex plug from the under side of the relay board See Figure F 2 7 4 power 115 to the black primary transformer leads pins 2 and 3 8 LN 8 LINCOLN 5 Using the voltmeter check for approximately 24VAC at the red secondary leads pins 1 and 4 If 115VAC is applied to the black primary leads 2 and 3 and the secondary voltage red leads 1 and 4 is missing or low the trig ger transformer may be faulty Replace Reconnect the Molex plug to the underside of the relay board Install the screws that secure the left side cover assembly Return to Sectio
60. D REVERSES 3CR NOTE 3 POWER SOURCE MOTOR FIELD REED SWITCH CONTACTOR MOMENTARILY CLOSES DYNAMIC BRAKE ELECTRODE IS CURRENT FLOWS COLD TO WORK THROUGH FREE DISCHARGES SLOW WHEELING DIODE D 7 ON ACCELERATION CONTROL BOARD CAPACITOR C3 ON CONTROL BOARD MOTOR STOPS RESETS SLOW ACCELERATION CIRCUIT UNIT READY FOR NEXT WELD NOTE 1 When interlock is open NOTE 2 When interlock is closed NOTE 3 3 CR is not used on units with code no 7926 and up LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 12 TROUBLESHOOTING AND REPAIR TRIGGER TRANSFORMER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WEL
61. D COMPONENT REPLACEMENT continued FIGURE 11 DRIVE MOTOR ELECTRICAL CONNECTIONS Return to Section TOC Return to Master TOC YELLOW 525 oio BE 5 5 25 BLACK IE 4541 o 2 2 BLUE EJS 539 lt L dc WHITE 4627 626 ee 515 BLUE TWO HE GROUND 528 e YELLOW cle 528 m REPAIR PROCEDURE 4 Using a Phillips screwdriver dis connect the drive motor ground 1 Using the 5 16 in nutdriver lead green from the case remove the screws from the left Side cover assembly 5 Separate ground lead protection wire 525 yellow at the in line Return to Section TOC Return to Master TOC Disconnect drive motor leads 539 blue and 541 black from the back of the Control PC board Refer to Figure F 11 Disconnect drive motor leads 626 red and 627 white from the side of the Relay PC board LN 8 LINCOLN 5 connector Remove the insulating tape from wire 528 yellow and disconnect it from the reed switch wire and gun receptacle wire 528 and both blue leads using a 11 32 in wrench and a Phillips screwdriver See the wiring diagram Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 5 Return to Section Return to Master TOC O 7 iv
62. D LEAD PROTECTOR REPLACEMENT GROUND LEAD PROTECTOR SWITCH FLATWASHER LOCKWASHER 5 NUT E CIRCUIT E Ld SWITCH MOUNT REPAIR PROCEDURE 1 Using the 5 16 in nutdriver remove the screws from the left side cover assembly Tag and remove the two connec tors from the back of the circuit breaker Refer to Figure F 8 Using the 9 16 in wrench remove the retaining nut that secures the circuit breaker to the center panel LN 8 LINCOLN 5 Pd 7 RETAINING NUT on the wire feeder Remove the circuit breaker from the wire feeder Install the new circuit breaker through the panel of the control box Secure the circuit breaker with the retaining nut Install the connectors onto the back of the circuit breaker at the positions they were removed from Install the screws that secure the left side cover assembly Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 28 TROUBLESHOOTING AND REPAIR GROUND LEAD PROTECTOR PUSH BUTTON SWITCH REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs per
63. E FRAME TERMINAL MARKED 77 NEAR THE POWER SOURCE TERMINAL STRIP OR TO AN UNPAINTED FRAME SCREW THE POWER SOURCE MUST BE PROPERLY GROUNDED 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 FOR DC 600 CODES BELOW 8200 CONNECT A JUMPER FROM N 5 ON LN 8 ONLY THERE IS NO NPS TERMINAL STRIP ON CODES ABOVE 8200 LINCOLN 9E ELECTRIC CLEVELAND OHIO U S A LN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio Fle 515 lo gt 8 E 515 2 tc Return to Section TOC Return to Master TOC a INSTALLATION 831 FIGURE A 7 CONNECTION OF LN 8 TO DC 250 400 AND CV CVI POWER SOURCES WARNING TURN OFF INPUT POWER e THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ELECTRIC ON THIS EQUIPMENT SHOCK CAN KILL POWER SOURCE T T 1 TO LN 8 INPUT 75 76 77 CABLE PLUG pre CV OUTPUT TERMINALS ON a DC 250 N NEGATIVE POSITIVE N B AND N C ELECTRODE CABLE TO WIRE FEED UNIT WORK THE DIAGRAM SHOWS THE ELECTRODE CONNECTED POSITIVE CHANGE POLARITY TURN OFF THE POWER REVERSE THE ELECTRODE AND WORK LEADS AT THE POWER SOURCE AND POSITION THE SWITCH ON
64. ECT LEAD 76 TO 76 ON THE TERMINAL STRIP AND CONNECT LEAD 77 77 ON THE TERMINAL STRIP UPPER TERMINAL STRIP 75 76 AND 77 MAY NOT APPEAR ON OLDER 835 MACHINES LEADS B AND C SHOULD BE TAPED UP THERE WILL BE NO ADJUSTMENT OF VOLTAGE BY THE LN 8 VOLTAGE CONTROL LINCOLN jo ELECTRIC CLEVELAND OHIO U S A LN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio Fle 515 lo PEN 8 Sis 2 tc Return to Section TOC Return to Master TOC INSTALLATION idis FIGURE A 4 CONNECTION OF LN 8 TO A SAM MOTOR GENERATOR OR ENGINE DRIVEN WELDER WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ELECTRIC ON THIS EQUIPMENT 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 TAPE UP BOLTED CONNECTION LN 8 INPUT CABLE PLUG CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT N B AUTO EQUIP STICK WORK SOURCE TO WORK CONNECT THE LN 8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 7 NEAR THE POWER SOURCE TERMINAL STRIP OR TO AN UNPAINTED FRAME SCREW THE POWER SOURCE MUST BE PROPERLY GROUNDED EXTEND LEAD 21 USING 14 OR LARGER INSULA
65. ED 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 gt LINCOLN jo ELECTRIC CLEVELAND U S A LN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio Fle 515 lo PEN elg lt 5 5 tc Return to Section TOC Return to Master TOC ie INSTALLATION es FIGURE 8 K318 DUAL PROCESS CONTACTOR KIT DC 400 CV 400 AND CVI 500 CONNECTION LN 8 FOR SAME POLARITY OPERATION WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ELECTRIC ON THIS EQUIPMENT SHOCK CAN KILL NBB he NBB 21 21B DUAL PROCESS CONTACTOR WELDING LEAD STUD ON BACK OF CONTACTOR KIT TO NEGATIVE OUTPUT POSITIVE OUTPUT STUD ON POWER STUD ON POWER SOURCE SOURCE WELDER CONTROL CABLE TO WORK WIRE FEEDER ELECTRODE FEEDER CONTROL CONTROL M CABE CABLE NV Se J MC TO WIRE FEEDER TO WIRE FEEDER FOR 50 HZ OPERATION DISCONNECT BOTH BROWN LEADS FROM TERMINAL 31B AND TAPE UP EACH LEAD UNTAPE BOTH RED LEADS AND CONNECT TO 31B
66. FIGURE F 7 POTENTIOMETER REMOVAL POTENTIOMETER VY LOCKWASHER P i 8 7 SCREW REPAIR PROCEDURE where they were removed Unsolder the three wires from the 1 Remove input power to the LN 8 potentiometer 2 Using the 5 16 in nutdriver 7 Solder the three wires to the new potentiometer on the correspond ing terminals from where they were removed remove the screws from the left side cover assembly 3 Using a 5 64 in Allen wrench or slothead screwdriver loosen the setscrew on the potentiometer knob and remove the knob from the potentiometer Refer to Figure F 7 8 Place the new potentiometer and insulation sheet through the cover assembly from the inside Ensure that the index pin in the poten tiometer fits in the locating hole on the cover assembly Install the lockwasher and nut on the poten tiometer Tighten the nut until it is snug 4 Remove the nut and lockwasher holding the potentiometer to the left side cover assembly 5 Remove the potentiometer and insulation sheet from the inside of the left side cover assembly 9 Install the knob onto the poten tiometer so the set screw aligns with the flat on the potentiometer 6 Tag the three wires on the poten Tighten the set screw tiometer so that they can be reat tached in the same location from 10 Install the screws that secure the left side cover assembly LN 8 LINCOLN 5 Return to Section Return to Mas
67. H BEFORE WORKING Return to Section TOC Return to Master TOC ELECTRIC SHOCK CAN KILL ON THIS EQUIPMENT NBB k NBB TO WORK 218 DUAL PROCESS CONTACTOR WELDING LEAD STUD ON BACK OF CONTACTOR KIT Return to Section TOC Return to Master TOC ojo 515 lo gt elg lt 5 5 tc Return to Section TOC Return to Master TOC TO NEGATIVE OUTPUT STUD ON POWER SOURCE TO POSITIVE OUTPUT STUD ON POWER SOURCE WELDER CONTROL J eT 7 vV TO A WIRE FEEDER TO B WIRE FEEDER ELECTRODE NEGATIVE ELECTRODE POSITIVE FOR 50 HZ OPERATION DISCONNECT BOTH BROWN LEADS FROM TERMINAL 31B AND TAPE UP EACH LEAD UNTAPE BOTH RED LEADS AND CONNECT TO 31B CONNECT THE LN 8 CONTROL CABLE GROUND LEAD TO THE FRAME MARKED 77 NEAR THE POWER SOURCE TERMINAL STRIP OR TO AN UNPAINTED FRAME SCREW THE POWER SOURCE MUST BE PROPERLY GROUNDED N B B EXTEND LEAD 221A 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 218 LEADS SHOULD BE TAPED TO THE WELDING WORK LEAD EAC
68. H 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 TO MAKE FEEDER POSITIVE POLARITY AND FEEDER NEGATIVE POLARITY REVERSE ELECTRODE CABLES CONNECTED TO POWER SOURCE OUTPUT STUDS LINCOLN jo ELECTRIC CLEVELAND U S A LN 8 Return to Section Return to Section TOC Return to Master TOC olo 5 a gt 9 tc Return to Section TOC Return to Master TOC Return to Master TOC POWER SOURCE INTERNALLY POWERED CONTACTOR OUTPUT CONTACTOR COIL ELECTRIC SHOCK CAN KILL ON THIS EQUIPMENT POWER SOURCE OUTPUT CONTACTOR COIL 115 VAC lt CONTACTOR q INSTALLATION FIGURE 10 FOR POWER SOURCES OTHER THAN LINCOLN ELECTRIC WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE BEFORE WORKING EXTERNALLY POWERED CONTACTOR ELECTRODE MAX RATING OR LN 8 2 TO 4 CIRCUIT 15 5 AMP 115 VAC OR 5 AMP 28 VDC 1 2 AMP 115 VDC TO 115 V
69. ITCH GROUNDING VA GUN CABL SCREW lt CASE BOLTED 2 21 i OPTIONALMETER CONNECTION L T4 6 y KIT RECEPTACLE ELECTRODE TO POWER SOURCE WORK TO POWER SOURCE O O E E 1x gt g 2 5 5 pile im METER SHUNT RELAY AND lt METER KIT LEAD COLOR CODING CONNECTOR CAVITY NUMBER TO CONTACTOR CIRCUIT RECEPTACLE B BLACK W WHITE A CONNECTIONS AS VIEWED FROM 115 VAC BURNBACK 3 9 U BLUE RHEOSTATS WHEN POWER SOURCE WORK AND VARIABLE 25 8 15 TERMINAL VOLTAGE BOARD 147 NOTES RESISTOR USED ON CODES 9090 AND BELOW FOR CODES ABOVE 9090 CAVITY NUMBERING SEQUENCE PIN SIDE THE GROUNDING LEAD PROTECTOR CONNECTS DIRECTLY TO THE CASE COMPONENT SIDE OF BOARD CONNECT GROUNDING SCREW N B THE VARIABLE VOLTAGE BOARD 15 FACTORY INSTALLED IN CV VV MODELS ELECTRICAL SYMBOLS PER E1537 AND DOES NOT INCLUDE JUMPER CONNECTOR M14679 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LN 8 G 3 LN 8
70. LEMS Check or replace the gun cable It may be kinked clogged or twisted Make certain the drive rolls and guide tubes are correct for the wire being used Check or replace the gun contact tip The electrode wire may be rusty or dirty Replace if necessary RECOMMENDED COURSE OF ACTION 1 If conditions are extremely dirty install a wiper on the wire before it enters the guide tube Use a piece of cloth saturated with Pyroil CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC olo 515 1 5 2 B 1 Return to Section Return to Master TOC Return to Master TOC is TROUBLESHOOTING AND REPAIR Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS The welding arc is variable or hunting Poor arc striking with sticking or blast offs The weld bead also be ropey and display weld porosity WELDING PROBLEMS Make sure the welding parame ters are correct for the welding procedure being used Check the welding cables for loose or faulty connections The gun cable may
71. PLUGGED i OPTIONAL BURNBACK WIRE FEED P C BOARD la t SPEED Return to Section Return to Master TOC 7 N B RHEOSTAT 2 i EE j N CONNECTOR A 632 ie T 5 i VARIABLE VOLTAGE CONNECTOR B P C BOARD 634 THERMAL CIRCUIT BREAKER gt 5 AMP CIRCUIT BREAKER POWER SOURCE NERO OUTPUI pow ee ee e crater i 32A RHEOSTAT A gt 1 32 INTERLOCK SWITCH 76 i OF WIRE 536 5 FEED DIRECTION W SWITCH ON OFF W Return to Section TOC Return to Master TOC BEAD PINS ON GROUNDING LEAD tee uu o R LOW VOLTAGE PROTECTOR 8 TRIGGER 926 gt 4 TRANSFORMER 531A 2 gt 32A 3 522 1 525A 9 2 i n 37212 iban D MF 1 2AMP 125V WE OE ee 250V SLOW e 32 lt 4 BLOW FUSE 4 7 21 529 525A 524 75 e 76 lt 1 AA QUICK CONNECT TERMINALS 7 amp 32A GND lt CONNECT AUXILIARY EQUIPMENT 115 V A C 25 AMP RATING 5 CASE rh 567 2CR REED SW
72. PPLICATIONS 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 835 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 LINCOLN ELECTRIC CLEVELAND U S A LN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio Fle 515 lo PEN 8 Sis 2 tc Return to Section TOC Return to Master TOC INSTALLATION wi FIGURE CONNECTION OF LN 8 TO AN IDEALARC R3S 400 600 OR 800 WITHOUT LVC DISCONTINUED WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE BEFORE WORKING ELECTRIC ON THIS EQUIPMENT SHOCK CAN KILL NE TO LN 8 INPUT CABLE PLUG pu LN 8 CONTROL 427 CABLE
73. Pa 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 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 9 5 1 0 hose Exact pressure is indicated on the pressure gage Air con sumption 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 separa tor 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 LN 8 LINCOLN amp SECTION 1 SECTION B 1 9 TABLE OF CONTENTS 5 OPERATION SECTION p i arriere Section B Safety Instructions B 2 Controls and Their B 2 Constant Current Controls
74. R PACK K240 CONTACTOR KIT K162 SPINDLE FOR MOUNTING READI REELS AND 10 THRU 30 lb 4 5 THRU 13 5 kg SPOOLS K377 SMALL MOUNTING STAND FOR READI REEL COILS OR 10 THRU 30 Ib 4 5 THRU 13 5 kg SPOOLS WITH 2 in 50 mm 1 0 K378 SMALL MOUNTING STAND FOR 13 14 Ib 6 0 6 4 kg INNERSHIELD COILS 11514 WIRE REEL DUST SHIELD DOOR FOR K303 SUBMERGED ARC WELDING GUN 600 AMPS Return to Section TOC Return to Master TOC olo 5 a gt 2 2 1 Return to Section Return to Master TOC LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 E CIS a gle 5 2 tc Return to Section TOC Return to Master TOC K163 UNDERCARRIAGE REQUIRES K303 K377 OR K378 The undercarriage includes casters wheels a handle and related hardware Casters are mounted at the front and wheels are mounted at the rear of the plat form The handle is bolted to the front of the platform so the wire feeder can be tilted back and wheeled like a two wheel truck Installation sheet M13424 is provid ed with the undercarriage K178 MOUNTING PLATFORM This is a turntable type platform for mounting the LN 8 to the top of Idealarc power sources Bolt the platform to the lift bail per the instructions supplied with the platform K261 METER KIT All LN 8 wire feed units with code no 7580 to
75. S 8 RESISTORS 5 1 4W UNLESS OTHERWISE SPECIFIED Tm INDUCTANCE HENRYS NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result LN 8 in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Ojo O O E 90 Oja gt 2 2 5 5 2 im Return to Section TOC Return to Master TOC G 8 ELECTRICAL DIAGRAMS VARIABLE VOLTAGE BOARD L5039 LAYOUT LINCOLN P C2 C4 C6 C7 C8 E TU C3 C9 D1 D2 D3 D4 D5 D6 D 513490 68 5 16668 5 022 50 2 516668 JJ 1 2 519400 8252 82 1 4W IDENTIFICATION 1K 5 19400 9092 90 9K LX L5 CAPACITORS MFD VOLTS INDUCTANCE HENRY 8 31 2001E L5039 1 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC
76. Solenoid If Used Must function when gun trigger is activated 1CR Relay Must function when gun trigger is activated 2CR Reed Switch Must close when welding current is present LN 8 LINCOLN 5 F 40 Return to Master Return to Master TOC D 5 Return to Master ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Wiring Diagrami xa ewe RR PEE dele ee tei x dA PELA RUE Connection Operating SchemMalic op egg dee a ed 8 Control Board 15767 Variable Voltage Board 5039 Control Board L5767 Variable Voltage Board L5039 Layout LINCOLN Section G G 2 G 3 G 4 G 5 G 6 G 7 G 8 G 1 G 2 ELECTRICAL DIAGRAMS G 2 Wiring Diagram LN 8N 8 8S AND 8SE WIRING DIAGRAM JUMPER CONNECTOR IS REMOVED AND CONNECTOR A PLUGGED INTO OPTIONAL VARIABLE VOLTAGE FeO BOARD POWER SOURCE BOARD JUMPER CONNECTOR IS REMOVED 2 502 4 504 581324 OPTIONAL M AND CONNECTOR
77. Spindle for Mounting Readi Reels and 10 thru 30 Ib m 4 5 thru 13 5 kg Spools ert EE Eo ce Pere Cx Yu HERE HEBR eps 4 8 K377 Small Mounting Stand for Readi Reel Coils or 10 thru 30 Ib 4 5 thru 13 5 kg Spools with 2 in 50 LD esinsin aiina C 4 K378 Small Mounting Stand for 13 to 14 6 0 to 6 4 kg Innershield Coils C 4 M11514 Wire Reel Dust Shield Door for 03 C 4 laf 5 GUNS 5 Submerged Arc Guns 5 GMAW GUNS T C 5 Welding Gun Accessories iii C 5 K70 e RS 5 K110 Hand Travel 5 2 Nano menus 5 5 Constant Current Conversion Parts 0 22 01 0 00 C 5 9 g 5 tc o O 0 9 gt 9 5 tc LN 8 LINCOLN amp ACCESSORIES GENERAL The following is a list of the accessories that can be A detailed description of each item is given later in the used with the LN 8 wire feeder unit section Return to Section TOC Return to Master TOC TABLE LN 8 WIRE FEEDER ACCESSORIES Product Number K163 UNDERCARRIAGE K178 MOUNTING PLATFORM K161 MECHANIZED TRAVEL POWE
78. TED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 516586 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 UP LEAD 75 LINCOLN ELECTRIC CLEVELAND U S A LN 8 i INSTALLATION ais FIGURE A 5 CONNECTION OF LN 8 TO R3S 250 AND R3S 325 WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ELECTRIC ON THIS EQUIPMENT SHOCK CAN KILL Return to Section TOC Return to Master TOC TAPE UP BOLTED CONNECTION POWER SOURCE NB TO LN 8 INPUT CABLE PLUG ad CONTROL CABLE Return to Section TOC Return to Master TOC NEGATIVE POSITIVE ELECTRODE CABLE TO LN 8 OR NA 3 AUTOMATIC SHUNT TO WORK 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
79. The accumulated dirt should be gently blown off all the electrical components Be sure the air that is used is dry Check all relay contacts WIRE DRIVE MOTOR AND GEARBOX Every year inspect the gearbox and coat the gear teeth with a moly disulfide filled grease Do not use graphite grease Every six months check the motor brushes Replace them if they are less than 1 4 in 6 4 mm long GUN AND CABLE MAINTENANCE For instructions on periodic maintenance for the weld ing gun and cables refer to the manual for your spe cific model of welding gun LN 8 LINCOLN P SECTION 1 SECTION 1 5 OF OPERATION SECTION Theory of Operation Section E General E 2 Power Input CICUS ces sea emen hme de ire dt de due due ru dac ada 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 SOR a d Rent 5 Return to Master Return to Master TOC D 5 Return to Master LN 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC olo O10 5 a gt EIE
80. V 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 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 lt edt beau Ead use esas B 12 Accessories xm RR on dan denied dede E RU Section C General ec carp wea eae 2 Reel Mounting Accessories C 4 Welding GUNS 5 Welding Gun Accessories C 5 Constant Current Conversion 5 Maintenance 2 cee n sans Section D Routine Maintenance D 2 Periodic Maintenance D 2 Theory of Operation ced RR ERR RI Ex RISE Section E General Description E 2 Power Input CIRCUITS din x galee e Said Soke eee E 2 Gun Trigger and 1CR Relay Contact Control Circuits E 3 Variable Voltage Board Meter Shunt Wire Speed and Remote Output Controls
81. accordance with the U S National Electrical Code and the manufacturer s recommendations Return to Master Return to Master TOC Q 2 E Return to Master SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions 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 suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique 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 machine 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
82. and remove the mount ing plate and insulation sheet Refer to Figure F 13 Using a flat blade screwdriver remove the three screws lock washers flat washers and spacers LN 8 LINCOLN 5 12 13 WIRE MOTOR GEARBOX INSULATION SHEET MOUNTING PLATE that secure the drive motor to the gearbox assembly and remove the drive motor For further disassembly of the wire drive assembly refer to Figure F 13 Secure the drive motor to the gear box assembly using three screws lockwashers flat washers and spacers F 38 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 39 14 TROUBLESHOOTING AND REPAIR WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT continued Install the gearbox assembly onto the insulation sheet and mounting plate using four hex head screws lockwashers and flat washers Ensure that the edge of the mount ing plate that has the single mounting hole is under the drive motor Place the wire drive assembly into the case Secure the wire drive assembly using three round head screws and lockwashers Position the reed switch bracket onto the front of the wire drive assembly and tighten the two hex head screws that secure it in place Refer to Figur
83. aster RETAINING DA CLIP ojo EB 515 ols TEST PROCEDURE Note The Molex plug located on the 8 8 board to be removed to 1 Remove input power to the LN 8 gain access to the 1CR relay 5 2 Using the 5 16 in nutdriver 5 Connect the 24VDC supply to ter remove the screws from the left minals and B on the 1CR side cover assembly relay Do not energize the power supply at this time 3 Lift the left side cover 6 Connect the ohmmeter across the 4 Locate the 1CR relay Slide the first set of terminals shown in retaining clip off the relay and Table F 2 carefully remove the relay from the relay board See Figure 4 Return to Section TOC Return to Master TOC LN 8 LINCOLN 5 TROUBLESHOOTING REPAIR 1CR RELAY TEST continued TABLE F 2 RELAY TEST TERMINAL CONNECTIONS Terminals Terminals Terminals Energized De energized Return to Section TOC Return to Master TOC are open Energize the 24VDC power supply and measure the 10 Install the screws that secure the resistance again Compare to the left side cover assembly conditions given in Table F 2 If the readings do not match the table the relay is faulty and should be replaced O10 e 7 Measure the resistance across the 8 Repeat the above procedure for all Sis contacts A resistance of less than of the contacts 9 one ohm indicates that the con
84. ble 4 0 A 18 Handling Procedures sese esee e agen mee x ca e A 18 LN 8S and LN 8SE Continuous Flux Feed Submerged Arc 18 1 B E 2 p B E 2 LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo e 5 5 elg tc Return to Section TOC Return to Master TOC me INSTALLATION he TECHNICAL SPECIFICATIONS LN 8 INPUT VOLTAGE 115 50 60 Hz 4 5 amps WIRE FEED SPEED 50 in to 600 in per minute 1 25 to 15 24 m min WIRE DIAMETERS 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 TEMPERATURE RATING OPERATING 4 F to 104 20 C to 40 C STORAGE 31 F to 185 F 35 C to 85 PHYSICAL DIMENSIONS WEIGHT WIRE TOTAL WEIGHT LENGTH WIDTH HEIGHT DRIVE UNIT ONLY LESS XIX LN 8 WITH K303 30 25 in 9 75 in 26 50 in 36 0 Ib 9 80 0 Ib 50 60 lb wire reel stand 768 mm 248 mm 673 mm 16 3 Ko 36 3 a dust cover over reel LN 8 WITH K377 22 19 in 9 44 in 17 00 in small stand equipped for 564 mm 240 mm 432 mm Readi Reel LN 8 WITH K378 25 68 in 9 44 in 17 00 in small stand equipped for 65
85. crews provided The cone also includes a new clamp to be used to hold the trigger pod to the gun Use it in place of the clamp shipped with the gun K310 FLUX SCREEN The unit was designed to fit the top of either the stan dard fill funnel or the K58 magnetic separator The unit has a steel screen with 0 065 to 0 075 in open ings and an air vibrator attached to the frame The vibrator can be used with air line pressures ranging from 20 through 100 psi For ease of handling the user should connect the incoming air line to the 1 8 in pipe elbow with the aid of a quick disconnect type air coupling It is very important that reclaimed flux to be used in the continuous flux feeding system be passed through the K310 screen or its equivalent K320 FLUX TANK The flux tank is available to permit the LN 8 to be used for submerged arc welding Installation instruc tions are shipped with the kit K161 MECHANIZED TRAVEL POWER PACK The power pack supplies the power needed by the K110 hand travel unit or the K62 Squirtmobile when used with the K114 sub arc welding gun Complete installation instructions are shipped with the kit LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo F CIS a gle 5 2 tc Return to Section TOC Return to Master TOC K240 CONTACTOR KIT Output contactor with pilot relay to make the elec
86. cts 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 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 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 o 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS be dangerous 1 Do not add the fuel near an open flame welding arc or when the engine is run
87. e F 12 Connect the two 567 blue leads and the 568 blue lead to the shunt Note lead placement Refer to Figure F 13 LN 8 LINCOLN 5 18 19 20 21 22 23 Connect the 4528 wire yellow from the drive motor to the reed switch wire and gun receptacle wire both 528 blue using the round head screw and nut Wrap the connection in insulating tape Refer to Figure F 11 Connect the drive motor wire 525 yellow to the ground lead protec tion wire at the in line connector Connect the drive motor ground lead green to the case Connect the drive motor leads 539 blue and 541 black to the back of the Control PC board Connect drive motor leads 626 red and 627 white to the side of the Relay PC board Install the screws that secure the left side cover assembly F 39 Return to Section Return to Master TOC Return to Section TOC O o EE S 0 PEN a gt 818 cic 515 2 1 Return to Section Return to Master TOC Return to Master TOC F 40 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR If a failed test indicates that any mechanical part that could affect the machine s electrical characteristics must be replaced or if any electrical components are repaired or replaced the machine must be retested and meet the following standards Wire Feed Speed Range 50 to 600 IPM Gas
88. e 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 pres sure 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 elec trode is unusually soft ES OPERATION ES 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 set tings 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 stamp
89. e spinner nut and remove the reel cover See Figure B 7 2 Before cutting the tie wires place the coil of elec trode on the reel so it unwinds from the bottom as the reel rotates 3 Tighten the spinner nut against the reel cover as much as possible by hand using the reel cover spokes for leverage DO NOT hammer on the spinner nut arms 4 Cut and remove only the tie wire holding the free end of the coil Hook the free end around the rim of the reel cover and wrap it around to secure Cut and remove the retaining tie wires OPERATION FIGURE B 7 K1504 1 COIL REEL SPINNER NUT SPRING LOADED ARM CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in backlash of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded 5 Be sure the coil is engaged with the spindle brake pin and the Release Bar and Retaining Collar pops up and that the collar retainers fully engage the retaining groove on the spindle LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo 5 a 5 9 9 2 tc Return to Section TOC Return to Master TOC FEEDING ELECTRODE TO THE LN 8N OR LN 8S 1 Turn the reel
90. ect 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 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
91. ed 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 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo o F CIS a gle 5 2 Return to Section TOC Return to Master TOC OPERATION EN FIGURE B 4 CV CC SWITCH CV CC SWITCH VARIABLE VOLTAGE PC BOARD VARIABLE VOLTAGE PC BOARD WELDING WITH A CONSTANT VOLTAGE POWER SOURCE Current and voltage adjustments Amps Control Power Sources Set
92. eturn to Section TOC Return to Master TOC ojo o F CIS a gle 5 2 tc Return to Section TOC Return to Master TOC ROUTINE MAINTENANCE DRIVE ROLLS AND GUIDE TUBES After feeding every coil of wire inspect the drive roll section Clean the assembly as necessary Do not use solvent to clean the drive roll assembly as it may wash the lubricant out of the bearings The drive rolls and guide tubes are stamped with the wire sizes they will feed If a wire size other than that stamped on the rolls is to be used the rolls and guide tubes must be changed The drive rolls for 0 068 and 0 120 in 1 7 thru 3 0 mm wire have a double set of teeth so they can be reversed for additional life Between the two knurled rolls is a shim washer which limits the damage to the electrode if wire feeding problems occur Drive rolls for 1 16 in 1 6 mm and smaller wire have no teeth and are not reversible Refer to the instructions included with the drive roll kit for installation and replacement of the drive rolls on the wire feeder WIRE REEL MOUNTING To prolong the life of the reel shaft on the 50 to 60 Ib coils periodically coat it with a thin layer of grease No maintenance to the two position brake is required If the brake shoe wears through to metal replace the brake assembly in MAINTENANCE pis PERIODIC MAINTENANCE CONTROL BOX Every six months open and inspect the control sec tion
93. fore operating your machine SAFETY INSTRUCTIONS WARNING e 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 gt cause fire or explosion Keep flammable material away Do not weld cut or gouge on containers that have held combustibles ARC RAYS 2 4 LZ Wear eye ear and body protection Only qualified personnel should operate this equip ment Observe all safety information throughout this manual e OPERATION CONTROLS 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 CURRENT CONTROL VOLTAGE CONTROL CIRCUIT BREAKER GROUND LEAD WIRE FEED DIRECTION PROTECTOR CONTROL RESET BUTTON LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo o F CIS a 5 1 Return to Sectio
94. formed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed 800 833 9353 WELD MATERIALS NEEDED 5 16 in nutdriver 3 32 in wrench Jewelers flat blade screwdriver Soldering iron and solder This procedure takes approximately 10 minutes to perform LN 8 LINCOLN 5 F 28 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 29 TROUBLESHOOTING AND REPAIR GROUND LEAD PROTECTOR PUSH BUTTON SWITCH REPLACEMENT continued REPAIR PROCEDURE 1 Using the 5 16 in nutdriver remove the screws from the left side cover assembly Using the 3 32 in wrench and jew elers flat blade screwdriver remove the ground lead protector switch from the switch mount Refer to Figure LN 8 LINCOLN 5 Remove insulation and unsolder the two leads from the ground lead protecto
95. ger activated or the gun trigger terminals jumpered together see wiring diagram check the motor armature volts at leads 541 and 539 Normal is 5 to 95VDC dependent upon the setting of the wire feed speed control With the LN 8 at idle gun trigger NOT activated check the motor field voltage at lead 626 and LN 8 LINCOLN 5 524 525 627 Normal is 115VDC When the gun trigger is activated or the gun terminals jumpered together Figure 6 the field voltage polari ty should reverse from the idle state Normal is 115VDC and is independent of motor speed Note The wire feed direction switch 53 must be in the forward or weld ing position 11 If the above voltages are present and motor does not operate the motor motor brushes or the gear box may be faulty If the armature voltage is not correct leads 539 and 541 the control board may be faulty If the field voltage is not correct leads 626 and 627 the 1CR relay or relay board may be faulty F 22 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv tc F 23 TROUBLESHOOTING AND REPAIR DRIVE MOTOR TEST continued To further check the drive motor 12 13 Remove input power 115
96. he 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 ELECTRODE CABLE WIRE REEL BASE CONTROL CABLE LN 8 INSTALLATION A 15 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 8 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 con nect the cables perform these steps 1 When shipped the hand crank on the wire reel
97. his door kit can be added to those units having a dust shield kit S14543 This door kit includes a hinged door and sliding bottom seal When these parts are attached to the reel support per the instructions included the unit becomes a completely enclosed housing Order part no M11514 LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 F CIS a g 2 5 1 Return to Section TOC Return to Master TOC WELDING GUNS INNERSHIELD GUNS The K126 gun and cable assembly is recommended for most Innershield electrodes at up to 350 amps The K115 gun and cable assembly is recommended for up to 450 amps The K116 gun and cable assembly is recommended for up to 600 amps NOTE Linconditioner guns are recommended for locations where smoke accumulation is a problem and conventional exhaust systems are ineffective The available smoke removal type Innershield guns and vacuum units can be used in these locations Instructions are shipped with the equipment SUBMERGED ARC GUNS The K112 gun and cable assembly is recommended for welding up to 500 amps The K113 gun and cable is recommended for use up to 600 amps The K114 gun and cable assembly is a 600 amp gun that includes a flux valve and receptacle for the K110 or 62 GMAW GUNS An expanding line of Magnum GMA gun and cable assemblies are available to allow weld
98. hooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LN 8 Return to Section Return to Section TOC Return to Master TOC O O E E 1x gt g 2 5 5 pile im Return to Section TOC Return to Master TOC Return to Master TOC G 6 ELECTRICAL DIAGRAMS VARIABLE VOLTAGE BOARD L5039 SCHEMATIC 12VDC D2 1 4007 03 134007 11431 12VDC 12VDC NOTES SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER 2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE Ft TO AGREE WITH PUBLISHED STANDARDS Xl LM2901 12VDC GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD1 022 5 V UNLESS OTHERWISE SPE
99. ing with solid and cored electrodes using the GMAW process See the appropriate Magnum literature for descriptions of the 100 500 ampere air cooled gun and cables that are available Gun cable lengths range from 10 to 25 ft 3 0 to 7 5 m and feed electrode sizes 0 023 to 3 32 in 0 6 to 2 4 mm NOTE Magnum GMA welding guns require a K466 1 connector for use with an LN 8 wire feeder i ACCESSORIES WELDING GUN ACCESSORIES K70 FILLET GUIDE The fillet guide is designed to help guide the K114 sub arc gun so the operator can make more uniform horizontal fillet welds with less effort It consists of a vertical plate roller guide and rear wheel assembly Once the roller guide and rear wheel are adjusted the weld is easily made by gently pushing the gun into the fillet The operator does not have to constantly control the drag of the flux cone against the vertical plate or carefully watch the angle of the gun K110 HAND TRAVEL UNIT The mechanized travel unit can be attached to the K114 sub arc gun and is used to obtain controlled travel speeds ranging from 7 to 60 inches Since the hand travel unit derives its control power from a mag amp source a K161 power pack is required for this mode of operation K62 SQUIRTMOBILE The Squirtmobile is a self propelled trackless carriage that carries the K114 sub arc gun on long welds for automatic welder economy without high fixture costs To use the LN 8S or LN 8SE with the Squirtmobile
100. ion Total current control is now at the LN 8 Amps Control SAM Power Sources Set the Current Control on the power source for the approximate current required Make final adjustments with the LN 8 Amps control 2 Set the Direction of Wire Feed switch so the wire feeds out of the gun 3 Adjust the welding current and voltage while welding as needed LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo 5 a 2 2 2 Return to Section TOC Return to Master TOC WIRE REEL LOADING 50 AND 60 Ib COILS K303 WIRE REEL STAND MOUNTING 50 OR 60 Ib COIL 1 To remove the wire reel from its shaft grasp the spring loaded knob and pull out This straightens the knob so it seats into the shaft when released Remove the reel 2 Lay the reel flat on the floor Loosen the spinner nut and remove the cover plate See Figure B 5 3 Place the coil of electrode on the reel so it unwinds as the reel rotates clockwise DO NOT cut the tie wires at this time 4 Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires 5 When loading the electrode be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil sides needed for trouble free
101. l plugs and connectors to the PC board in the same loca tion they were removed from Install the screws that secure the left side cover assembly Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 35 TROUBLESHOOTING AND REPAIR WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD MATERIALS NEEDED Offset flat blade screwdriver Flat blade screwdriver Phillips screwdriver 7 16 in wrench 1 2 in wrench 11 32 in wrench Insulating tape This procedure takes approximately 40 minutes to perform LN 8 LINCOLN 5 F 35 moe TROUBLESHOOTING AND REPAIR deus WIRE DRIVE ASSEMBLY AN
102. lay Check the relay board Replace if faulty The 2CR reed switch may be faulty Check to see if it closes when welding Check the interlock switch S2 for proper operation Check the continuity zero ohms of leads 523 and 536 between the interlock switch 52 and the relay board See wiring diagram The relay board may be faulty CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC olo 5 5 10 1 gt 5 9 B 1 Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued The circuit breaker 5 amp 1 Check or replace the gun trigger 1 Perform the repeatedly trips when the gun trig and leads Make sure the trigger Transformer Test ger is activated leads are not shorted to the elec trode or work cables 2 Perform the Drive Motor Test Disconnect any accessory that 3 Remove the molex plug from the may be connected to ter
103. lectrode may be rusty or dirty Clean or replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O 9 Hs o o 5 Return to Section Return to Master TOC O 0 iv z o a TROUBLESHOOTING REPAIR E Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued The wire feed speed cannot be 1 If the LN 8 is being used for sub 1 Check for loose connections controlled The motor runs and merged arc welding with the vari between the speed control the feeds wire but the speed cannot able voltage board switch in the control board and the variable be changed regardless of control VV position change it to the CV voltage board See wiring setting position If proper motor speed diagram control returns the variable volt age board may be faulty Check the speed control rheostat for proper operation Normal resistance is 5000 ohms Perform the Drive Motor Test The control board may be fault
104. left side cover assembly TROUBLESHOOTING REPAIR RELAY BOARD REMOVAL CONTROL PC BOARD REPLACEMENT REMOVAL AND REPLACEMENT Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc 1 If the Relay PC board is being replaced remove the 1CR Relay from the PC board Disconnect all plugs and connec tors Remove mounting screws Place the new PC board into the case and install the mounting screws Install the 1CR Relay into the PC board CAUTION Do not use excessive force when installing the 1CR Relay Excessive force can damage the Relay PC board If the relay does not fit prop erly remove it and try again 6 Connect all plugs and connectors 7 to the PC board in the same loca tion they were removed from Install the screws that secure the left side cover assembly LN 8 LINCOLN 5 Disconnect all plugs and connec tors from the Control PC board Using a Phillips screwdriver remove the screws that secure the Control PC board to the case Carefully move the Control Board away from the case Check to ensure that all plugs and connec tors have been disconnected Place the new PC board into the case and install the mounting screws Connect al
105. llen wrench BRASS BLOCK the control cable extension into the mating DET INGOING receptacle on the back of the wire feeder Refer to GUIDE Figure A 13 EXTENSION TUBE CONNECTOR 8 At the wire feeder connect the polarized plug of Return to Section TOC Return to Master TOC LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio E a 2 5 2 Return to Section Return to Master TOC A 17 9 10 11 12 INSTALLATION 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 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 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 ha
106. lt 5 5 tc Return to Section TOC Return to Master TOC 28 INSTALLATION FIGURE 6 CONNECTION LN 8 DC 600 WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ELECTRIC ON THIS EQUIPMENT SHOCK CAN KILL POWER SOURCE 2 TO LN 8 INPUT CABLE PLUG T N S NE NEGATIVE POSITIVE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED POSITIVE TO CHANGE POLARITY TURN OFF THE POWER REVERSE THE ELECTRODE AND WORK LEADS AT THE POWER SOURCE AND POSITION THE SWITCH ON THE POWER SOURCE TO PROPER POLARITY WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS 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 TH
107. minals relay board If the circuit breaker 7 32A See wiring dia continues to trip the control gram If the problem is resolved board may be faulty If the cir the accessory may be faulty cuit breaker does not trip the relay board may be faulty The circuit breaker 5 amp trips Disconnect any kits or acces Check the wiring harness leads when power is applied to the LN 8 sories that may be incorporated 32 32A 31 and 531 for Gun trigger is NOT activated in the LN 8 Be sure to install shorts or grounds See wiring any necessary jumper plugs If diagram problem is resolved the fault may be in the disconnected kit Perform the Transformer Test Remove the molex plug from the relay board If the circuit breaker continues to trip the control board may be faulty If the cir cuit breaker does not trip the relay board may be faulty Perform the Drive Motor Test The 1 2 amp fuse on the relay Check to make sure the correct Perform the Drive Motor Test board repeatedly fails input voltage 115VAC is being applied to the LN 8 Perform the Transformer Test Very rapid and repetitive gun triggering can possibly cause the 2 The relay board may be faulty field fuse to fail The drive motor thermostat opens 1 Check for mechanical restric 1 Perform the Drive Motor Test while welding tions in the wire feeding path This condition could cause the motor to overheat The e
108. n Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 14 TROUBLESHOOTING AND REPAIR INTERNAL VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION This test will aid the technician in determining if the correct voltages are present in the LN 8 This procedure takes approximately 20 minutes to perform MATERIALS NEEDED 5 16 in nutdriver Volt Ohmmeter Wiring diagram LN 8 LINCOLN 5 F 14 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 5 Return to Section Return to Master TOC O 7 iv
109. n TOC Return to Master TOC 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 cir cuit 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 con trolled 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 constan
110. nd size to be used See the para graph on Welding Guns in the 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 maintenance instructions following the 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 INSTALLATION A 18 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 feed ing problems The air for the automatic flux feeding system is obtained from the regular plant compressed air sys tem providing the plant system pressure is between 60 and 120 psi 414 and 827 k
111. ndles 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 If the extension is being used with 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 17 conductor cable is 22 1 2 ft 6 9 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 LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio E tz a g 2 5 tc Return to Section TOC Return to Master TOC 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 a
112. ng in the wire feed cable or a defective motor or control com ponent 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 E OPERATION 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
113. ning 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 eliminated 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 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 2 d 1 Route the electrode and work cables together Secure 1 e In some cases it may be necessary to remove safety them with tape when possible 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 4 2 Never coil the electrode lead around your body
114. o IDENTIFICATION 5 8 Ci 1 513490 42 1 0 35 2 C2 1 _ S13490 67 2 50 8 C3 1 513490 104 39uF 20V 5 5 C4 1 _ S13490 25 4 7 35 2 2 5 1__ 11577 26 1 100 C6 C10 C11 012 C13 5 1516668 5 022 50 C7 C8 2 S13490 102 047 100 C9 1 11577 52 0047 or 005 1400 1021 i RS ms D1 D2 D8 D9 D10 D11 D12 D13 Di4 9 Ti2199 1 1 4004 DA fl D3 D4 2 12199 2 1 4007 olo 010 815 E e y Ha Li 1 112218 2 5 6mH 5 S 5555555416 D8 1 5 E E E GE 1 142787 2 1 1 1 9 2 ur 829978 218 Eu 42 46 01 03 2 T12704 69 214403 ce m 02 03 01 Q2 1 12704 68 284401 8 5 FR221 5 QUI 1 _ T12707 4 2N6027 a is s C LD R1 1 519400 6811 R JE R2 1 T10812 73 2K 1 2W aa R3 R14 R16 R22 4 819400 1002 R5 R6 2 519400 4751 uS R7 1 S19400 15R0 N R8 R9 2 519400 3322 R10 1 519400 7500 gjo R24 5 0 5 11 1 10812 39 1 2W Fle e R12 1 519400 2672 6 5 R13 1 819400 3922 ETE gt R17 1 _ 519400 2212 I R18 R25 2 714648 11 4700 SW 5 5 R19 1 519400 5622 9 e R20 R29 2 519400 1502 R21 1 519400 1501 R23 1 14764 2 25 R24 R26 2 T10812 68 1K 1 2W R27 1 _ 519400 1500 R28 R31 2 519400 5110 R30 1 519400 5232 olo SCR1 SCR2 2 S15161 6 286397 O10 1 1 13640 11 45 Fle 515 519 2 CAPACITORS MFD VOLT
115. oltage of 30VDC or more POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION Check for loose or faulty con nections between the input receptacle the circuit breaker and the 2 ohm resistor See wiring diagram Check the 2 ohm resistor Replace if faulty Perform the Trigger Transformer Test Perform the nternal Voltage Perform the 7CR Relay Test Check the relay board Replace if faulty Check the variable voltage board if used Replace if faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 LN 8 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o o 5 Return to Section Return to Master TOC O 0 iv tc gt TROUBLESHOOTING REPAIR dis Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued The wire feeds when the gun trig ger is activated but there is no arc voltage The wire continues to feed with the gun trigger open and the wire is electrically hot
116. on between the gate and cathode the voltage between these terminals must be slightly greater than 0 6 VDC Once the SCR has fired it is not necessary to continue the flow of gate current As long as current continues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC supply voltage passes through zero into the negative portion of the sine wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing time is later in the cycle the conduction time is less resulting in lower SCR output E 5 6 o zE O 5 DOL Je1Se N 0 DOL 4 0 DOL 4 0 DOL Je1Se N 01 DOL uonoeg 0 DOL uonoes 0 DOL uonoes 0 DOL uonoes 0 Ole TROUBLESHOOTING AND REPAIR ar 9 TABLE OF CONTENTS TROUBLESHOOTING REPAIR Troubleshooting and Section F How to Use Troubleshooting 1 F 2 E PC Board Troubleshooting Procedures F 3 Troubleshooting 4
117. peration Power Sources other than Lincoln Electric LN 8 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio Fle 515 lo gt 8 Sis 2 tc Return to Section TOC Return to Master TOC ni INSTALLATION a FIGURE A 2 CONNECTION OF LN 8 TO AN IDEALARC R3S 400 600 OR 800 WITH LVC DISCONTINUED WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ELECTRIC ON THIS EQUIPMENT SHOCK CAN KILL S TO OPTIONAL R3S LINE VOLTAGE COMPENSATOR TO LN 8 INPUT CABLE PLUG puo LN 8 CONTROL CABLE NEGATIVE POSITIVE POWER SOURCE TAPE UP BOLTED CONNECTION THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED FOR POSITIVE POLARITY TO CHANGE POLARITY TURN OFF THE POWER REVERSE THE ELECTRODE AND 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 77 NEAR THE POWER SOURCE TERMINAL STRIP OR TO AN UNPAINTED FRAME SCREW THE POWER SOURCE MUST BE PROPERLY GROUNDED 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 A
118. procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims LN 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o 5 Return to Section Return to Master TOC O 7 iv TROUBLESHOOTING REPAIR ET TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS No wire feed or arc voltage when the gun trigger is activated The drive rolls do not turn The LN 8 appears dead FUNCTION PROBLEMS Check the Ground Lead Protector GLP Reset if necessary Check the circuit breaker Reset if necessary Make sure 115 is being applied to the LN 8 at the input receptacle Pin C lead 31 and pin D lead 32 Check the 1 2 amp fuse located on the relay board Replace if necessary If the LN 8 has a variable voltage board and the power source is a constant current supply check to make sure the switch on the vari able voltage board is in the VV position If the switch on the variable board is in the VV position make sure the power source is set for an open circuit v
119. r 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 cur rent 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 INSTALLATION oe 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
120. r switch Solder the two leads onto the new switch and reinsulate the connections Place the switch onto the switch mount and install the screws flat washers lockwashers and nuts that secure the switch into place Install the screws that secure the left side cover assembly F 29 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 30 TROUBLESHOOTING AND REPAIR TRIGGER TRANSFORMER REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD MATERIALS NEEDED 5 16 in nutdriver Flat blade screwdriver Needlenose pliers This procedure takes approximately 12 minutes to perform LN 8 LINCOLN 5 F 30 id TROU
121. rd 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 a 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 6 h Also see item 1 c SAFETY LN 8 LINCOLN amp CYLINDER may explode o gt s if damaged 7 a Use only compressed gas cylinders containing the corr
122. rm phosgene a highly toxic gas and other irritating products 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 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 Mar 95 Return to Master Return to Master TOC Return to Master TOC Return to Master TOC 7 WELDING SPARKS gt 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 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 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 haza
123. service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Devices Handle only at Tools which come in contact with the PC board must be either conductive anti sta
124. start crank ing the wire thru the system Keep the conductor cable as straight as possible during the loading operation This will facilitate cranking the wire through 7 Crank until the wire touches the drive roll and then pull the gun trigger This will start the drive rolls and feed the wire the rest of the way through the cable and gun assembly A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with the gun trigger electrode and drive mechanism are hot to work and ground 8 Push the plastic of the hand crank to the in position as shown in Figure B 8 9 Shift the ingoing guide tube to the forward position FIGURE B 8 HAND CRANK POSITION BRASS LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio o F CIS a gle 5 2 tc Return to Section TOC Return to Master TOC B 12 SLOW ACCELERATION STARTING CODE 7926 AND ABOVE The LN 8 has the capability of optimum starting for dif ferent processes This is accomplished by designing the LN 8 to start with two different speeds of con trolled acceleration As shipped the unit is connected for fast acceleration which is best for most open arc procedures The slower acceleration may be more desirable for long sticko
125. t current con trols are illustrated in Figure B 2 Refer to the figure and the following explanations of the controls OPERATION ade VOLTAGE CONTROL Adjusts arc voltage by control ling power source output voltage CURRENT CONTROL Adjusts wire feed speed to control welding current FIGURE 2 CONSTANT VOLTAGE CONTROLS CONTROLS VOLTAGE CONTROLS LN 8 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio o E a 2 5 2 Return to Section Return to Master TOC CIRCUIT PROTECTION FIELD CIRCUIT FUSE This 1 2 amp slow blow fuse located on the Relay PC board protects the field cir cuit 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 pro tector 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 locat ed above the drive rolls normally trips only when an overload occurs because of excessive loadi
126. ter TOC Return to Section TOC Return to Master TOC 2 o 5 Return to Section Return to Master TOC O 7 iv E tc F 26 TROUBLESHOOTING AND REPAIR CIRCUIT BREAKER REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precau tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD MATERIALS NEEDED 5 16 in nutdriver 9 16 in wrench This procedure takes approximately 6 minutes to perform LN 8 LINCOLN 5 F 26 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 5 Return to Section Return to Master TOC O 0 iv tc F 27 TROUBLESHOOTING AND REPAIR CIRCUIT BREAKER REPLACEMENT continued FIGURE F 8 CIRCUIT BREAKER AND GROUN
127. the welding current or wire feed speed with the LN 8 Amps control Volts Control DC 600 Power Source a Set the mode switch on the power source to CV Innersheild or CV Subarc as required b Place power source output control toggle switch in the Output Control Remote posi tion Total voltage control is now at the LN 8 Volts Control Idealarc R3S Power Sources Set the power source to the approximate voltage required per the R3S instruction manual Make final adjustments with the LN 8 Volts control or the Fine Voltage Control on the optional Line Voltage Compensator Volts Control SAM Power Sources Set the power source for the approximate voltage required per the SAM instruction manual Make final adjustments with the LN 8 Volts control If using the variable inductance control see SAM instruction manual set the SAM Current Control as desired in the 8 o clock range 2 Set the Direction of Wire Feed switch so the wire feeds out of the gun 3 Adjust the electrical stickout and the actual welding current and voltage as needed WELDING WITH A CONSTANT CURRENT POWER SOURCE 1 Current and voltage adjustments Volts Control All Power Sources Set the welding voltage with the LN 8 Volts control Amps Control CC Power Sources a Place mode switch in the CC submerged arc position b Place power source output control toggle switch in the Output Control Remote posi t
128. tic or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this
129. to metal contact TABLE A 1 WORK LEAD SPECIFICATIONS Current Amps 60 Duty 25 ft 50 ft 100 ft 7 5 m 15 m 45 m Cycle 49 o ww 8X o wo 909 o ooo wo 0007 LN 8 LINCOLN amp INSTALLATION 9 LN 8S AND LN 8SE CONVERTED FIGURE A 1 POWER SOURCE SELECTION LN 8N LN 8NE SWITCH olo 9 1 Use either constant voltage constant current POWER SOURCE p type power source as required for the application SELECTION SWITCH Ensure the power source is set for 3 5 constant voltage or constant current welding as d appropriate per the instructions in the power VARIABLE source operating manual VOLTAGE PC BOARD 2 Setthe 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 Return to Section TOC Return to Master TOC
130. trode cold when not welding Must be ordered when using the LN 8 with SA 750 SAE TM R3M and R3R Idealarcs Contactor kits are rated at 600 amps maxi mum and cannot be paralleled with each other K317 DUAL PROCESS KIT NO POLARITY CHANGE The Dual Process Kit is a transfer device that con nects two wire feeders to a single power source and enables each wire feeder to weld a different proce dure without changing any of the dials When used with the DC 600 the wire feeders can be set for differ ent modes CV Innershield or CV Submerged Arc Both wire feeders will operate at the same polarity K318 DUAL PROCESS CONTACTOR KIT WITH POLARITY CHANGES The Dual Process Contactor Kit permits the connec tion of two wire feeders to a single power source and enables each wire feeder to weld at a different proce dure and polarity without changing any dials or switch es When used with the DC 600 the wire feeders can be set for different modes CV Innershield or CV Submerged Arc The kit can also be connected to operate with the same polarity on each wire feeder REEL MOUNTING ACCESSORIES K303 50 TO 60 Ib 22 7 TO 27 2 kg WIRE REEL STAND This assembly includes a framework to which is attached a 50 to 60 Ib 22 7 to 27 2 kg wire reel a mounting spindle a lift bail and a cable clamp for fas tening the input cable assembly K1524 1 UNIVERSAL REEL STAND AND BASE ASSEMBLY The wire reel stand comes with a 2 in spindle With
131. ut applications and most sub merged arc procedures If the electrode being used does not give satisfactory starting because of stub bing or blast off the slower acceleration can be obtained by modifying the LN 8 as follows 1 Turn off the control power to the LN 8 at the power source 2 Remove the screws holding the control section cover in place and swing open 3 Switch circuit 1 of S1 on the Control PC board from position F to position S 4 Reassemble OPERATION FLUX TANK LOADING Either turn off the incoming air line or remove the quick disconnect if one has been installed Slightly loosen the tank cap and let the air in the tank escape in the holes in the side of the cap After pressure has been released remove the cap from the tank Using the funnel provided put 100 pounds of flux in the tank It is very important that only new or properly reclaimed flux be put in the tank Coarse particles and or mag netic particles will stop the flux feeding process New Lincoln flux is properly screened at the factory All reclaimed flux must be separately screened through a vibrating screen with 0 065 to 0 075 in openings and be put through a magnetic separator The K310 vibrat ed screen and K58 magnetic separator are available for this purpose The screen in the funnel supplied with the tank has much larger openings and its only purpose is to keep paper and slag out of the tank Screw the tank cap back on and
132. y The wire feed coasts when the 1 Make sure the gun trigger is not 1 Perform the gun trigger is released sticking The wire feeds normally and welds 1 Check or replace the solenoid With the gun trigger activated but the solenoid is not operating check for the presence of 115VAC at terminals 32A and 7 If the proper voltage is present the solenoid may be faulty If the correct voltage 115VAC is NOT present the relay board may be faulty When the gun trigger is activated 1 Check wire feed direction switch The 1CR relay may be faulty the wire backs up instead of feed for proper direction and operation Check or replace ing forward If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 LN 8 LINCOLN P Return to Section Return to Master TOC Return to Section TOC olo 515 1 5 2 B 1 Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS When the gun trigger is activated the drive rolls turn but the wire will not feed or wire feeding is rough POSSIBLE AREAS OF MISADJUSTMENT S FEEDING PROB
133. yes 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 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 5 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 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 fo

Lincoln Electric LN-8 SVM132-A User's Manual

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