Lincoln Electric LN-15 Service Manual Download Page 70

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LN-15

F-32

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TROUBLESHOOTING AND REPAIR

BOOST POWER SUPPLY BOARD

REMOVAL AND REPLACEMENT PROCEDURE (Continued)

Figure F.11 - BOOST POWER BOARD LOCATION

REMOVAL PROCEDURE

1. Remove input power to the LN-15.

2. Perform the Cover and Spindle

Mount Removal Procedure.

3. Locate the Boost Power Supply Board.

See Figure F.11.

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

5. Using the 3/8” wrench remove the

three nuts holding the board in place.

6. Carefully remove the Boost Power

Supply Board.

REPLACEMENT PROCEDURE

1. Set the new Board on the mounting

studs.

2. Secure with the three nuts previously

removed.

3. Replace plug J47 previously removed.

See Figure F.12.

4. Replace the Cover and Spindle mount.

BOOST POWER BOARD

Summary of Contents for LN-15

Page 1: ...TIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machines having Code Number 11033 11035 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S...

Page 2: ...US INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free cop...

Page 3: ...e work or metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total ...

Page 4: ...area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent h...

Page 5: ...à proximité au soudage à l aide d écrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans laterau...

Page 6: ...FOR ALL SECTIONS Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual P482 Series ...

Page 7: ...C Return to Master TOC LN 15 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation Section A Technical Specifications A 2 Safety Precautions A 3 High Frequency Protection A 3 Connections A 4 Gun Cable Assembly A 6 Feeding Wire Electrode A 7 ...

Page 8: ...RAGE 40o C to 70o C 40o F to 185o F RATED CURRENT INPUT VOLTAGE TECHNICAL SPECIFICATIONS LN 15 K1870 1 K1870 2 CE HEIGHT WIDTH DEPTH WEIGHT 12 7 Inches 8 7 Inches 23 Inches 30lbs 323 mm 221mm 584 mm 14kg SPOOL SIZE CAPABILITY 8 200mm Dia x 4 100mm Wide Spools including AWS 8 DIA 10 15lbs JIS S 3 200mm max 5 7 kg DIN 200 5 kg ELECTRODE DIAMETERS and SPEED RANGE PHYSICAL DIMENSIONS Electrode Size Sp...

Page 9: ...ctrically hot even if the gun trigger is off Care should be taken to only handle the LN 15 work clip lead by its nonmetal insulated portions and or the welding power source should be turned off before handling the work clip Do not attach the work clip lead to the roll cage or bottom skids of the LN 15 Attach the work clip only to the work piece The work clip lead is present only on Across the Arc ...

Page 10: ...5 can be used with any DC welding power source A constant voltage power source is recom mend however the LN 15 can also be used with a constant current power source as long as the open cir cuit voltage is less than 110VDC To prevent possible damage to the LN 15 do not connect the LN 15 to non Lincoln TIG or square wave power sources TIG high frequency should never be applied to the LN 15 WARNING C...

Page 11: ...er K1870 1 wire feeder K1870 1 wire feeder K1870 1 CV655 DC400 DC600 DC655 V350 PRO RANGER 9 RANGER 300 DLX COMMANDER 300 COMMANDER 500 RANGER 250 RANGER 305G Output Output Terminals erminals Always Hot Always Hot Power source contactor Power source contactor switch must be in the switch must be in the ON position or use a ON position or use a K848 Junper Plug Kit CONNECTION DIAGRAM ACROSS THE ARC...

Page 12: ... control cable Table A 2 Trigger Connector J1 5 Pin PIN Lead Function A 556 Trigger B Not used C 554 Trigger 83 Procedure ground D 555 83 Procedure E 554 Trigger 83 Procedure ground PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES Turn off input power at the welding power source before installation or changing drive roll and or wire guides Do not touch electrically live parts 0such as the wire dri...

Page 13: ... or spool until the free end of the elec trode is accessible 2 While tightly holding the electrode cut off the bent end and straighten the first 6 15 cm Cut off the first 1 2 5 cm If the electrode is not properly straightened it may not feed or may jam 3 Insert the free end through the incoming guide bush ing 4 Press the Cold Feed switch and push the electrode into the drive roll 5 Feed the electr...

Page 14: ...LN 15 NOTES A 8 A 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 15: ...ration Section B Safety Precautions B 2 General Description B 3 Duty Cycle B 3 Operational Features and Controls B 3 Case Front Controls B 4 Power up Sequence B 5 CV CC Mode B 6 WFS Units B 6 Internal Controls B 6 Cold Feed Gas Purge Switch B 7 Two Step Trigger Interlock B 8 Constant Current Operation B 9 Setting Wire Feed Speed B 10 Making a Weld B 11 ...

Page 16: ...t the results obtained in using the LN 15 wire feeder These variables include but are not limited to welding proce dure plate chemistry and temperature weld ment design fabrication methods and service requirements The available range of the LN 15 wire feeder may not be suitable for all applica tions and the builder user is and must be sole ly responsible for welding settings FUMES AND GASSES can b...

Page 17: ...the work clip to the work piece and then connect the LN 15 to the electrode cable to the power source and it is ready to weld An internal contactor in Across the Arc Models ener gizes the electrode output in response to the gun trig ger DUTY CYCLE The LN 15 wire feeders are intended for semi auto matic use The maximum rating of the LN 15 is based upon a 60 duty cycle welding 6 minutes of welding f...

Page 18: ...s minute 1 27 m min The 83 procedure is most commonly used during pipe and out of position welding Requires Magnum 400 Dual Procedure Gun Equivalent FIGURE B 1 CASE FRONT CONTROLS See Figure B 1 ACROSS THE ARC MODEL 1 WIRE FEED SPEED DISPLAY The Wire Feed Speed display shows the rate the LN 15 will feed electrode during welding The default WFS units for domestic models are inches minute and can be...

Page 19: ...econds no other action is taken the LN 15 will then revert to normal operation 2 Rotate the WFS knob until the desired timer is dis played Preflow Postflow Burnback 3 Activate and then release the GAS PURGE switch to select the timer The time will then display in the right hand side of the display Example 4 Rotate the WFS knob to adjust the time to the new setting 5 Press the GAS PURGE switch agai...

Page 20: ...H 2 STEP TRIGGER INTERLOCK SWITCH SPINDLE BRAKE INTERNAL CONTROLS Figure B 2 Rotate the WFS knob until the desired parameter is displayed CV CC Mode WFS Units 2 Activate and release the GAS PURGE switch to select the parameter The present value will then display in the right hand side of the display Example 3 Rotate the WFS knob to change the parameter set ting CV CC MODE CU for Constant Voltage p...

Page 21: ...er source nor the gas solenoid will be energized Adjust the speed of cold feeding by rotating the WFS knob Cold feeding or cold inching the electrode is useful for threading the electrode through the gun WIRE DRIVE CONFIGURATION See Figure B 2b Changing the Gun Receiver Bushing ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before installation or changing drive rolls ...

Page 22: ...SWITCH The 2 Step Trigger Interlock switch changes the function of the gun trigger 2 Step trigger operation turns welding on and off in direct response to the trigger Trigger Interlock operation allows weld ing to continue when the trigger is released for comfort on long welds Place the toggle switch in the UP position for 2 Step operation or in the DOWN position for Trigger Interlock operation 2 ...

Page 23: ...ing cable length electrode diameter wire feed speed contact tip to work distance etc Changes in the wire feed speed WFS or contact tip to work distance CTWD affect the arc voltage when constant current power sources are used Lowering the wire feed speed raises the voltage raising the wire feed speed lowers the voltage Lengthening the con tact tip to work distance raises the voltage shortening the ...

Page 24: ...ng required for the DESIRED IN MIN and ARC VOLTS used for the welding procedures TABLE B 1 CC WIRE SPEED SETTING Arc Volts Used Desired In Min 16 18 20 22 24 26 28 30 32 34 50 109 97 88 80 73 67 63 58 55 51 60 131 117 105 95 88 81 75 70 66 62 70 153 136 123 111 102 94 88 82 77 72 80 175 156 140 127 117 108 100 93 88 82 90 197 175 158 143 131 121 113 105 98 93 100 219 194 175 159 146 135 125 117 10...

Page 25: ...o be grounded as stated in Arc Welding Safety Precautions Connect the LN 15 electrode cable to the power source for the polarity and process to be used Check that the appropriate power source settings are made for the procedure to be used Refer to the power source operating and connection instructions Place the LN 15 conveniently near the work area in a safe location to minimize exposure to weld s...

Page 26: ...LN 15 NOTES B 12 B 12 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 27: ...ter TOC Return to Master TOC Return to Master TOC Return to Master TOC LN 15 Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION Accessories Section C Factory Installed Equipment C 2 Optional Equipment C 2 ...

Page 28: ...6 030S Including stainless steel 035 0 9mm KP1696 035S 040 045 1 0 1 2mm KP1696 045S 052 1 4mm KP1696 052S Cored Wires 030 035 0 8 0 9mm KP1697 035C 040 045 1 0 1 2mm KP1697 045C 052 1 4mm KP1697 052C 1 16 1 6mm KP1697 1 16C 068 1 7mm KP1697 068 5 64 2 0mm KP1697 5 64 Aluminum Wires 035 0 9mm KP1695 035A 040 1 0mm KP1695 040A 3 64 1 2mm KP1695 3 64A OPTIONAL EQUIPMENT K1500 1 3 5 Gun Receiver Bush...

Page 29: ...C Return to Master TOC Return to Master TOC LN 15 Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE SECTION Maintenance Section D Routine Maintenance D 2 Periodic Maintenance D 2 Calibration Specification D 2 Major Component Locations D 3 ...

Page 30: ...inside the feeder PERIODIC MAINTENANCE Replace the drive rolls and inner wire guide when they are worn Replace the pig tail if the insulation is cut abraded or damaged CALIBRATION SPECIFICATION All calibration is factory set on the LN 15 To verify the wire feed speed Assemble a 045 1 2mm drive roll kit into the LN 15 Load a spool of 045 1 2mm electrode and thread the electrode through the wire dri...

Page 31: ...turn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE D 1 MAJOR COMPONENT LOCATIONS 1 Molded Case Assembly 2 Control Box Assembly 3 Control Box Cover Assembly 4 Wire Drive Contactor Assembly LN 15 ...

Page 32: ...LN 15 NOTES D 4 D 4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 33: ...TRODE INPUT VOLTAGE TOROID ASSEMBLY FULL WAVE BRIDGE WORK SENSING LEAD ON OFF SWITCH MOV BOOST POWER SUPPLY BOARD FEED HEAD BOARD SUPPLY DRIVE MOTOR SUPPLY WORK VOLTAGE FEEDBACK 21 GAS SOLENOID ELECTRODE FEEDBACK VOLTAGE 67 FEED PLATE M O T O R HALL EFFECT MODULE RPM FEEDBACK ARMATURE WELDING GUN DISPLAY BOARD COLD INCH SWITCH WIRE FEED SPEED CONTROL TRIGGER INPUT PROCEDURE TRIGGER INTERLOCK SWITC...

Page 34: ...nd gas metal arc welding GMAW to obtain code quality results For non critical quality applications a constant current power source may be used The LN 15 comes factory equipped with a K1500 2 Tweco style 2 4 gun bushing The dual procedure mode drops the wire feed speed 83 from the original set point The voltage setting remains the same INPUT POWER The DC voltage supplied from the power source is ap...

Page 35: ...closing the contactor When activated the Trigger Interlock Switch keeps the gun trigger circuit closed even when the operator releases the trigger This is useful when making long welds E 3 E 3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE Unshaded areas of Block Logic ...

Page 36: ...ide a command voltage for the Feed Head Control Board The Hall Effect module Tach monitors the motor RPM and outputs a digital voltage frequency feed back that is delivered to the Feed Head Board When operating in the constant voltage CV mode the Feed Head Board monitors the feedback signal and compares it to the command voltage and delivers the appropriate armature voltage to the wire feed motor ...

Page 37: ...hen the LN 15 is configured for elec trode negative processes All of the LEDs will briefly light when the machine is first turned on E 5 E 5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E 5 DISPLAY BOARD CONTACTOR ELECTRODE INPUT VOLTAGE TOROID ASSEMBLY FULL WAVE BR...

Page 38: ...LN 15 NOTES E 6 E 6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 39: ...Troubleshooting Guide F 4 Test Procedures Boost Power Board Test F 11 Gas Solenoid Valve Test F 15 Contactor Test F 17 Drive Motor Test F 19 Hall Effect Module Test F 21 Replacement Procedures Contactor Removal and Replacement F 23 Feedhead Control Board Removal and Replacement F 27 Boost Power Supply Board Removal and Replacement F 31 Wire Drive Assembly Removal and Replacement F 35 Cover Spindle...

Page 40: ...JUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies th...

Page 41: ...ment Do not touch electrically hot parts Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is c...

Page 42: ...dge See the wiring diagram 3 Perform the Boost Power Supply Board Test 4 The control board may be faulty 5 If the Display Board is not lit check the input voltages to the Display Board See the Wiring Diagram When the gun trigger is activated the wire drive runs and electrode wire feeds but there is no welding output 1 Make sure the contactor is func tioning correctly 2 Check the current carrying l...

Page 43: ...the correct voltage is being applied to the drive motor and the motor does not run the motor or motor brushes may be faulty 3 If the correct voltage is not being applied to the drive motor the Control Board may be faulty The wire feeds for a short period of time but then stops feeding When the gun trigger is released then re activated the wire resumes feeding but soon stops again 1 The drive motor...

Page 44: ... range is only 50 to 374 IPM 1 3 to 9 5m min 1 The 83 wire feed speed dual procedure is activated with the low speed gear 1 Turn off the 83 procedure switch to return to the full wire feed speed range 2 Check the wiring between the procedure switch and the con trol board See the Wiring Diagram 3 The control board may be faulty Replace The wire feed speed range is only 50 to 600 IPM 1 3 to 15 3 m m...

Page 45: ...Hall Effect Module Test 3 The Control Board may be faulty Replace The wire feed speed varies during welding but the meter reading remains constant 1 The drive rolls may be slipping causing feeding problems 2 The LN 15 may be in the Constant Current mode Verify on power up that the LN 15 is set for Constant Voltage weld ing 3 Reduce the spindle brake resis tance 1 Perform the Wire Drive Motor Test ...

Page 46: ... tip may be worn 4 The welding voltage may be set too high or the wire feed speed set too low 5 Check the wire drive tension 1 Perform the Wire Drive Motor Test 2 Perform the Hall Effect Module Test The Display board shows POS PRE or BRN 1 The LN 15 is in the Press and Spin set up mode 2 One of the dip switches on the control board is set to ON for the timer setting mode 1 The Control board may be...

Page 47: ... the faults before replacing the printed circuit board The wire drive motor has overheated Check to make sure the electrode slides easily through the liner of the gun Reduce the spindle brake resistance Reduce the amount of tension in the wire drive tension arm For the best results use only Lincoln electrodes Wait 10 minutes for the wire feeder to cool Verify that nothing is jammed in the wire dri...

Page 48: ...LN 15 NOTES F 10 F 10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 49: ... the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 LN 15 F 11 F 11 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WARNING TROUBLESHOOTING REPAIR BOOST POWER BOARD TEST TEST...

Page 50: ...DC 5 Check for the correct input voltage to the Boost Power Board at leads 526A to 527A 15 110 VDC See Figure F 3 If the input voltage is not present check the input rectifier bridge and associ iated circuits See the wiring diagram 6 Check for approximately 80 VDC at leads 501 to 502 See Figure F 3 7 Check for approximately 80 VDC at leads labeled POS to NEG See Figure F 3 8 If the correct input v...

Page 51: ...turn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR C9 C10 J47 R2 R1 R71 R72 R14 R15 R16 FIGURE F 2 BOOST POWER BOARD 526A Neg Pos 501 502 527A FIGURE F 3 PLUG J47 LEAD LOCATIONS BOOST POWER BOARD TEST continued ...

Page 52: ...LN 15 NOTES F 14 F 14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 53: ...perator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call...

Page 54: ... leads 552 553 from the solenoid valve See Figure F 4 4 Make sure the gas supply for the solenoid is hooked up and then apply 12 VDC to the gas solenoid 5 If the solenoid activates and allows gas flow then the solenoid valve is good NOTE There should not be any gas flow until the solenoid is activated 6 If the solenoid does not activate and allow gas to flow then the solenoid is faulty Replace 7 T...

Page 55: ...e technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistanc...

Page 56: ...m Damage to contactor may result 5 If the contactor does not activate when the 12 VDC is applied the contactor is faulty Replace Note The normal contactor coil resistance is approximately 4 4 ohms 6 If the contactor activates when the 12 VDC is applied check the resistance between the two large terminal studs with the contactor activated The resistance should be very low 0 to 1 ohm 7 If the resist...

Page 57: ...ine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed...

Page 58: ...sconnect from motor Note pin location for reassembly See Figure F 6 5 Apply a variable DC voltage to the drive motor from lead 550 white to lead 551 gray 6 When the supply voltage is varied from 3 to 26 VDC the drive motor speed RPM should vary accordingly If the motor does not run or vary in speed the motor gearbox or motor brushes may be faulty Check or replace 7 Check the resistance between eac...

Page 59: ...erator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call ...

Page 60: ...ead 5 Check for the presence of 5VDC from lead 563 Red to lead 561 Black If the 5VDC is not present or low the feed head control board may be faulty 6 Activate the LN 15 trigger circuit make sure the drive motor is running and check for the presence of approximately 2 8VDC from lead 562 Red to lead 561 Black The value of 2 8VDC represents the correct feedback voltage from the Hall Effect device to...

Page 61: ...l invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877...

Page 62: ... Figure F 8 Also leads 567 567A 6 Disconnect the two coil leads at their in line connectors 7 Disconnect and clear ground leads as necessary 8 Using the 7 16 wrench remove the two bolts mounting the contactor assembly to the divider plate See Figure F 8 9 Carefully remove the contactor assembly from the LN 15 10 Using the 11 16 wrench remove the cable and copper bus bar from the contactor 11 The c...

Page 63: ... the copper bus bar and cable 3 Install the the contactor assembly into the case 4 Using the 7 16 wrench mount the contactor assembly to the divider plate 5 Install the two rubber mounts previously removed 6 Connect the two coil leads 7 Connect all group leads previously removed 8 Using the 3 4 wrench replace the welding cable and lead 567 and 567A 9 Replace the wire drive assembly 10 Replace the ...

Page 64: ...LN 15 NOTES F 26 F 26 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 65: ...d will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935...

Page 66: ... and Spindle Mount Removal Procedure 3 Locate the Feed head Control Board and plugs J81 J82 J83 J84 J85 J86 and J88 See Figure F 9 See Figure F 10 4 Remove the seven plugs from the board taking note of placement for reassembly 5 Using the 3 8 wrench remove the four nuts holding the board in place 6 Carefully remove the Feed head Control Board REPLACEMENT PROCEDURE 1 Set the new Feed head Control B...

Page 67: ...o Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR FEED HEAD CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE Continued Figure F 10 FEED HEAD CONTROL BOARD J81 J82 J83 J84 J85 J86 J88 3 8 Mounting Nuts 3 8 Mounting Nuts ...

Page 68: ...LN 15 NOTES F 30 F 30 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 69: ... will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 ...

Page 70: ...PROCEDURE 1 Remove input power to the LN 15 2 Perform the Cover and Spindle Mount Removal Procedure 3 Locate the Boost Power Supply Board See Figure F 11 4 Disconnect plug J47 See Figure F 12 5 Using the 3 8 wrench remove the three nuts holding the board in place 6 Carefully remove the Boost Power Supply Board REPLACEMENT PROCEDURE 1 Set the new Board on the mounting studs 2 Secure with the three ...

Page 71: ...C Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR BOOST POWER SUPPLY BOARD REMOVAL AND REPLACEMENT PROCEDURE Continued Figure F 12 BOOST POWER BOARD PLUG MOUNT LOCATION C9 C10 J47 R2 R1 R71 R72 R14 R15 R16 3 8 Mounting Nuts 3 8 Mounting Nut ...

Page 72: ...LN 15 NOTES F 34 F 34 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 73: ...ate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 WARNING ...

Page 74: ...case See Figure F 13 4 Using small pliers disconnect the gas hose from the conductor block 5 Carefully maneuver the drive assembly out of the case 6 Using the 3 4 wrench remove the cable from the conductor block 7 Remove lead 67 from the conductor block See Wiring Diagram 8 Remove plug J2 REPLACEMENT PROCEDURE 1 Connect previously removed plug J2 to the new conductor block 2 Replace lead 67 into t...

Page 75: ... your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 WARNING COV...

Page 76: ...See Figure F 14 4 Using the 1 2 wrench remove the one bolt from the top of the cover 5 Using the 3 8 wrench remove the five mounting screws See Figure F 15 6 Using the large pliers loosen and remove the cord grip nut See Figure F 14 7 Pull the electrode cable inward through the rear case 8 Disconnect the gas hose from the conductor block on the Wire Drive Assembly 9 Carefully remove the cover and ...

Page 77: ...D SPINDLE MOUNT REMOVAL AND REPLACEMENT PROCEDURE Continued REPLACEMENT PROCEDURE 1 Replace all leads to switches and solenoid 2 Maneuver assembly into case 3 Connect gas hose to conductor block 4 Replace five mounting screws 5 Replace bolt into top of case 6 Replace the electrode cable into the cord grip Replace and tighten the nut Figure F 15 COVER AND SPINDLE MOUNT SCREW LOCATION 1 2 Bolt Screw...

Page 78: ...LN 15 F 40 F 40 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES ...

Page 79: ...e operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed C...

Page 80: ...Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR ROLL CAGE REMOVAL AND REPLACEMENT PROCEDURE Continued Figure F 16 ROLL CAGE BOLT LOCATION REMOVAL PROCEDURE 1 Remove input power to the LN 15 2 Using a 7 16 Wrench remove the five bolts securing the roll cage to the LN 15 case 3 Carefully remove the roll cage 1 2 Bolt 7 16 Bolts ...

Page 81: ...EST AFTER REPAIR If a failed test indicates that any mechanical part that could affect the machine s electri cal characteristics must be replaced or if any electrical components are repaired of replaced the machine must be retested and meet the following standards Wire Feed Speed 50 thru 700 inches per minute Gas Solenoid Must operate when gun trigger is activated Contactor Must operate when gun t...

Page 82: ...LN 15 NOTES F 44 F 44 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 83: ... Boost PC Board Schematic L11818 2 G 4 Boost PC Board Assembly M19753 2 G 5 Feedhead PC Board Schematic G3883 1E0 1 G 6 Feedhead PC Board Schematic G3883 1E0 2 G 7 Feedhead PC Board Assembly G3884 1 G 8 SPI Display PC Board Schematic L11756 1E1 G 9 SPI Display PC Board Assembly L11757 1 G 10 NOTE Many PC Board Assemblies are now totally encapsulated and are therefore consid ered to be unserviceabl...

Page 84: ...7 589 554A ON OFF SWITCH 526C S3 526C 526B 526 EN 168 L11436 1 SEMI AUTOMATIC WIRE FEEDER LN 15 WIRING DIAGRAM ACROSS THE ARC 1 1 L11436 TJP KJ E ENYEDY UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE WITH PUBLISHED STANDARDS MATERIAL TOLERANCE TO AGREE t DO NOT SCALE THIS DRAWING DRAWN BY DE...

Page 85: ...power source It may be likely that a different power source is required Boost Circuit Common to input enabling circuit COM ISOLATION SWITCH FET INPUT COM INPUT COM MOTOR SUPPLY FEEDHEAD SUPPLY INPUT R U 15 110 VDC The boost board takes the weld voltage and boosts it to 80VDC for the rest of the LN 15 There are two supplies on the boost board one for the motor and the other for the feedhead board W...

Page 86: ...TE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 87: ...1 GASKET 1 6 M19436 8 POTTING TRAY 1 7 S8025 96 SELF TAPPING SCREW 2 8 SEE ABOVE BOOST PC BD BLANK 1 9 E2527 EPOXY ENCAPSULATING RESIN 10 S20590 2 HEAT SINK 1 11 S25253 1 HEAT SINK MOUNTING CLIP 1 N B N F 12 E3768 4 LABEL 2 THESE ITEMS NOT SHOWN 4 J47 C1 C7 C6 C4 C5 DZ1 DZ2 D1 R10 R9 R11 R18 R17 R19 R7 R8 R5 R12 R6 X1 R20 C21 R55 X2 R52 R51 R40 R39 R38 R37 R21 Q7 Q6 Q5 D6 DZ7 DZ6 C14 C9 C10 BOOST ...

Page 88: ... NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 89: ... NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 90: ... only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 8 LN 15 PC BOARD ASSEMBLY FEEDHEAD G3884 1 G 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Sect...

Page 91: ...9 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 92: ...ncoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 10 LN 15 PC BOARD ASSEMBLY SPI DISPLAY P C BOARD L11757 1 G 10 Return to Section TOC Return to Section TOC Return to Section TOC Return...

Page 93: ...__ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ _________________...

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Lincoln Electric LN-15, Service Manual

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