RETURN TO MAIN INDEX
SVM132-A
May, 2002
LN-8 SEMIAUTOMATIC WIRE FEEDER
For use with code numbers: 9963, 9964
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.
SERVICE MANUAL
Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
LN-8
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
LN-8
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iv
iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
LN-8
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v
v
RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - LN-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LN-8S and LN-8SE Continuous Flux Feed (Submerged Arc) . . . . . . . . . .
A-2
A-3
A-3
A-5
A-18
A-18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Avoiding Ground Lead Protector (GLP) Activation . . . . . . . . . . . . . . . . . .
Wire Feed Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting for CV or CC Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding with a Constant Voltage Power Source . . . . . . . . . . . . . . . . . . . .
Welding with a Constant Current Power Source . . . . . . . . . . . . . . . . . . . .
Wire Reel Loading - 50 and 60 lb. Coils (K303 Wire Reel Stand) . . . . . . .
Wire Reel Loading (K1524-1 Unversal Wire Reel Stand) . . . . . . . . . . . . . .
Slow Acceleration Starting (Code 7926 and Above) . . . . . . . . . . . . . . . . .
Flux Tank Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
B-2
B-4
B-4
B-5
B-6
B-7
B-7
B-8
B-9
B-12
B-12
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reel Mounting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Constant Current Conversion Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
C-4
C-5
C-5
C-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gun Trigger and 1CR Relay Contact Control Circuits . . . . . . . . . . . . . . . .
Variable Voltage Board, Meter Shunt, Wire Speed
E-2
E-2
E-3
and Remote Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-4
E-5
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LN-8 Electrical Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-2
F-3
F-4
F-10
F-12
F-24
F-40
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P293 Series
LN-8
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SECTION A-1
SECTION A-1
INSTALLATION
TABLE OF CONTENTS
-INSTALLATION SECTION-
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - LN-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LN-8N and LN-8NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LN-8S and LN-8SE (and converted LN-8N and LN-8NE) . . . . . . . . . . . . . . . . . . . . . .
Power Source Connection Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of the LN-8 to an Idealarc R3S-400, 600 or 800
A-2
A-3
A-3
A-3
A-4
A-5
(with LVC) (Discontinued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of LN-8 to an Idealarc R3S-400, 600 or 800
A-6
(without LVC) (Discontinued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of LN-8 to a Sam Motor-Generator or Engine Driven Welder. . . . . . . . . .
Connection of LN-8 to R3S-250 and R3S-325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of LN-8 to DC-600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of LN-8 to DC-250, 400 and CV/CVI Power Sources . . . . . . . . . . . . . . . .
K318 Dual Process Contactor Kit DC-400, CV-400 and CVI-500 Connection
to LN-8 for Same Polarity Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K318 Dual Process Contactor Kit DC-400, CV-400 and CVI-500 Connection
to LN-8 for Opposite Polarity Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For Power Sources Other Than Lincoln Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LN-8N and LN-8S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LN-8NE and LN-8SE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gun Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LN-8S and LN-8SE Continuous Flux Feed (Submerged Arc) . . . . . . . . . . . . . . . . . . . . . .
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-15
A-15
A-18
A-18
A-18
A-18
A-18
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS – LN-8
INPUT – VOLTAGE
115 VAC, 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)
0.062 in. through 0.120 in. (1.57 through 3.05 mm)
CORED
TEMPERATURE RATING
OPERATING
STORAGE
-4˚F to 104˚F (-20˚C to 40˚C)
-31˚F to 185˚F (-35˚C to 85˚C)
PHYSICAL DIMENSIONS
WEIGHT WIRE
TOTAL WEIGHT
LENGTH
30.25 in.
WIDTH
HEIGHT DRIVE UNIT ONLY LESS ELECTRODE
LN-8 WITH K303
(50-60 lb wire reel stand
9.75 in.
26.50 in.
36.0 lb (◊)
(16.3 kg)
80.0 lb. (◊)
(36.3 kg)
(768 mm) (248 mm) (673 mm)
with dust cover over reel)
*
**
***
LN-8 WITH K377
(small stand equipped for
22.19 in.
9.44 in.
17.00 in.
36.0 lb
(16.3 kg)
48.0 lb.
(21.8 kg)
(564 mm) (240 mm) (432 mm)
Readi-Reel)
LN-8 WITH K378
(small stand equipped for
25.68 in.
9.44 in.
17.00 in.
36.0 lb
(16.3 kg)
48.0 lb.
(21.8 kg)
(652 mm) (240 mm) (432 mm)
14 lb 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 lbs (3.32 kg) to total weight if door kit is attached.
(
◊) Codes below 7926-33.5 lbs (15.2 kg) and 78.5 lbs (35.6 kg)
LN-8
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A-3
A-3
INSTALLATION
LN-8N AND LN-8NE
MOUNTING LOCATION
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.
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.
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.
POWER SOURCE CONNECTIONS
Use the type of power source required for the specific
welding application.
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.
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.
3. Connect a work lead of sufficient size and length
per Table A.1, between the appropriate output
terminal on the power source and the work.
Ensure the connection to the work makes tight
metal-to-metal contact.
____________________________________
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.
TABLE A.1 – WORK LEAD SPECIFICATIONS
Copper Work Cable Length
Current Amps
60% Duty
Cycle
25 ft
(7.5 m)
50 ft
(15 m)
100 ft
(45 m)
Formerly, a constant current power source was rec-
ommended for most submerged arc welding. With the
innovation of the new DC power sources, a special
mode (CV Sub-Arc) is available and is preferred for
most submerged arc welding.
300
400
500
600
0
0
000
0000
00
00
00
000
000
0000
000
Two 000
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.
LN-8
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A-4
A-4
INSTALLATION
FIGURE A.1 – POWER SOURCE SELECTION
SWITCH
LN-8S AND LN-8SE (AND CONVERTED
LN-8N AND LN-8NE)
1. Use either a constant voltage or constant current
type power source as required for the application.
Ensure the power source is properly set for
constant voltage or constant current welding, as
appropriate, per the instructions in the power
source operating manual.
POWER SOURCE
SELECTION SWITCH
VARIABLE
VOLTAGE
PC BOARD
2. Set the LN-8 wire feeder for a constant voltage or
constant current power source as appropriate per
the following:
a. There are two nameplates on the front of the
wire feeder, one mounted on top of the other.
Be sure the ‘Constant Current Power Source’
nameplate is on top when using a constant
current power source. When connected to a
constant voltage power source, be sure the
‘Constant Voltage Power Source’ nameplate is
on top.
b. Turn the power to the wire feeder off. Open the
door to the control section and switch the
power source selection switch to constant
current ‘CC’ or constant voltage ‘CV’ as
appropriate. See Figure A.1.
3. Connect the LN-8 input cable to the power source
exactly as specified in the wire connection
diagrams in Table A.2. Include any jumpers on
the terminal strips as shown in the connection
diagrams.
VARIABLE
VOLTAGE
PC BOARD
4. Connect a work lead of sufficient size and length,
per Table A.1, between the appropriate output
terminal on the power source and the work.
Ensure the connection to the work makes tight
metal-to-metal contact.
LN-8
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A-5
A-5
INSTALLATION
POWER SOURCE CONNECTION DIAGRAMS
Table A.2 – LN-8 Power Source Connection Diagrams
Figure No.
A.2
Power Source
Connection of LN-8 to an Idealarc® R3S-400, 600 or 800 (with LVC) (Discontinued)
Connection of LN-8 to an 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 R3S-325
A.3
A.4
A.5
A.6
A.7
A.8
Connection of LN-8 to DC-600
Connection of LN-8 to DC-250, 400 and CV/CVI Power Sources
K318 Duel Process Contactor Kit
DC-400, CV-400, and CVI-500 Connection to LN-8 for Same Polarity Operation
K318 Duel Process Contactor Kit
A.9
DC-400, CV-400, and CVI-500 Connection to LN-8 for Opposite Polarity Operation
Power Sources other than Lincoln Electric
A.10
LN-8
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A-6
A-6
INSTALLATION
FIGURE A.2 – CONNECTION OF LN-8 TO AN IDEALARC R3S-400, 600 OR 800
(WITH LVC) (DISCONTINUED)
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
CAN KILL
TO OPTIONAL R3S
LINE VOLTAGE
COMPENSATOR
76 77
75
N.A.
TO LN-8
INPUT CABLE PLUG
21
2
31 32
4
A
B
C
4
N.D.
GND
LN-8 CONTROL
CABLE
32
31
2
N.B.
21
POSITIVE
NEGATIVE
ELECTRODE CABLE TO
WIRE FEED UNIT
N.C.
N.B.
TO WORK
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 "TO WORK" LEADS AT THE POWER SOURCE, AND REVERSE THE "CONTROL SWITCH" AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. ON EARLIER R3S-400, -600, AND -800 MACHINES, TERMINALS #67 AND #1 WERE ALSO ON THE TERMINAL STRIP.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD
#21 SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.D. LN-8 LEADS A, B, AND C (#75, #76, AND #77 ON OLDER LN-8 CONTROL CABLES) ARE TAPED UP WHEN THE R3S LINE VOLTAGE
COMPENSATOR IS CONNECTED. ARC VOLTAGE IS CONTROLLED BY THE LINE VOLTAGE COMPENSATOR RHEOSTAT. THERE WILL BE NO
ADJUSTMENTS OF VOLTAGE BY THE LN-8 VOLTAGE CONTROL.
CLEVELAND, OHIO U.S.A.
LN-8
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A-7
A-7
INSTALLATION
FIGURE A.3 – CONNECTION OF LN-8 TO AN IDEALARC R3S-400, 600 OR 800
(WITHOUT LVC) (DISCONTINUED)
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
CAN KILL
N.E.
76 77
75
N.A.
TO LN-8
INPUT CABLE PLUG
21
2
31 32
4
C
B
A
4
N.D.
GND
LN-8 CONTROL
CABLE
32
31
2
N.B.
21
POSITIVE
NEGATIVE
ELECTRODE CABLE TO
WIRE FEED UNIT
N.C.
N.B.
TO WORK
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 "TO WORK" LEADS AT THE POWER SOURCE, AND REVERSE THE "CONTROL SWITCH" AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. ON EARLIER R3S-400, -600, AND -800 MACHINES, TERMINALS #67 AND #1 WERE ALSO ON THE TERMINAL STRIP.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD
#21 SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.D. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON THE TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON THE TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.
N.E. UPPER TERMINAL STRIP (#75, #76 AND #77) MAY NOT APPEAR ON OLDER R3S MACHINES. LEADS A, B, AND C SHOULD BE TAPED UP.
THERE WILL BE NO ADJUSTMENT OF VOLTAGE BY THE LN-8 VOLTAGE CONTROL.
CLEVELAND, OHIO U.S.A.
LN-8
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A-8
A-8
INSTALLATION
FIGURE A.4 – CONNECTION OF LN-8 TO A SAM MOTOR-GENERATOR OR ENGINE DRIVEN WELDER
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
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
N.A.
TO LN-8 INPUT
CABLE PLUG
21
67
1
CONTROL CABLE
21
2
2
31
32
C4
31
32
ELECTRODE CABLE TO
WIRE FEED UNIT
4
GND
C
77
N.B.
76
75
B
A
AUTO
EQUIP.
STICK WORK
TAPE
UP
POWER
SOURCE
TO WORK
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.B. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #76 TO #76 ON TERMINAL
STRIP, CONNECT LEAD #77 TO #75 ON THE TERMINAL STRIP, AND TAPE UP LEAD #75.
CLEVELAND, OHIO U.S.A.
LN-8
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A-9
A-9
INSTALLATION
FIGURE A.5 – CONNECTION OF LN-8 TO R3S-250 AND R3S-325
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
CAN KILL
TAPE UP
BOLTED
CONNECTION
N.B.
POWER SOURCE
TO LN-8 INPUT
CABLE PLUG
CONTROL CABLE
21
4
21
4
31
32
31
32
2
GND
77
C
B
N.C.
76
75
A
NEGATIVE
POSITIVE
ELECTRODE CABLE TO LN-8 OR
NA-3 AUTOMATIC SHUNT
N.A.
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 THE POWER SOURCE, AND REVERSE THE 'CONTROL SWITCH' AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACKET.)
N.C. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING), CONNECT LEAD #75 TO #75 ON THE TERMINAL
STRIP, LEAD #76 TO #76 ON THE TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.
CLEVELAND, OHIO U.S.A.
LN-8
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A-10
A-10
INSTALLATION
FIGURE A.6 – CONNECTION OF LN-8 TO DC-600
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
CAN KILL
POWER SOURCE
TO LN-8 INPUT
CABLE PLUG
21
4
2
31 32
75 76 77 80 81
C
B
N.E.
A
32
31
2
4
21
CONTROL
CABLE
GND
N
P
S
N.B. AND N.C.
N.F.
POSITIVE
N.D.
NEGATIVE
ELECTRODE CABLE TO
WIRE FEED UNIT
N.A.
TO WORK
THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN OFF THE POWER, REVERSE THE
ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND POSITION THE SWITCH ON THE POWER SOURCE TO PROPER
POLARITY.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ] REMOTE
VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK.)
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL
STRIP OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.E. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON TERMINAL STRIP.
N.F. FOR DC-600 CODES BELOW 8200, CONNECT A JUMPER FROM 'N' TO 'S' ON LN-8 ONLY. THERE IS NO NPS TERMINAL STRIP ON CODES
ABOVE 8200.
CLEVELAND, OHIO U.S.A.
LN-8
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A-11
A-11
INSTALLATION
FIGURE A.7 – CONNECTION OF LN-8 TO DC-250, 400 AND CV/CVI POWER SOURCES
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
CAN KILL
POWER SOURCE
TO LN-8 INPUT
CABLE PLUG
76 77
75
21
4
2
31 32
C
B
N.E.
A
32
31
2
CONTROL CABLE
4
CV OUTPUT
TERMINALS ON
DC-250
GND
21
NEGATIVE
POSITIVE
N.D.
N.B. AND N.C.
ELECTRODE CABLE TO
WIRE FEED UNIT
N.A.
TO WORK
THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN OFF THE POWER, REVERSE THE
ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND POSITION THE SWITCH ON THE POWER SOURCE AND WIRE FEEDER
(IF EQUIPPED) TO PROPER POLARITY. ALSO REFER TO THE FOLLOWING NOTE:
NOTE: IF LEAD #21 IS TO BE CONNECTED TO THE TERMINAL STRIP, CONNECT TO TERMINAL #21 THAT MATCHES WORK POLARITY. THIS
CONNECTION MUST BE CHANGED WHENEVER THE ELECTRODE POLARITY IS CHANGED. THIS DOES NOT APPLY TO DC-400 BELOW
CODE 9200 WITH POLARITY SWITCH.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (IF THE LENGTH OF THE WORK LEAD CIRCUIT IS SHORT, AND CONNECTIONS CAN BE
EXPECTED TO BE RELIABLE, THEN CONTROL CABLE LEAD #21 DOES NOT NEED TO BE EXTENDED AND CAN BE DIRECTLY CONNECTED
TO TERMINAL #21 ON THE TERMINAL STRIP. NOTE THAT THIS IS NOT THE PREFERRED CONNECTION BECAUSE IT ADDS ERROR TO THE
WIRE FEEDER VOLTMETER READING.)
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL
STRIP. THE POWER SOURCE GROUNDING TERMINAL STRIP (MARKED AND LOCATED NEAR THE POWER SOURCE INPUT POWER
CONNECTIONS) MUST BE PROPERLY CONNECTED TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL.
N.E. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.
CLEVELAND, OHIO U.S.A.
LN-8
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A-12
A-12
INSTALLATION
FIGURE A.8 – K318 DUAL PROCESS CONTACTOR KIT DC-400, CV-400 AND CVI-500 CONNECTION TO
LN-8 FOR SAME POLARITY OPERATION
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
CAN KILL
N.B.B.
N.B.B.
21B
21A
DUAL PROCESS
CONTACTOR
WELDING LEAD STUD ON
BACK OF CONTACTOR KIT
DC-400
31 32
GND
GND
N.C.
81
76 77
75
21
4
2
A
B
80
75
76
77
75
76
77
A
B
C
A
B
C
77
76
75
4
21
21
N.A.A.
GND
2
4
2
4
2
4
2
32
31
4
2
32
31
31
32
32
31
32
31
N.F.
A
B
N.B.
N.B.
TO POSITIVE OUTPUT
STUD ON POWER
SOURCE
TO NEGATIVE OUTPUT
STUD ON POWER
SOURCE
WELDER
CONTROL
CABLE
N.E.
N.D.
N.A.
ELECTRODE
CABLES
WIRE FEEDER
CONTROL
CABLE
WIRE FEEDER
CONTROL
CABLE
TO WORK
N.A.
N.A.
TO "A" WIRE FEEDER
TO "B" 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.
N.A.A. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL
STRIP OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.B.B. EXTEND LEAD #21A & #21B USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THESE EXTENDED #21A AND #21B
LEADS SHOULD BE TAPED TO THE WELDING WORK LEAD. EACH LEAD MUST BE CONNECTED DIRECTLY TO THE WORK AND LEADS MUST
NOT BE CONNECTED TOGETHER.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. BOLT AND TAPE CONNECTIONS.
N.C. TAPE UP SEPARATELY.
N.D. PUT TRANSFER SWITCH IN "SAME POLARITY ON FEEDERS" POSITION.
N.E. MODE SWITCHES ON CONTACTOR KIT ARE NOT FUNCTIONAL WHEN USED WITH THE POWER SOURCE.
N.F. CONNECTION SHOWN FOR NEGATIVE POLARITY. FOR POSITIVE POLARITY REVERSE ELECTRODE AND WORK CABLES CONNECTED TO
POWER SOURCE OUTPUT STUDS.
CLEVELAND, OHIO U.S.A.
LN-8
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A-13
A-13
INSTALLATION
FIGURE A.9 – K318 DUAL PROCESS CONTACTOR KIT DC-400, CV-400 AND CVI-500 CONNECTION TO
LN-8 FOR OPPOSITE POLARITY OPERATION
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
CAN KILL
N.B.B.
N.B.B.
TO WORK
N.A.
21B
21A
DUAL PROCESS
CONTACTOR
WELDING LEAD STUD ON
BACK OF CONTACTOR KIT
DC-400
31 32
GND
GND
N.C.
81
76 77
75
21
4
2
A
B
80
75
76
77
75
76
77
A
B
C
A
B
C
77
76
75
4
21
21
N.A.A.
GND
2
4
2
4
2
4
2
32
31
4
2
32
31
31
32
32
31
32
31
N.F.
A
B
N.B.
N.B.
TO POSITIVE OUTPUT
STUD ON POWER
SOURCE
TO NEGATIVE OUTPUT
STUD ON POWER
SOURCE
WELDER
CONTROL
CABLE
N.E.
N.D.
ELECTRODE
CABLES
WIRE FEEDER
CONTROL
CABLE
WIRE FEEDER
CONTROL
CABLE
N.A.
N.A.
N.A.
TO "A" WIRE FEEDER
ELECTRODE NEGATIVE
TO "B" WIRE FEEDER
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.
N.A.A. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME MARKED
NEAR THE POWER SOURCE TERMINAL STRIP OR
TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.B.B. EXTEND LEAD #21A AND #21B USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THESE EXTENDED #21A AND
#21B LEADS SHOULD BE TAPED TO THE WELDING WORK LEAD. EACH LEAD MUST BE CONNECTED DIRECTLY TO THE WORK AND LEADS
MUST NOT BE CONNECTED TOGETHER.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. BOLT AND TAPE CONNECTIONS.
N.C. TAPE UP SEPARATELY.
N.D. PUT TRANSFER SWITCH IN "OPPOSITE POLARITY ON FEEDERS" POSITION.
N.E. MODE SWITCHES ON CONTACTOR KIT ARE NOT FUNCTIONAL WHEN USED WITH THE POWER SOURCE.
N.F. TO MAKE "A" FEEDER POSITIVE POLARITY AND "B" FEEDER NEGATIVE POLARITY, REVERSE ELECTRODE CABLES CONNECTED TO
POWER SOURCE OUTPUT STUDS.
CLEVELAND, OHIO U.S.A.
LN-8
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A-14
A-14
INSTALLATION
FIGURE A.10 – FOR POWER SOURCES OTHER THAN LINCOLN ELECTRIC
TURN OFF INPUT POWER
WARNING
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ELECTRIC
SHOCK
ON THIS EQUIPMENT.
CAN KILL
POWER SOURCE
POWER SOURCE
INTERNALLY POWERED CONTACTOR
OUTPUT CONTACTOR COIL
EXTERNALLY POWERED CONTACTOR
OUTPUT CONTACTOR COIL
(115 VAC)
ELECTRODE
ELECTRODE
FOR POWER TO
OPERATE CONTACTOR
WORK
MAX. RATING OF LN-8
#2 TO #4 CIRCUIT IS
5 AMP 115 VAC
5 AMP 28 VDC
1/2 AMP 115 VDC
WORK
MAX. RATING OR LN-8
#2 TO #4 CIRCUIT IS
5 AMP 115 VAC OR
5 AMP 28 VDC
1/2 AMP 115 VDC
GND
21
GND
21
4
4
TO 115 VAC 350 VOLT-AMP
FOR LN-8 PLUS
CONTACTOR
2
2
31
32
75
76
77
31
32
75
76
77
TO 115 VAC 350
VOLT-AMP CAPACITY
REQUIREMENTS
TAPE UP
EACH LEAD
TAPE UP
EACH LEAD
TO
WORK
TO
WORK
INPUT
CONTROL
CABLE
INPUT
CONTROL
CABLE
TO LN-8 CIRCUIT
TO LN-8 CIRCUIT
31 32
2
4
31 32
2
4
ELECTRODE CABLE
ELECTRODE CABLE
LN-8 WIRE FEEDER
LN-8 WIRE FEEDER
REFER TO THE POWER SOURCE WIRING DIAGRAM TO FIND THE TYPE OF CONTACTOR CIRCUIT.
CLEVELAND, OHIO U.S.A.
LN-8
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A-15
A-15
INSTALLATION
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.
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.
3. Pass the single electrode cable through the holes
provided in the back corner of the control section
and fasten it to the tab on the conductor above
the rear brass block of the wire feeder.
LN-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:
LN-8NE AND LN-8SE
1. Connect the polarized plug of the control cable to
the mating connector on the back of the wire
feeder.
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:
FIGURE A.11 – INPUT CONTROL CABLE AND
ELECTRODE CABLE CONNECTIONS
1. When shipped, the hand crank on the wire reel
mount is equipped to feed 1/16 through 0.120 in.
(1.6 through 3.0 mm) electrode.
CABLE
CLAMP
CONDUCTOR
ELECTRODE
CABLE
WIRE
REEL
BASE
CONTROL
CABLE
LN-8
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A-16
A-16
INSTALLATION
FIGURE A.12 – INPUT CONTROL CABLE AND ELECTRODE CABLE EXTENSIONS
WIRE
DRIVE
UNIT
POLARIZED
CONTROL
PLUGS
CONTROL
CABLE
CABLE
EXTENSION
ELECTRODE
CABLE
ELECTRODE
EXTENSION
CABLE
WIRE
REEL
BASE
BRASS
BLOCK
HAND
CRANK
2. The standard cable setup consists of an electrode
cable and a control cable with a polarized plug on
the wire feeder end. Position the control cable
with the polarized plug at the wire reel base. Refer
to Figure A.12.
FIGURE A.13 – CABLE EXTENSION
CONNECTIONS TO WIRE FEEDER
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
cable together.
CONTROL
CABLE
EXTENSION
6. Place both the control and electrode cables under
the clamp on the wire reel base and tighten the
screws.
7. Insert the connector on the electrode cable
extension into the brass block of the hand crank
assembly and tighten with a 3/16 in. Allen wrench.
REAR
BRASS
BLOCK
8. At the wire feeder, connect the polarized plug of
the control cable extension into the mating
receptacle on the back of the wire feeder. Refer to
Figure A.13.
ELECTRODE
CABLE
EXTENSION
CONNECTOR
INGOING
GUIDE
TUBE
LN-8
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A-17
9. Remove the ingoing guide tube from the rear
A-17
INSTALLATION
conductor cable is 22-1/2 ft (6.9 m) long, tip to tip,
and can be used to measure the length of hose
cut off.) If the flux hose is taped to the extension
cables or gun cable, it should be done in such a
manner as not to deform or collapse the hose.
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.
FIGURE A.14 – WIRE FEEDER HANDLE
INSTALLATION
10. If using over 450 amperes, connect a length of
1/0 cable between the brass block on the wire reel
base and the tab on the rear brass block of the
wire feeder. Tape this cable to the extension
assembly. Proper cable lengths are:
SELF-TAPPING
SCREW
HINGE
PIN
• For a 22-1/2 ft (6.9 m) extension use 23-1/2 ft
(7.2 m) - order M5906-106
• For 45 ft (13.7 m) extension use 46 ft (14 m) -
order M5906-104
11. To mount the wire feeder handle provided with
the extension unit, remove the two self-tapping
screws that hold the hinge pin in the top of the
wire feeder. Push the hinge pin out, leaving the
covers intact. Place the handles into the slots
provided and push the hinge pin back into the
assembly making sure that the pin goes through
the holes in the handle. Put the two self-tapping
screws back into their respective positions. Refer
to Figure A.14.
HANDLE
12. If the extension is being used with a K306 Wire
Reel Flux Tank assembly, the hose attached to
the bottom of the flux tank may have to be
shortened. This hose is 64 ft (19.5 m) long, and is
the correct length for use with the 45 ft (13.7 m)
extension. If a 22-1/2 ft (6.9 m) extension is to be
used, cut 22-1/2 ft (6.9 m) off the flux hose to give
the correct length of 41-1/2 ft (12.6 m). (The
LN-8
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A-18
A-18
INSTALLATION
GUN AND CABLE ASSEMBLIES
LN-8S AND LN-8SE CONTINUOUS
FLUX FEED (SUBMERGED ARC)
GENERAL
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 LN-8 is used with various guns. In all cases, the
gun is shipped connected to the cable and is ready to
weld. Use the gun recommended for the wire type
(solid or cored) and size to be used. See the para-
graph on Welding Guns in the Accessories Section
for more information on the different types of guns.
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 kPa). The tank is
equipped with a pressure regulator to reduce the input
pressure to the 30 psi (207 kPa) required for the flux
feeding system. This pressure is set at the factory
before the machine is shipped. When the LN-8SE
with the 22-1/2 or 45 ft. (6.9 or 13.7 m) extension is
used, and the flux hose is long, set the air pressure at
45 psi (310 kPa) for 1/2 in. (12 mm) I.D. hose, and 55
psi (379 kPa) for 3/8 in. (9.5 mm) I.D. hose. Exact
pressure is indicated on the pressure gage. Air con-
sumption is normally less than 1.5 cubic feet
(4.2 cubic meters) per minute of welding.
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
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.
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.
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.
3. Do not allow dolly wheels or trucks to run over the
cables.
4. Keep the cable clean by following the
maintenance instructions.
5. Use only clean, rust-free electrode wire.
6. Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or
deformed.
LN-8
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SECTION B-1
SECTION B-1
OPERATION
TABLE OF CONTENTS
-OPERATION SECTION-
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Constant Current Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Constant Voltage Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Avoiding Ground Lead Protector (GLP) Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Feed Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting for CV or CC Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding with a Constant Voltage Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding with a Constant Current Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Reel Loading - 50 and 60 lb Coils (K303 Wire Reel Stand). . . . . . . . . . . . . . . . . . . .
Wire Reel Loading (K1524-1 Universal Wire Reel Stand) . . . . . . . . . . . . . . . . . . . . . . . . .
Feeding Electrode to the LN-8N or LN-8S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feeding Electrode to the LN-8NE or LN-8SE (With Extension) . . . . . . . . . . . . . . . . . .
Slow Acceleration Starting (Code 7926 and Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flux Tank Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
B-2
B-2
B-3
B-4
B-4
B-5
B-6
B-7
B-7
B-8
B-9
B-11
B-11
B-12
B-12
LN-8
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B-2
B-2
OPERATION
Read and understand this entire section before
operating your machine.
CONTROLS AND THEIR
FUNCTIONS
SAFETY INSTRUCTIONS
CONSTANT CURRENT CONTROLS
WARNING
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.
ELECTRIC SHOCK can kill.
FIGURE B.1 – CONSTANT CURRENT CONTROLS
• 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.
____________________________________
CURRENT
CONTROL
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
VOLTAGE
CONTROL
• Keep flammable material away.
• Do not weld, cut or gouge on containers
that have held combustibles.
____________________________________
CIRCUIT
BREAKER
ARC RAYS
can burn.
TRIGGER
INTERLOCK
• Wear eye, ear and body protection.
____________________________________
Only qualified personnel should operate this equip-
ment. Observe all safety information throughout this
manual.
GROUND LEAD
PROTECTOR
RESET BUTTON
WIRE FEED
DIRECTION
CONTROL
LN-8
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B-3
B-3
OPERATION
CURRENT CONTROL. Adjusts welding current by
VOLTAGE CONTROL. Adjusts arc voltage by control-
controlling power source output.
ling power source output voltage.
VOLTAGE CONTROL. Adjusts arc voltage by control-
CURRENT CONTROL. Adjusts wire feed speed to
ling wire feed speed.
control welding current.
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.
FIGURE B.2 – CONSTANT VOLTAGE CONTROLS
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.
CURRENT
CONTROLS
VOLTAGE
CONTROLS
CONSTANT VOLTAGE CONTROLS
Operator controls for welding using a constant voltage
power source that differ from the constant current con-
trols are illustrated in Figure B.2. Refer to the figure
and the following explanations of the controls.
LN-8
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B-4
B-4
OPERATION
CIRCUIT PROTECTION
AVOIDING GROUND LEAD
PROTECTOR (GLP) ACTIVATION
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.
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.
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.
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.
CIRCUIT BREAKER. The 5 amp circuit breaker locat-
ed above the drive rolls normally trips only when an
overload occurs because of excessive loading in the
wire feed cable, or a defective motor or control 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.
Be sure that all work lead connections to the work
make tight metal-to-metal contact.
DO NOT allow excess input cable or work cable to be
placed closer than three feet from the wire feeder.
DO NOT coil excess input cable assembly or use a
coiled assembly as shipped from the factory. Instead,
loop the excess cable length back and forth in three to
six foot straight lengths. Coiling the input cable results
in a transformer action between the electrode
conductor cable and the ground lead in the
multiconductor control cable. This transformer action
can cause a current to flow in the ground lead which
will falsely activate the GLP circuit.
To reset the GLP circuit, press the white button above
the drive motor and to the right of the circuit breaker.
LN-8
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B-5
B-5
OPERATION
3. Install the drive roll and replace the clamping col-
lar. Tighten the drive roll screw.
WIRE FEED ROLLS AND GUIDE
TUBES
4. Remove idle roll shaft screw. Install the idle roll
and idle roll shaft screw.
The drive rolls and guide tube kits are ordered sepa-
rately. Refer to Figure B.3 and install these parts per
the following instructions:
5. Remove the large ingoing guide from the rear
brass block by loosening the locking screw.
1. Loosen the idle roll spring pressure screw.
6. Loosen the ingoing guide tube clamping screw.
Install the ingoing guide tube (which is stenciled
“in”) through the rear brass block. Tighten the
clamping screw.
2. Remove the drive roll screw and clamping collar
from the drive shaft.
FIGURE B.3 – WIRE FEED ROLLS AND GUIDE TUBE INSTALLATION
INGOING
GUIDE
TUBE
DRIVE
CLAMPING DRIVE ROLL
COLLAR ROLL SCREW
OUTGOING
GUIDE TUBE
LOCKING
SCREW
CLAMPING
SCREW
LARGE
INGOING
GUIDE
LOCKING
IDLE ROLL
SHAFT SCREW
IDLE
ROLL
SCREW
IDLE ROLL
SPRING PRESSURE
SCREW
LN-8
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B-6
7. Install the large ingoing guide into the rear brass
B-6
OPERATION
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.
block and tighten the locking screw.
8. Install the outgoing guide tube with its plastic
insert through the front brass block. Tighten the
locking screw so the dog point goes into the
groove on the O.D. of the guide tube.
9. Set the drive roll spring pressure:
a. For wire sizes from 0.030 thru 0.052 in. (0.8
thru 1.3 mm) – With wire in the system, the
idle roll pressure indicator should be set to the
wire size shown on the “solid” side of the
nameplate. (For 0.030 in. (0.8 mm) solid wire,
set the pressure indicator to slightly less than
the 0.035 in. (0.9 mm) marking.) This setting
is a starting point and may have to be
changed depending upon the type of wire,
surface condition, lubrication, and hardness.
The optimum idle roll setting can be 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 electrode is
removed from the cable, there will be a slight
waviness in the electrode for about a foot
beyond the slip marks on the electrode. If
there is no waviness, the pressure is set too
low.
NOTE: The indicator settings for these larger wire
sizes are accurate enough so that there is no need to
readjust, unless the electrode is unusually soft.
The drive rolls are stamped with the wire size for
which they are designed. If a wire size is used
that is not stamped on the drive roll, the drive
rolls and guide tubes will have to be changed.
SETTING FOR CV OR CC POWER
SOURCES
The LN-8N and LN-8NE weld only with a constant
voltage (CV) power source. These machines can be
converted for constant current (CC) welding by
installing the proper parts.
The LN-8S and LN-8SE weld with either a CV or CC
power source. Set the equipment for either “CV” or
“CC” as appropriate per the following:
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.
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.
NOTE: These indicator settings are accurate enough
so that there is no need to readjust unless the elec-
trode is unusually soft.
3. There are two nameplates on top of each other
on the front of the wire feeder control box. Make
sure the correct nameplate for the power source
being used is on top.
LN-8
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B-7
B-7
Volts Control — Idealarc R3S Power Sources
OPERATION
FIGURE B.4 – CV-CC SWITCH
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).
CV-CC
SWITCH
VARIABLE
VOLTAGE
PC BOARD
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.
VARIABLE
VOLTAGE
PC BOARD
b. Place power source output control toggle
switch in the ‘Output Control Remote’ posi-
tion. Total current control is now at the LN–8.
WELDING WITH A CONSTANT
VOLTAGE POWER SOURCE
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.
1. Current and voltage adjustments
Amps Control — All Power Sources
Set the welding current (or wire feed speed) 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.
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.
LN-8
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B-8
B-8
OPERATION
FIGURE B.5 – LOADING A 50 OR 60 lb COIL
WIRE REEL LOADING – 50 AND
60 lb COILS (K303 WIRE REEL
STAND)
SPINNER
NUT
COVER
PLATE
MOUNTING A 50 OR 60 lb 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.
SLOTS
CARDBOARD
COIL
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.
LINER
COIL
4. Be sure the coil is placed so the spring loaded
arms will not interfere with the later removal of
the coil tie wires.
TIE
WIRE
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 wire feeding.
REEL
SPRING
LOADED
ARM
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.
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.
7. Tighten the cover as much as possible by hand.
DO NOT hammer on the spinner nut arms.
CAUTION
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.
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.
____________________________________
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B-9
B-9
OPERATION
6. Set one of the Readi-Reel inside cage wires on
the slot in the retaining spring tab.
WIRE REEL LOADING (K1524-1
UNIVERSAL WIRE REEL STAND)
7. Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.
TO MOUNT A 30 lb (14 kg) READI-REEL
PACKAGE (USING THE MOLDED PLASTIC
K363-P READI-REEL ADAPTER):
8. Slide the cage all the way onto the adapter until
the retaining spring “pops up” fully.
The spindle should be located in the LOWER mount-
ing hole.
CAUTION
1. Depress the Release Bar on the Retaining Collar
and remove it from the spindle. See Figure B.6.
Check to be sure the Retaining Spring has fully returned
to the locking position and has SECURELY locked the
Readi-Reel cage in place. The Retaining Spring must
rest on the cage, not the welding electrode.
2. Place the Adapter on the spindle.
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.
____________________________________
9. To remove the Readi-Reel from the Adapter,
depress the retaining spring tab with a thumb
while pulling the Readi-Reel cage from the molded
adapter with both hands. Do not remove the
Adapter from the spindle.
4. Rotate the spindle and adapter so the retaining
spring is at the 12 o’clock position.
5. Position the Readi-Reel so that when it rotates
the wire is de-reeled from the bottom of the coil.
FIGURE B.6 – READI-REEL MOUNTING
ADAPTER
2 IN. O.D.
SPINDLE
RETAINING
SPRING
BRAKE
HOLDING
PIN
RETAINING
COLLAR
GROOVES
READI-REEL
INSIDE CAGE
WIRES
RELEASE
BAR
LN-8
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B-10
B-10
OPERATION
TO MOUNT 10 TO 44 lb (4.5 to 20 kg) SPOOLS
(12 in./300 mm DIAMETER) OR 14 lb (6 kg)
INNERSHIELD COILS:
FIGURE B.7 – K1504-1 COIL REEL
SPINNER NUT
The spindle should be located in the lower mounting
hole.
COVER
PLATE
[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.]
SLOTS
1. Depress the Release Bar on the Retaining Collar
and remove it from the spindle.
CARDBOARD
COIL LINER
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.
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.
TIE WIRE
SPRING
LOADED ARM
TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COIL:
(USING K1504-1 COIL REEL) (FOR 50 to 60 lb
READI-REELS A K438 READI-REEL ADAPTER
MUST BE USED.)
REEL
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 the spinner nut and remove the reel
cover. See Figure B.7.
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.
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.
____________________________________
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.
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.
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B-11
B-11
OPERATION
FEEDING ELECTRODE TO THE LN-8N OR
LN-8S
4. Pull the plastic hand crank handle to the out posi-
tion in the arm.
1. Turn the reel until the free end of the electrode is
accessible.
5. Pull the shaft and drive roll assembly to the out
position.
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”.)
6. Apply downward pressure to the idler roll pres-
sure arm. Maintain this pressure and 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.
3. Insert the free end through the incoming guide
tube.
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.
4. Press the gun trigger and push the electrode into
the drive roll.
WARNING
WARNING
ELECTRIC SHOCK can kill.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• 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.
• When inching with the gun trigger,
electrode and drive mechanism are
“hot” to work and ground.
____________________________________
____________________________________
5. Inch the electrode through the gun.
8. Push the plastic of the hand crank to the in
position, as shown in Figure B-8.
FEEDING ELECTRODE TO THE LN-8NE
OR LN-8SE (WITH EXTENSION)
9. Shift the ingoing guide tube to the forward
position.
1. Slide the ingoing guide tube of the hand crank to
the forward position.
FIGURE B.8 – HAND CRANK POSITION
BRASS
BLOCKS
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.
HAND CRANK
ARM
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
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B-12
B-12
OPERATION
SLOW ACCELERATION STARTING
(CODE 7926 AND ABOVE)
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 tighten hand tight.
Reconnect the incoming air supply.
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 stickout 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”.
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.
4. Reassemble.
LN-8
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SECTION C-1
SECTION C-1
ACCESSORIES
TABLE OF CONTENTS
-ACCESSORIES SECTION-
Accessories............................................................................................................................. Section C
General................................................................................................................................
K163 Undercarriage (Requires K303, K377, or K378) ..................................................
K178 Mounting Platform................................................................................................
K261 Meter Kit...............................................................................................................
K202 Burnback Kit.........................................................................................................
K58 Magnetic Separator ...............................................................................................
K119 Gravity Feed Flux Cone .......................................................................................
K310 Flux Screen..........................................................................................................
K320 Flux Tank .............................................................................................................
K161 Mechanized Travel Power Pack...........................................................................
K240 Contactor Kit ........................................................................................................
K317 Dual Process Kit (No Polarity Change)................................................................
K318 Dual Process Contactor Kit (With Polarity Changes)...........................................
Reel Mounting Accessories.................................................................................................
K303 50 to 60 lb (22.7 to 27.2 kg) Wire Reel Stand......................................................
K1524-1 Universal Reel Stand and Base Assembly .....................................................
K162 Spindle for Mounting Readi-Reels and 10 thru 30 lb
C-2
C-3
C-3
C-3
C-3
C-3
C-3
C-3
C-3
C-3
C-4
C-4
C-4
C-4
C-4
C-4
(4.5 thru 13.5 kg) Spools ............................................................................................
K377 Small Mounting Stand for Readi-Reel Coils or 10 thru 30 lb
C-4
(4.5 thru 13.5 kg) Spools with 2 in. (50 mm) I.D.........................................................
K378 Small Mounting Stand for 13 to 14 lb (6.0 to 6.4 kg) Innershield Coils ................
M11514 Wire Reel Dust Shield Door for K303..............................................................
Welding Guns......................................................................................................................
Innershield Guns ...........................................................................................................
Submerged Arc Guns....................................................................................................
GMAW Guns .................................................................................................................
Welding Gun Accessories ...................................................................................................
K70 Fillet Guide.............................................................................................................
K110 Hand Travel Unit ..................................................................................................
K62 Squirtmobile ...........................................................................................................
Constant Current Conversion Parts ....................................................................................
C-4
C-4
C-4
C-5
C-5
C-5
C-5
C-5
C-5
C-5
C-5
C-5
LN-8
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C-2
C-2
ACCESSORIES
GENERAL
The following is a list of the accessories that can be
used with the LN-8 wire feeder unit.
A detailed description of each item is given later in the
section.
TABLE C.1 – LN-8 WIRE FEEDER ACCESSORIES
Name
Product Number
K163
UNDERCARRIAGE
MOUNTING PLATFORM
METER KIT
K178
K261
K202
K58
BURNBACK KIT
MAGNETIC SEPARATOR
GRAVITY FEED FLUX CONE
FLUX SCREEN
K119
K310
K320
K161
K240
K317
K318
K303
K1524-1
K162
FLUX TANK
MECHANIZED TRAVEL POWER PACK
CONTACTOR KIT
DUAL PROCESS KIT (NO POLARITY CHANGE)
DUAL PROCESS CONTACTOR KIT (WITH POLARITY CHANGES)
50 THRU 60 lb (22.7 THRU 27.2 kg) WIRE REEL STAND
UNIVERSAL REEL STAND AND BASE ASSEMBLY
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 lb
(4.5 THRU 13.5 kg) SPOOLS WITH 2 in. (50 mm) I.D.
K378
M11514
K112
K113
K114
K115
K116
K126
K497
K471
K527
K70
SMALL MOUNTING STAND FOR 13-14 lb. (6.0-6.4 kg) INNERSHIELD COILS
WIRE REEL DUST SHIELD DOOR FOR K303
SUBMERGED ARC WELDING GUN - 500 AMPS
SUBMERGED ARC WELDING GUN - 600 AMPS
SUBMERGED ARC WELDING GUN - 600 AMPS
INNERSHIELD WELDING GUN - 450 AMPS
INNERSHIELD WELDING GUN - 400 AMPS
INNERSHIELD WELDING GUN - 350 AMPS
MAGNUM GMA WELDING GUN - 200 AMPS
MAGNUM GMA WELDING GUN - 300 AMPS
MAGNUM GMA WELDING GUN - 400 AMPS
FILLET GUIDE
K110
K62
HAND TRAVEL UNIT
SQUIRTMOBILE
CONSTANT CURRENT CONVERSION PARTS
LN-8
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C-3
C-3
ACCESSORIES
K163 UNDERCARRIAGE
K58 MAGNETIC SEPARATOR
(REQUIRES K303, K377, OR K378)
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.
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.
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 screws 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.
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.
K310 FLUX SCREEN
K261 METER KIT
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.
All LN-8 wire feed units with code no. 7580 to 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.
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.
K202 BURNBACK KIT
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.
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:
K320 FLUX TANK
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.
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.
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.
K161 MECHANIZED TRAVEL
POWER PACK
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.
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
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C-4
C-4
ACCESSORIES
K363P
K435
K468
K1504-1
K438
30 lb Readi-Reel Adapter
Spindle Adapter for 14 lb coils
Spindle Kit
60 lb Wire Reel
60 lb Readi-Reel Adapter
K240 CONTACTOR KIT
Output contactor with pilot relay to make the electrode
‘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.
K162 SPINDLE FOR MOUNTING
READI-REELS AND 10 THRU 30 lb
(4.5 THRU 13.5 kg) SPOOLS
K317 DUAL PROCESS KIT
(NO POLARITY CHANGE)
For use with the K303 wire reel stand. To mount this
spindle kit, remove the shaft from the standard 50 to
60 lb (22.5 to 27.2 kg) wire coils from the mounting
framework. Install the spindle per the instructions
shipped with the kit.
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.
K377 SMALL MOUNTING STAND FOR
READI-REEL COILS OR 10 THRU 30 lb
(4.5 THRU 13.5 kg) SPOOLS WITH 2 in.
(50 mm) I.D.
K318 DUAL PROCESS CONTACTOR KIT
(WITH POLARITY CHANGES)
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., a 12 in. maximum O.D., and a
4 in. width. The spindle has an adjustable breaking
system.
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.
K378 SMALL MOUNTING STAND FOR
13 TO 14 lb (6.0 TO 6.4 kg)
INNERSHIELD COILS
REEL MOUNTING ACCESSORIES
K303 50 TO 60 lb (22.7 TO 27.2 kg)
WIRE REEL STAND
This assembly includes the smaller frame as used in
the K377 and the fully enclosed canister system for
derailing of the 14 lb coil. This system has a fixed
brake for the 14 lb coil.
This assembly includes a framework to which is
attached a 50 to 60 lb (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.
M11514 WIRE REEL DUST SHIELD DOOR
FOR K303
K1524-1 UNIVERSAL REEL STAND
AND BASE ASSEMBLY
In extremely dusty and dirty locations, this 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.
The wire reel stand comes with a 2 in. spindle. With
the addition of the proper spindle and Readi-Reel
adapters, it can accomodate various sizes of coils,
spools, and Readi-Reels.
LN-8
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C-5
C-5
ACCESSORIES
WELDING GUNS
WELDING GUN ACCESSORIES
INNERSHIELD GUNS
K70 FILLET GUIDE
The K126 gun and cable assembly is recommended
for most Innershield electrodes at up to 350 amps.
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.
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.
TM
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.
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.
SUBMERGED ARC GUNS
The K112 gun and cable assembly is recommended
for welding up to 500 amps.
K62 SQUIRTMOBILE
The K113 gun and cable is recommended for use up
to 600 amps.
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,
install the K161 mechanized travel power pack.
The K114 gun and cable assembly is a 600 amp gun
that includes a flux valve and receptacle for the K110
or K62.
GMAW GUNS
CONSTANT CURRENT
CONVERSION PARTS
An expanding line of Magnum GMA gun and cable
assemblies are available to allow welding 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).
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).
NOTE: Magnum GMA welding guns require a K466-1
connector for use with an LN-8 wire feeder.
LN-8
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C-6
C-6
NOTES
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SECTION D-1
SECTION D-1
MAINTENANCE
TABLE OF CONTENTS
-MAINTENANCE SECTION-
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Reel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive Motor and Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gun and Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
D-2
D-2
D-2
D-2
D-2
D-2
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D-2
D-2
MAINTENANCE
ROUTINE MAINTENANCE
PERIODIC MAINTENANCE
DRIVE ROLLS AND GUIDE TUBES
CONTROL BOX
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.
Every six months, open and inspect the control sec-
tion. 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.
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.
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
Refer to the instructions included with the drive roll kit
for installation and replacement of the drive rolls on
the wire feeder.
For instructions on periodic maintenance for the weld-
ing gun and cables, refer to the manual for your spe-
cific model of welding gun.
WIRE REEL MOUNTING
To prolong the life of the reel shaft on the 50 to 60 lb
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.
LN-8
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SECTION E-1
SECTION E-1
THEORY OF OPERATION
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gun Trigger and 1CR Relay Contact Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable Voltage Board, Meter Shunt, Wire Speed and Remote Output Controls . . . . . . .
SCR Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-2
E-2
E-3
E-4
E-5
LN-8
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E-2
E-2
THEORY OF OPERATION
FIGURE E.1 – POWER INPUT CIRCUITS
REMOTE
OUTPUT
CONTROL
ELECTRODE
METER
SHUNT
#21
#567
VARIABLE VOLTAGE
BOARD
#75
#76
#77
WIRE FEED
SPEED CONTROL
CIRCUIT
BREAKER
WIRE
FEED
MOTOR
THERMAL
CIRCUIT
BREAKER
ARMATURE
#32
#32A
INPUT
RECEPTACLE
CONTROL
BOARD
#31
#2
&
2 OHMS
#3
2
A
#4
C
O
N
T
A
C
T
O
R
#531
FIELD
FUSE
RELAY
BOARD
CONTROL
GUN
CABLE
RECEPTACLE
OPTIONAL
BURNBACK
BOARD
WIRE
FEED
REED
SWITCH
TRIGGER
TRANS.
INTERLOCK
SWITCH
GLP
SWITCH
receptacle, through the circuit breaker
and 2 ohm resistor to the control board,
the relay board, and the trigger trans-
former.
GENERAL DESCRIPTION
The LN-8 is a semiautomatic wire feeder
designed for Innershield (FCAW) and
gas metal arc processes with the appro-
priate accessories. It 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.
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 con-
trol board is rectified and controlled by
SCRs (See SCR Operation) and
applied to the armature of the wire feed
motor.
POWER INPUT CIRCUITS
The relay board rectifies the 115VAC
and applies it to the field winding of the
wire feed motor.
The 115VAC is applied (usually from the
welding power source) via the input
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
LN-8
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E-3
E-3
THEORY OF OPERATION
FIGURE E.2 – GUN TRIGGER AND 1CR CONTACT CONTROL CIRCUITS
REMOTE
OUTPUT
CONTROL
ELECTRODE
METER
SHUNT
#21
#567
VARIABLE VOLTAGE
BOARD
#75
#76
#77
WIRE FEED
SPEED CONTROL
CIRCUIT
BREAKER
WIRE
FEED
MOTOR
THERMAL
CIRCUIT
BREAKER
ARMATURE
#32
#32A
INPUT
RECEPTACLE
CONTROL
BOARD
#31
#2
&
2 OHMS
#3
2
A
#4
C
O
N
T
A
C
T
O
R
#531
FIELD
FUSE
RELAY
BOARD
CONTROL
GUN
CABLE
RECEPTACLE
OPTIONAL
BURNBACK
BOARD
WIRE
FEED
REED
SWITCH
TRIGGER
TRANS.
INTERLOCK
SWITCH
GLP
SWITCH
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.
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
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
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
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E-4
E-4
THEORY OF OPERATION
FIGURE E.3 – VARIABLE VOLTAGE BOARD, METER SHUNT, WIRE SPEED,
AND REMOTE OUTPUT CONTROLS
REMOTE
OUTPUT
CONTROL
ELECTRODE
METER
SHUNT
#21
#567
VARIABLE VOLTAGE
BOARD
#75
#76
#77
WIRE FEED
SPEED CONTROL
CIRCUIT
BREAKER
WIRE
FEED
MOTOR
THERMAL
CIRCUIT
BREAKER
ARMATURE
#32
#32A
INPUT
RECEPTACLE
CONTROL
BOARD
#31
#2
&
2 OHMS
#3
2
A
#4
C
O
N
T
A
C
T
O
R
#531
FIELD
FUSE
RELAY
BOARD
CONTROL
GUN
CABLE
RECEPTACLE
OPTIONAL
BURNBACK
BOARD
WIRE
FEED
REED
SWITCH
TRIGGER
TRANS.
INTERLOCK
SWITCH
GLP
SWITCH
operator. The control board adjusts the
armature voltage applied to the wire
feed motor to change the motor speed.
VARIABLE VOLTAGE
BOARD, METER SHUNT,
WIRE SPEED AND
REMOTE OUTPUT
CONTROLS
The remote output control permits
power source control from the LN-8
unit. The remote control is coupled to
the welding power source via leads #75,
#76, and #77 through the input
receptacle.
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 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.
The wire speed control dictates to the
control board the directives of the
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
LN-8
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E-5
E-5
THEORY OF OPERATION
FIGURE E.4 – SILICON-CONTROLLED RECTIFIER OPERATION
INPUT
CATHODE
OUTPUT
ANODE
GATE
GATE
NOTE: AS THE GATE PULSE IS
APPLIED LATER IN THE
CYCLE, THE SCR OUTPUT
IS DECREASED.
An SCR is fired by a short burst of cur-
SCR OPERATION
rent into the gate. This gate pulse must
be more positive than the cathode volt-
age. Since there is a standard PN junc-
tion 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.
A 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.
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E-6
E-6
NOTES
LN-8
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SECTION F
SECTION F
TROUBLESHOOTING AND REPAIR
TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTION-
Troubleshooting and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LN-8 Electrical Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1CR Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potentiometer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Lead Protector Push Button Switch Replacement. . . . . . . . . . . . . . . . . . . . . .
Trigger Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive Assembly and Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Retest After Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-2
F-3
F-4
F-10
F-12
F-12
F-14
F-17
F-20
F-24
F-24
F-26
F-28
F-30
F-32
F-35
F-40
LN-8
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F-2
F-2
TROUBLESHOOTING AND 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 3. RECOMMENDED COURSE OF
ACTION
The last column labeled “Recommended
Course of Action” lists 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. If there
are a number of possible components,
check the components in the order listed to
eliminate one possibility at a time until you
locate the cause of your problem.
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.
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.
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.
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
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- 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.
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- 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.
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:
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.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
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.
PC board can be damaged by static electricity.
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.
- 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
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
grounded part of the
equipment frame.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
- 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.
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.
Workstations
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
LN-8
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F-4
F-4
TROUBLESHOOTING AND REPAIR
TROUBLESHOOTING GUIDE
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
No wire feed or arc voltage when
the gun trigger is activated. The
drive rolls do not turn. The LN-8
appears “dead”.
1. Check the Ground Lead
Protector (GLP). Reset if
necessary.
1. Check for loose or faulty con-
nections between the input
receptacle, the circuit breaker,
and the 2 ohm resistor. See
wiring diagram.
2. Check the circuit breaker. Reset
if necessary.
2. Check the 2 ohm resistor.
Replace if faulty.
3. Make sure 115VAC is being
applied to the LN-8 at the input
receptacle. Pin “C” lead #31 and 3. Perform the Trigger
pin “D” lead #32.
Transformer Test.
4. Check the 1/2 amp fuse located
on the relay board. Replace if
necessary.
4. Perform the Internal Voltage
Test.
5. Perform the 1CR Relay Test.
5. If the LN-8 has a variable voltage
board and the power source is a 6. Check the relay board. Replace
constant current supply, check to
make sure the switch on the vari-
if faulty.
able voltage board is in the “VV” 7. Check the variable voltage board
position.
(if used). Replace if faulty.
6. If the switch on the variable
board is in the “VV” position,
make sure the power source is
set for an open circuit voltage of
30VDC or more.
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
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F-5
F-5
TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)
The wire feeds when the gun trig- 1. Check the welding cables for
1. The 1CR relay, located on the
power board, may be faulty.
Check or replace. Note: The
relay may operate but the indi-
ger is activated but there is no arc
voltage.
loose or faulty connections.
2. Put a jumper wire from #2 to #4
on the power source terminal
strip. (machines with 14 pin
vidual contacts may not be func-
tioning properly.
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.
2. If a burnback kit is installed,
remove and install the jumper
plug. If the problem is solved,
the burnback kit is faulty.
3. Check the #2 and #4 leads in the
LN-8 wiring harness for loose or
faulty connections. See wiring
diagram.
3. Check the continuity of leads #2
and #4 through the control cable.
Replace if “open”.
4. The welding gun may be faulty.
Check or replace.
The wire continues to feed with the
gun trigger open, and the wire is
electrically “hot”. The interlock
switch is in the “off” position.
1. Disconnect the gun trigger cable. 1. The 1CR relay may be stuck
If the problem is solved, the gun
trigger or cable is faulty. Repair
or replace.
closed. Perform the 1CR Relay
Test.
2. Check the relay board. Replace
if faulty.
1. 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 2CR reed switch may be
faulty. Check to see if it closes
when welding.
With the interlock switch (S2) in the
“ON” postion, the wire feed stops
when the gun trigger is released.
2. Check the interlock switch (S2)
for proper operation.
3. Check the continuity (zero ohms)
of leads #523 and #536 between
the interlock switch (S2) and the
relay board. See wiring diagram.
4. The relay board may be faulty.
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
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F-6
F-6
TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)
The circuit breaker (5 amp)
repeatedly trips when the gun trig-
ger is activated.
1. Check or replace the gun trigger 1. Perform the Trigger
and leads. Make sure the trigger
leads are not shorted to the elec-
trode or work cables.
Transformer Test.
2. Perform the Drive Motor Test.
2. Disconnect any accessory that
may be connected to terminals
#7 and #32A. See wiring dia-
gram. If the problem is resolved,
the accessory may be faulty.
3. 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.
The circuit breaker (5 amp) trips
when power is applied to the LN-8.
Gun trigger is NOT activated.
1. Disconnect any kits or acces-
sories that may be incorporated
in the LN-8. Be sure to install
any necessary jumper plugs. If
problem is resolved the fault may
be in the disconnected kit.
1. Check the wiring harness leads
#32, #32A, #31, and #531 for
shorts or grounds. See wiring
diagram.
2. Perform the Trigger
Transformer Test.
3. 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.
4. Perform the Drive Motor Test.
The 1/2 amp fuse on the relay
board repeatedly fails.
1. Check to make sure the correct 1. Perform the Drive Motor Test.
input voltage (115VAC) is being
applied to the LN-8.
2. Perform the Trigger
Transformer Test.
2. 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.
2. The electrode 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
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F-7
F-7
TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)
The wire feed speed cannot be
controlled. The motor runs and
feeds wire but the speed cannot
be changed regardless of control
setting.
1. If the LN-8 is being used for sub- 1. Check for loose connections
merged arc welding with the vari-
able voltage board switch in the
VV position, change it to the CV
position. If proper motor speed
control returns, the variable volt-
age board may be faulty.
between the speed control, the
control board, and the variable
voltage board. See wiring
diagram.
2. Check the speed control rheostat
for proper operation. Normal
resistance is 5000 ohms.
3. Perform the Drive Motor Test.
4. The control board may be faulty.
The wire feed “coasts” when the
gun trigger is released.
1. Make sure the gun trigger is not 1. Perform the 1CR Relay Test.
“sticking”.
The wire feeds normally and welds 1. Check or replace the solenoid.
but the solenoid is not operating.
1. With the gun trigger activated,
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
the wire “backs up” instead of feed-
ing forward.
1. Check wire feed direction switch 1. The 1CR relay may be faulty.
for proper direction and operation.
Check 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
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F-8
F-8
TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
When the gun trigger is activated,
the drive rolls turn but the wire will
not feed or wire feeding is rough.
1. Check or replace the gun cable. 1. If conditions are extremely dirty,
It may be kinked, clogged or
twisted.
install a wiper on the wire before
it enters the guide tube. Use a
piece of cloth saturated with
“Pyroil B”.
2. Make certain the drive rolls and
guide tubes are correct for the
wire being used.
3. Check or replace the gun contact
tip.
4. The electrode wire may be rusty
or dirty. Replace if necessary.
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
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F-9
F-9
TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The welding arc is variable or
“hunting”.
1. Make sure the welding parame- 1. Put the power source in
ters are correct for the welding
procedure being used.
“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.
2. Check the welding cables for
loose or faulty connections.
3. The gun cable may be faulty.
Check or replace.
2. Perform the Drive Motor Test.
4. The gun contact tip may be
worn. Check or replace.
5. The welding power supply may
be faulty. Check or replace.
Poor arc striking with sticking or
“blast offs”. The weld bead may
also be ropey and display weld
porosity.
1. Make sure the welding parame- 1. Put the power source in
ters and techniques are correct
for the welding procedure being
used.
“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.
2. Check the welding cables for
loose or faulty connections.
3. The gun cable may be faulty.
Check or replace.
4. The gun contact tip may be
worn. Check or replace.
5. The welding power source may
be faulty. Check 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
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F-10
F-10
TROUBLESHOOTING AND REPAIR
LN-8 ELECTRICAL SEQUENCE OF OPERATION
FIGURE F.1 – LN-8 ELECTRICAL SEQUENCE 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
FEED MOTOR
FIELD
ENERGIZES
POWER SOURCE
CONTACTOR
ENERGIZES
CONTROL CIRCUIT
(AND AUX. EQUIPMENT IF
CONNECTED TO 7-32A)
ELECTRODE NOW
"HOT" TO GROUND
WIRE FEEDS DOWN
ARC STARTS
ENERGIZES 2 CR
(REED SWITCH)
MOTOR ACCELERATES
TO WELDING SPEED
INTERLOCKS 1 CR IF
INTERLOCK SWITCH
IS CLOSED
WELDING
LN-8
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F-11
F-11
TROUBLESHOOTING AND REPAIR
FIGURE F.1 – LN-8 ELECTRICAL SEQUENCE OF OPERATION (continued)
WELDING
RELEASE
GUN TRIGGER
BREAK
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
POWER SOURCE
PILOT RELAY
DISCONNECTS MOTOR ARMATURE
AND CONTROL CIRCUIT FROM
INPUT AC LINE - (DE-ENERGIZES
AUX. EQUIPMENT IF CONNECTED)
REVERSES
MOTOR FIELD
3CR (NOTE 3)
REED SWITCH
MOMENTARILY
CLOSES
DE-ENERGIZES
POWER SOURCE
CONTACTOR
DYNAMIC BRAKE
CURRENT FLOWS
THROUGH FREE
ELECTRODE IS
COLD TO WORK
DISCHARGES SLOW
ACCELERATION
WHEELING DIODE (D-7 ON
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
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F-12
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 (WELD).
_____________________________________________________________
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
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F-13
F-13
TROUBLESHOOTING AND REPAIR
TRIGGER TRANSFORMER TEST (continued)
FIGURE F.2 – TRIGGER TRANSFORMER TEST POINTS
6 5 4
RED
3 2 1
BLACK
BLACK
RELAY
BOARD
5. Using the voltmeter, check for
TEST PROCEDURE
approximately 24VAC at the red
secondary leads, pins 1 and 4.
1. Remove input power to the LN-8.
6. 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.
2. Using the 5/16 in. nutdriver,
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. Reconnect the Molex plug to the
underside of the relay board.
4. Apply power (115VAC) to the
black primary transformer leads,
pins 2 and 3.
8. Install the screws that secure the
left side cover assembly.
LN-8
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F-14
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
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F-15
F-15
TROUBLESHOOTING AND REPAIR
INTERNAL VOLTAGE TEST (continued)
FIGURE F.3 – VOLTAGE TEST POINTS
INPUT
RECEPTACLE
32
32A
B
INPUT
CIRCUIT
BREAKER
C
E
A
115 VAC
APPLIED
CONTROL
BOARD
PIN #12
(32A)
H
D
CONNECTOR
PLUG
G
F
PIN #2
(7)
CONTROL
BOARD
541
539
PIN #1 PIN #4
(32A) (531)
627
626
E
A
D
7
32A
525
(A)
2 OHM
RESISTOR (R4)
GUN TRIGGER
RECEPTACLE
31
531
RELAY
BOARD
B
C
4. Apply 115VAC to the input
receptacle at pins C and D.
TEST DESCRIPTION
1. Remove input power to the LN-8.
5. Using the voltmeter, carefully
test the voltages per Table F.1
at the test points shown in
Figure F.3.
2. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
6. When testing is complete,
install the screws that secure
the left side cover assembly.
3. Lift the left side cover.
LN-8
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F-16
F-16
TROUBLESHOOTING AND REPAIR
INTERNAL VOLTAGE TEST (continued)
TABLE F.1 – VOLTAGE TEST POINTS
ACCEPTABLE
VOLTAGE
CHECKPOINT
LOCATIONS
TEST
DESCRIPTION
LEAD NO.
READING
Input Circuit Breaker
and
Input voltage before the
circuit breaker and 2
ohm resistor (R4).
#31 and #32
103 to 126VAC
103 to 126VAC
103 to 126VAC
34 to 42VDC
Resistor R4
Input Circuit Breaker
and
Input voltage after the
circuit breaker.
#31 and #32A
#531 and #32A
Resistor R4
Input Circuit Breaker
and
Input voltage after the
circuit breaker and 2
ohm resistor (R4).
Resistor R4
Gun trigger receptacle
pins A and C
Check voltage across
gun trigger -
#524 (pin A) and
#528 (pin C)
- trigger open.
Terminals #7 and #32A
located on relay board
Auxiliary terminals
(gas solenoid)
#7 and #32A
103 to 126VAC
Note: Gun trigger must
be activated.
Terminals #626 and
#627 located on relay
board
Drive motor field
voltage.
#626 and #627
#539 and #541
102 to 125VDC
Terminals #539 and
#541 located on control
board
Drive motor armature
voltage.
Note: Gun trigger must
be activated and
4VDC (min) -
90VDC (max).
armature voltage will
be dependent upon wire
speed setting.
Control board
connector plug
Check that 115VAC is
being applied to control
board when gun trigger
is activated.
#32A (pin 12) and
#7 (pin 2)
103 to 126VAC
103 to 126VAC
Relay board connector
plug
Check that 115VAC is
being applied to the
control board.
#32A (pin 1) and
#531 (pin 4)
LN-8
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F-17
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 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 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
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F-18
F-18
TROUBLESHOOTING AND REPAIR
1CR RELAY TEST (continued)
FIGURE F.4 – 1CR RELAY TEST POINTS
2
5
3
6
1
4
NORMALLY CLOSED
NORMALLY OPEN
8
9
7
COMMON
A
B
-
+
24VDC
1CR RELAY
RETAINING
CLIP
MOLEX
PLUG
RELAY
BOARD
Note: The Molex plug located on the
relay board may have to be removed to
gain access to the 1CR relay.
TEST PROCEDURE
1. Remove input power to the LN-8.
5. Connect the 24VDC supply to ter-
minals A- and B+ on the 1CR
relay. Do not energize the power
supply at this time.
2. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
3. Lift the left side cover.
6. Connect the ohmmeter across the
first set of terminals shown in
Table F.2.
4. Locate the 1CR relay. Slide the
retaining clip off the relay and
carefully remove the relay from the
relay board. See Figure F.4.
LN-8
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F-19
F-19
TROUBLESHOOTING AND REPAIR
1CR RELAY TEST (continued)
TABLE F.2 – RELAY TEST TERMINAL CONNECTIONS
Terminals
A&B
Terminals
A&B
De-energized
Closed
Open
Terminals
7-1
Energized
Open
7-4
Closed
Open
8-2
Closed
Open
8-5
Closed
Open
9-3
Closed
Open
9-6
Closed
8. Repeat the above procedure for all
of the contacts.
7. Measure the resistance across the
contacts. A resistance of less than
one ohm indicates that the con-
tacts are closed. An infinite resis-
tance indicates that the contacts
are open. Energize the 24VDC
power supply and measure the
resistance again. Compare to the
conditions given in Table F.2. If the
readings do not match the table,
the relay is faulty and should be
replaced.
9. Re-install relay into the relay
board.
10. Install the screws that secure the
left side cover assembly.
LN-8
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F-20
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
Variable DC voltage supply 0 to 90VDC
Isolated DC voltage supply 120VDC
LN-8
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F-21
F-21
TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST (continued)
FIGURE F.5 – DRIVE MOTOR TEST POINTS
#541
#539
#626
#627
3. Using the 5/16 in. nutdriver,
TEST PROCEDURE
remove the screws from the left
side cover assembly.
1. Remove input power to LN-8.
4. Lift the left side cover.
2. Remove the electrode wire or dis-
engage drive rolls.
5. Locate leads #539 and #541 at the
control board. See Figure F.5.
LN-8
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F-22
F-22
TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST (continued)
FIGURE F.6 – GUN TERMINAL JUMPER LOCATIONS
1CR
RELAY
627
626
7
529 32A 524(A) 525(A)
6. Locate leads #626 and #627 at the
relay board.
#627. Normal is 115VDC. When
the gun trigger is activated or the
gun terminals jumpered together,
Figure F.6, the field voltage polari-
ty should reverse from the idle
state. Normal is 115VDC and is
independent of motor speed.
7. If a variable voltage board is
installed in the LN-8, make cer-
tain the mode switch is in the CV
position.
8. Apply 115VAC to the input recep-
tacle at pins C and D.
Note: The wire feed direction switch
(S3) must be in the forward, or “weld-
ing” position.
9. With the gun trigger 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.
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.
10. With the LN-8 at idle (gun trigger
NOT activated) check the motor
field voltage at lead #626 and
LN-8
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F-23
F-23
TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST (continued)
To further check the drive motor:
3. Apply field voltage first (leads #626
and #627) to the motor. Then
slowly apply the armature voltage
at leads #539 and #541.
12. Remove input power (115VAC)
from the LN-8.
13. Locate and remove leads #539
and #541 from the control board,
see Figure F.5.
4. The motor should run and the
speed should vary with changes to
the armature voltage.
14. Locate and remove leads #626
and #627 from the relay board.
5. If the motor does NOT run and
change speed correctly, the motor
or gear box may be faulty.
15. Using the ohmmeter, measure the
resistances per Table F.3.
6. To stop the motor, remove the
armature voltage first, leads #539
and #541.
16. If the motor resistance test is
good, proceed to the Motor
Applied Voltage Test.
AFTER TESTING
MOTOR APPLIED
VOLTAGE TEST
1. Replace motor leads.
2. Install the screws that secure the
left side cover assembly.
1. Carefully connect the isolated
120VDC supply (supply turned off)
to motor leads #626 and #627, see
Figure F.5.
3. If disengaged, engage the drive
rolls.
4. If removed, feed the electrode
back into the wire drive unit.
2. Carefully connect the variable 0 to
120VDC supply (supply turned off)
to motor leads #539 and #541.
TABLE F.3 – DRIVE MOTOR TEST POINTS
TEST POINTS
RESISTANCE
DC VOLTAGE
0 to 90VDC
Lead #539 to #541
Armature
3 to 5 ohms
Lead #626 to #627
Field Winding
750 to 950 ohms
90 to 120VDC
N/A
All leads to
motor shell
500,000 ohms
min.
LN-8
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F-24
F-24
TROUBLESHOOTING AND REPAIR
POTENTIOMETER 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
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
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F-25
F-25
TROUBLESHOOTING AND REPAIR
POTENTIOMETER REPLACEMENT (continued)
FIGURE F.7 – POTENTIOMETER REMOVAL
POTENTIOMETER
NUT
KNOB
INSULATION
LOCKWASHER
SET
SCREW
where they were removed.
Unsolder the three wires from the
potentiometer.
REPAIR PROCEDURE
1. Remove input power to the LN-8
7. Solder the three wires to the new
potentiometer on the correspond-
ing terminals from where they were
removed.
2. Using the 5/16 in. nutdriver,
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.
Tighten the set screw.
6. Tag the three wires on the poten-
tiometer so that they can be reat-
tached in the same location from
10. Install the screws that secure the
left side cover assembly.
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F-26
F-26
TROUBLESHOOTING AND REPAIR
CIRCUIT BREAKER 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
5/16 in. nutdriver
9/16 in. wrench
This procedure takes approximately 6 minutes to perform.
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F-27
F-27
TROUBLESHOOTING AND REPAIR
CIRCUIT BREAKER REPLACEMENT (continued)
FIGURE F.8 – CIRCUIT BREAKER AND GROUND LEAD PROTECTOR REPLACEMENT
CIRCUIT
BREAKER
SCREW
RETAINING
NUT
GROUND LEAD
PROTECTOR SWITCH
SWITCH
MOUNT
FLATWASHER
LOCKWASHER
NUT
on the wire feeder. Remove the
circuit breaker from the wire
feeder.
REPAIR PROCEDURE
1. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
4. Install the new circuit breaker
through the panel of the control
box. Secure the circuit breaker
with the retaining nut.
2. Tag and remove the two connec-
tors from the back of the circuit
breaker. Refer to Figure F.8.
5. Install the connectors onto the
back of the circuit breaker at the
positions they were removed from.
3. Using the 9/16 in. wrench, remove
the retaining nut that secures the
circuit breaker to the center panel
6. Install the screws that secure the
left side cover assembly.
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F-28
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 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
3/32 in. wrench
Jewelers’ flat blade screwdriver
Soldering iron and solder
This procedure takes approximately 10 minutes to perform.
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F-29
F-29
TROUBLESHOOTING AND REPAIR
GROUND LEAD PROTECTOR PUSH BUTTON
SWITCH REPLACEMENT (continued)
3. Remove insulation and unsolder
REPAIR PROCEDURE
the two leads from the ground lead
protector switch.
1. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
4. Solder the two leads onto the
new switch and reinsulate the
connections.
2. 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 F.8.
5. Place the switch onto the switch
mount and install the screws, flat
washers, lockwashers and nuts
that secure the switch into place.
6. Install the screws that secure the
left side cover assembly.
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F-30
F-30
TROUBLESHOOTING AND REPAIR
TRIGGER TRANSFORMER 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
5/16 in. nutdriver
Flat blade screwdriver
Needlenose pliers
This procedure takes approximately 12 minutes to perform.
LN-8
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F-31
F-31
TROUBLESHOOTING AND REPAIR
TRIGGER TRANSFORMER REPLACEMENT (continued)
FIGURE F.9 – TRIGGER TRANSFORMER REMOVAL
ROUNDHEAD
SCREW
RELAY
PC BOARD
INSULATION
SHEET
TRIGGER
TRANSFORMER
NUT
5. Place the insulation sheet and new
trigger transformer into the case
and install the screws and nuts
that secure the transformer in
place.
REPAIR PROCEDURE
1. Using the 5/16 in. nutdriver
remove the screws from the left
side cover assembly.
6. Install the Relay PC board as
described in the PC Board
Replacement procedure.
2. Remove the Relay PC board as
described in the PC Board
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
F.9.
8. Install the screws that secure the
left side cover assembly.
4. Using a flat blade screwdriver and
needlenose pliers, remove the trig-
ger transformer and insulation
sheet from the case.
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F-32
F-32
TROUBLESHOOTING AND REPAIR
PC BOARD 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
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.
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F-33
F-33
TROUBLESHOOTING AND REPAIR
PC BOARD REPLACEMENT (continued)
FIGURE F.10 – PC BOARD LOCATIONS
CONTROL
PC BOARD
VARIABLE
VOLTAGE
PC BOARD
RELAY
PC BOARD
REPAIR PROCEDURE
2. Using a Phillips screwdriver,
remove the screws that secure the
variable voltage PC board to the
case.
1. Observe the static precautions
detailed in the PC Board
Troubleshooting Procedures at
the beginning of this section.
NOTE: The screws that secure the
Variable Voltage PC board are on the
wire drive assembly side of the unit.
2. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
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.
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.
4. Place the new PC board into the
case and install the mounting
screws.
VARIABLE VOLTAGE BOARD
REMOVAL AND REPLACEMENT
5. Connect all plugs and connectors
to the PC board in the same loca-
tion they were removed from.
1. Disconnect all plugs and connec-
tors that can be reached without
removing the variable voltage PC
board. Refer to Figure F.10.
6. Install the screws that secure the
left side cover assembly.
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F-34
F-34
TROUBLESHOOTING AND REPAIR
RELAY BOARD REMOVAL AND
REPLACEMENT
CONTROL PC BOARD
REMOVAL AND
REPLACEMENT
1. If the Relay PC board is being
replaced, remove the 1CR Relay
from the PC board.
1. Disconnect all plugs and connec-
tors from the Control PC board.
2. Disconnect all plugs and connec-
tors.
2. Using a Phillips screwdriver,
remove the screws that secure the
Control PC board to the case.
3. Remove mounting screws.
3. Carefully move the Control Board
away from the case. Check to
ensure that all plugs and connec-
tors have been disconnected.
4. Place the new PC board into the
case and install the mounting
screws.
5. Install the 1CR Relay into the PC
board.
4. Place the new PC board into the
case and install the mounting
screws.
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.
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
left side cover assembly.
6. Connect all plugs and connectors
to the PC board in the same loca-
tion they were removed from.
7. Install the screws that secure the
left side cover assembly.
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F-35
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
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F-36
F-36
TROUBLESHOOTING AND REPAIR
WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT (continued)
FIGURE F.11 – DRIVE MOTOR ELECTRICAL CONNECTIONS
YELLOW
(#525)
BLACK
(#541)
BLUE
(#539)
WHITE
(#627)
RED
(#626)
BLUE (TWO)
GREEN
(#528)
(GROUND)
YELLOW
(#528)
4. Using a Phillips screwdriver, dis-
REPAIR PROCEDURE
connect the drive motor ground
lead (green) from the case.
1. Using the 5/16 in. nutdriver,
remove the screws from the left
5. Separate ground lead protection
side cover assembly.
wire #525 (yellow) at the in-line
connector.
2. Disconnect drive motor leads #539
(blue) and #541 (black) from the
6. Remove the insulating tape from
back of the Control PC board.
wire #528 (yellow) and disconnect
Refer to Figure F.11.
it from the reed switch wire and
gun receptacle wire (#528, and
3. Disconnect drive motor leads #626
both blue leads) using a 11/32 in.
(red) and #627 (white) from the
wrench and a Phillips screwdriver.
side of the Relay PC board.
See the wiring diagram.
LN-8
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F-37
F-37
TROUBLESHOOTING AND REPAIR
WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT (continued)
FIGURE F.12 – REED SWITCH REMOVAL AND SHUNT ELECTRICAL CONNECTIONS
HEX HEAD
SCREWS
REED
SWITCH
BRACKET
SHUNT
#568
#567
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.
the front of the wire drive assem-
bly. Slide the bracket off the front
of the wire drive assembly.
9. 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.
8. Using a 7/16 in. wrench, loosen
the two hex head screws that
secure the reed switch bracket to
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F-38
F-38
TROUBLESHOOTING AND REPAIR
WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT (continued)
FIGURE F.13 – WIRE DRIVE ASSEMBLY REMOVAL
BRUSH
WIRE
DRIVE
MOTOR
BRUSH
SCREW
GEARBOX
INSULATION
SHEET
MOUNTING
PLATE
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, and remove the mount-
ing plate and insulation sheet.
Refer to Figure F.13.
that secure the drive motor to the
gearbox assembly, and remove
the drive motor.
12. For further disassembly of the wire
drive assembly, refer to Figure
F.13.
11. Using a flat blade screwdriver,
remove the three screws, lock-
washers, flat washers and spacers
13. Secure the drive motor to the gear-
box assembly using three screws,
lockwashers, flat washers, and
spacers.
LN-8
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F-39
F-39
TROUBLESHOOTING AND REPAIR
WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT (continued)
14. 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.
18. Connect the #528 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.
19. Connect the drive motor wire #525
(yellow) to the ground lead protec-
tion wire at the in-line connector.
15. Place the wire drive assembly into
the case. Secure the wire drive
assembly using three round head
screws and lockwashers.
20. Connect the drive motor ground
lead (green) to the case.
16. 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 Figure F.12.
21. Connect the drive motor leads
#539 (blue) and #541 (black) to
the back of the Control PC board.
22. Connect drive motor leads #626
(red) and #627 (white) to the side
of the Relay PC board.
17. Connect the two #567 (blue) leads
and the #568 (blue) lead to the
shunt. Note lead placement. Refer
to Figure F.13.
23. Install the screws that secure the
left side cover assembly.
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F-40
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 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
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board (L5767) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable Voltage Board (L5039) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board (L5767) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable Voltage Board (L5039) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-2
G-3
G-4
G-5
G-6
G-7
G-8
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G-2
G-2
ELECTRICAL DIAGRAMS
Wiring Diagram
LN-8N, -8NE, -8S, AND -8SE WIRING DIAGRAM
JUMPER CONNECTOR IS REMOVED AND CONNECTOR
"A" PLUGGED INTO OPTIONAL VARIABLE VOLTAGE
P.C. BOARD
BURNBACK
POWER SOURCE BOARD.
N.B.
2
4
531
4
502
32A
5
(OPTIONAL)
504
JUMPER CONNECTOR IS REMOVED
AND CONNECTOR "B" PLUGGED
INTO OPTIONAL BURNBACK
P.C. BOARD.
567
3
636
21
1
635
4
637
6
WIRE FEED
SPEED
*
32A
7
541
8
2
11
5
1
2
6
3
RHEOSTAT
CONTROL
P.C.
BOARD
632
CONNECTOR "A"
2
5
2
4
531
502
504
32A
VARIABLE VOLTAGE
P.C. BOARD
543
32A
637
636
635
631
632
634
10
12
*
CONNECTOR "B"
541
5K OHMS
634
631
(OPTIONAL)
635
637
*
21
636
567
7
6
1
J1
THERMAL CIRCUIT
BREAKER
R
626
539
POWER SOURCE
OUTPUT
RHEOSTAT
5 AMP CIRCUIT BREAKER
B
541
9
4
3
32A
76
WIRE
FEED
MOTOR
INTERLOCK SWITCH
528
525
32
DIRECTION
OF WIRE
627
536
682
FEED
683
683
10K OHMS
75
OFF
U
539
ON
SWITCH
523
77
W
W
627
W
G
BEAD PINS ON
BOTTOM OF BOARD
GROUNDING
LEAD
W
LOW VOLTAGE
TRIGGER
R
32A
531
502
536
PROTECTOR
B
7
9
1CR
526
531A
32A
522
504
10
523
627
682
525
4
2
3
1
6
5
TRANSFORMER
525A
B
R
4CR
2
4
31
32
21
A
B
C
D
E
5
12
8
6
11
1
3
7
2
4
1/ 2AMP 125V.
RELAY
P.C. BOARD
GND
*
OR 250V. SLOW
BLOW FUSE
627
626
32A
7
525A
524
529
75
76
F
G
N.A.
524
528
A
B
C
D
E
77
H
I
QUICK CONNECT TERMINALS 7 & 32A
TO CONNECT AUXILIARY EQUIPMENT
115 V.A.C., .25 AMP RATING
G
GND
.1 OHMS
531
529
528
2CR REED SWITCH
568
543
567
CASE
GROUNDING
SCREW
GND
21
541
9
567
GUN CABLE
31
568
CASE
BOLTED
CONNECTION
GROUNDING
SCREW
OPTIONAL METER
KIT RECEPTACLE
2 OHMS
4
7
1
3
8
5
6
2
METER SHUNT
METER KIT
*
WORK
RELAY AND
CONTROL BOARD
RECEPTACLE
LEAD COLOR CODING
CONNECTOR CAVITY NUMBER
TO CONTACTOR CIRCUIT
115 VAC
*
W = WHITE
U = BLUE
B = BLACK
G = GREEN
10
11
12
1 4
3
2
4
7
8
9
6
5
4
1
9
8
BURNBACK
CONNECTIONS AS VIEWED FROM
BACK OF RHEOSTATS WHEN
COVER IS UP
2
3
5
6
2
5
6
AND VARIABLE
TO POWER SOURCE WORK
TERMINAL
R = RED
7
VOLTAGE BOARD
1
3
NOTES:
PIN SIDE OF
CONNECTOR
N.A. RESISTOR USED ON CODES 9090 AND BELOW. FOR CODES ABOVE 9090
THE GROUNDING LEAD PROTECTOR CONNECTS DIRECTLY TO THE CASE
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF BOARD)
GROUNDING SCREW.
N.B. THE VARIABLE VOLTAGE BOARD IS FACTORY INSTALLED IN CV-VV MODELS
AND DOES NOT INCLUDE JUMPER CONNECTOR.
ELECTRICAL SYMBOLS PER E1537
2-1-2002M
M14679
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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G-3
G-3
ELECTRICAL DIAGRAMS
CONNECTION SCHEMATIC
1 4 6 M 6 9
W O R K T O P O W E R S O U R C E
5 2 2
3 2 A
5 3 1 A
5 2 6
5 2 9
5 2 5 A
5 2 3
5 3 6
2
E L E C T R O D E T O P O W E R S O U R C E
Ch’ge. Sht. No.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E2056
THIS SHEET CONTAINS PROPRIETARY INFORMATION
EQUIP.
TYPE
LN-8N AND -8S
THE LINCOLN ELECTRIC CO.
OWNED BY
AND IS
3-31-83N
11-14-86G
2-13-87G
THE LINCOLN ELECTRIC CO.
ON 2 PLACE DECIMALS IS .02
CLEVELAND, OHIO U.S.A.
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
ON 3 PLACE DECIMALS IS .002
ON ALL ANGLES IS .5 OF A DEGREE
CONNECTION SCHEMATIC
SUBJECT
NONE
SCALE
SHT.
NO.
t
MATERIAL TOLERANCE (" ") TO AGREE
3-4-83
THE LINCOLN ELECTRIC CO.
14669
6-20-97
FI
REF.
DR
DATE
CHK
SUP’S’D’G
M
WITH PUBLISHED STANDARDS.
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.
LN-8
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G-4
G-4
ELECTRICAL DIAGRAMS
OPERATING SCHEMATIC
75
CASE
N.A. JUMPER PLUG IS REMOVED AND CONNECTOR "B" IS PLUGGED INTO
METER KIT RECEPTACLE
GROUNDING
SCREW
OPTIONAL BURNBACK P.C. BOARD. SEE S15123 FOR OPERATING
SCHEMATIC.
76
GND
21
543
568
541
567
N.B. RESISTOR USED ON CODES 9090 AND BELOW ONLY. FOR CODES
ABOVE 9090 THE GROUNDING LEAD PROTECTOR CONNECTS
DIRECTLY TO THE CASE GROUNDING SCREW.
THERMAL
CIRCUIT
77
GND LEAD
PROTECTOR
SWITCH
5 AMP CIRCUIT
BREAKER
D103
D104
BREAKERS
R126
32A
568
567
32A
32
R127
R124
R125
B
635
C113
525
528
S304
PT301
R306
N.A.
A
TH1
524
2CR
529
D101
32A
531
4
504
502
2
S
F
S1
TO
5
4
2
3
6
1
GUN
VV
CV
CABLE
541
(B)
Q101
DZ301
C306
LN-8
SHUNT
Q103
PT101
PT101
683
TO POWER
SOURCE TO
OPERATE
S2
682
S3
Q302
637
SCR101
SCR102
D109
627
(U)
CONTACTOR
7
T1
D204
D110
2
C109
ARC
VOLTAGE
1CR
DZ302
R101
(W)
Q102
R122
TP101
1CR
504
4
GND LEAD
PROTECTOR
COIL
631
1CR
C111
C202
QU301
D112
(R)
TO
WIRE
Q301
C307
QU101
POWER
FEED
MOTOR
FIELD
SCR
201
626
SOURCE
GND
634
N.B.
21
R311
531
539
CASE GROUNDING
SCREW
531
31
R4
VARIABLE VOLTAGE CONTROL CIRCUIT TO RIGHT OF THIS LINE. TO
OPERATE LN-8 WHEN THIS CIRCUIT IS NOT INSTALLED IN UNIT,
RELAY CIRCUIT (BOARD #2)
CONTROL CIRCUIT (BOARD #1)
POINT "A" TO "B" IS JUMPERED.
C201
C202
C203
C204
C205
C206
1CR
D201
D202
D203
D204
D205
R201
R202
R203
R204
R205
R206
F201
50MFD
.02MFD
50MFD
.005MFD
50MFD
.005MFD
C101 1MFD
C102 2MFD
C103 39MFD ~10%
C104 4.7MFD
C105 .10MFD
C106, C110,C111
C112, C113
C107, C108
C109 .005MFD
L101
Q101
Q102
Q103
5.6MH
VARIABLE VOLTAGE CIRCUIT (BOARD #3)
COMPONENTS NOT ON P.C. BOARD
2N4125
2N4123
2N5815
C301
C302
C303
C304
C305
C306, C307
D301
D302
D303
2MFD
.10MFD
.01MFD
.047MFD
.01MFD
.02MFD
1A.
2A.
3A.
4A.
62V
R301
R302
R303
R304
R305
R306
R307
R308
R309
R310
R311
S304
6.8K
5.6K (2%)
1K (2%)
3.9K (2%)
3.3K
4.7K 2W
100
R4
2
50W
R9
5K 2W POT.
R20
T1
10K 2W POT.
QU101 2N6027
TP101 TRANSIENT PROTECTION
110-24V TRANSFORMER
REED SWITCH (ACTUATED BY WELDING CURRENT)
GROUNDING LEAD PROTECTOR
SPST GUN SWITCH
.02 MFD
3PDT 24V.D.C.
2CR
4CR
S1
SCR101 12A 400V
SCR102 12A 400V
1A.
1A.
1A.
1A.
1A.
40 12W
100
100K
.047MFD
PT101
1:1:1 PULSE TRANSFORMER
5K TRIMMER
S2
S3
SPDT INTERLOCK SWITCH
SPDT DIRECTION SWITCH
15
47
68
D101
D102
D103
D104
D105
D106
D107
D108
D109
D110
D111
D112
D113
D114
1A.
1A.
1A.
1A.
16A.
16A.
16A.
1A.
1A.
1A.
1A.
1A.
1A.
1A.
R101
R102
R103
R105
R106
R107
R108
R109
R110
R111
R112
R113
R114
R115
6.8K
2K TRIMMER
10K
4.7K
4.7K
15
33K
33K
R116 10K
R117 22K
D304
FOR CONTROL P.C. BOARDS L5767-1 AND HIGHER, USE
M16802 SCHEMATIC FOR COMPONENT VALUES AND
CIRCUIT CONNECTIONS
DZ301
DZ302
Q301
R118 4.7K 4W
R119 27K
10V
2N3393
2N4125
POWER SOURCE
SELECTOR SWITCH
UJT
FOR VARIABLE VOLTAGE P.C. BOARD L5039-1 OR HIGHER,
USE M16441 SCHEMATIC FOR COMPONENT VALUES AND
CIRCUIT CONNECTIONS
R120 15K
R121 1.5K
R122 10K
27
4.7K
1K
Q302
QU301
PT301
TP301
1:1:1 PULSE TRANSFORMER
TRANSIENT PROTECTION
R123 .25 7W
R124 1K TRIMMER
R125 4.7K 4W
R126 1K TRIMMER
R127 150
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT
BOARD MAY CHANGE WITHOUT AFFECTING THE INTER-
CHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM
MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY
1/2A 125V CR 250V
SLOW BLOW FUSE
SCR201 4A 400V
TP201 TRANSIENT PROTECTION
750
50K TRIMMER
LEAD COLOR CODING
ELECTRICAL SYMBOLS
PER E1537
27K
39K
10K
68K
B - BLACK
R - RED
U - BLUE
W - WHITE
OF CONTROLS HAVING A COMMON CODE NUMBER.
R128 1K
R129 15K
12-3-92E
M14680
DZ101 20V.
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.
Download from Www.Somanuals.com. All Manuals Search And Download.
LN-8
G-5
G-5
ELECTRICAL DIAGRAMS
CONTROL BOARD (L5767) SCHEMATIC
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 repaiDrsowcnoloualddfrroemsuWlwt win.Sdomamanauaglse.cotom.thAlel MmanaucahlsinSeea.rch And Download.
LN-8
G-6
G-6
ELECTRICAL DIAGRAMS
VARIABLE VOLTAGE BOARD (L5039) SCHEMATIC
12-3-92E
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.
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G-7
G-7
ELECTRICAL DIAGRAMS
CONTROL BOARD (L5767) LAYOUT
ITEM
REQ’D. PART No.
IDENTIFICATION
C1
C2
C3
C4
C5
1
1
1
1
1
5
2
1
S13490-42
S13490-67
S13490-104
S13490-25
T11577-26
S16668-5
1.0/35
2/50
39uF/20V
4.7/35
.1/100
C6,C10,C11,C12,C13
C7,C8
C9
.022/50
.047/100
.0047 or .005/1400
S13490-102
T11577-52
D1,D2,D8,D9,D10,D11,D12,D13,D14
D3,D4
DZ1
9
T12199-1
T12199-2
T12702-4
T12702-29
1N4004
1N4007
IN4747
2
1
1
DZ2
1N4744A
L1
PT1
1
1
T12218-2
T12737-2
5.6mH
1:1:1
N
2 1 3 O 4 5 6 7 8
Q1,Q3
Q2
QU1
2
1
1
T12704-69
T12704-68
T12707-4
2N4403
2N4401
2N6027
R1
R2
1
1
4
2
1
2
1
1
1
1
1
1
2
1
2
1
1
2
1
2
1
S19400-6811
T10812-73
2K 1/2W
R3,R14,R16,R22
R5,R6
R7
R8,R9
R10
R11
R12
R13
R15
R17
R18,R25
R19
R20,R29
R21
R23
R24,R26
R27
R28,R31
R30
S19400-1002
S19400-4751
S19400-15R0
S19400-3322
S19400-7500
T10812-39
S19400-2672
S19400-3922
S19400-6812
S19400-2212
T14648-11
50K 1/2W
4700 5W
S19400-5622
S19400-1502
S19400-1501
T14764-2
.25 7W
1K 1/2W
T10812-68
S19400-1500
S19400-5110
S19400-5232
SCR1,SCR2
TP1
2
1
S15161-6
T13640-11
2N6397
45J
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS/ 1/4W UNLESS OTHERWISE SPECIFIED
INDUCTANCE = HENRYS
1-24-97B
L5767-1
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 repairsDcoowunllodadrefrosmulWt iwnwd.Saommaanguealst.ocomth.eAllmMaacnuhailnseS.earch And Download.
LN-8
G-8
G-8
ELECTRICAL DIAGRAMS
VARIABLE VOLTAGE BOARD (L5039) LAYOUT
ITEM
REQ’D
PART NO.
IDENTIFICATION
CAPACITORS = MFD VOLTS
INDUCTANCE = HENRY
8-31-2001E
L5039-1
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.
Download from Www.Somanuals.com. All Manuals Search And Download.
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:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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