Lincoln Electric LN-9F GMA, IM355-C, LN-9 GMA User Manual

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IM355-C

 

 

June, 2010

LN-9 GMA and LN-9F GMA Wire Feeder

For use with machines having Code Numbers: 9100 and Above

Safety Depends on You

Lincoln arc welding equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation. . . and thoughtful operation on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

OPERATOR’S MANUAL

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

i

SAFETY

 

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

ARC WELDING CAN bE HAzARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIbLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR bEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

bE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY bY QUALIFIED INDIVIDUALS.

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes

have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

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ii

SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES

can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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iii

SAFETY

WELDING and CUTTING

SPARKS can

cause fire or explosion.

6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent the welding sparks from starting a fire.

Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended

Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits.

This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention

During Welding, Cutting and Other Hot Work”, available from

NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1.Protegez-vous contre la secousse électrique:

a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b.Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.

e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enroule le câble-électrode autour de n’importe quelle partie du corps.

3.Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b.Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnementde l’arc.

c.Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflamma- bles.

4.Des gouttes de laiter en fusion sont émises de l’arc de soudage. Se protéger avec es vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5.Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir ttout risque d’incendie dû étincelles.

7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8.S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de la faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou atres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumées toxiques.

10.Ne pas souder en présence de vapeurs de chlore provenant d’opéerations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement roxique) ou autres produits irritants.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1.Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2.Autant que possible, l’installation et l’entretien du poste seront effectués par un électricien qualifié.

3.Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4.Garder tous les couvercles et dispostifis de sûreté à leur place.

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Thank You

v

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••

as much pride as we have in bringing this product to you!

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

-Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then “Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

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vi

 

 

TAbLE OF CONTENTS

 

 

 

 

 

 

 

 

Page

 

 

Safety .................................................................................................................................................

i-iv

 

 

 

 

 

 

 

Installation.............................................................................................................................

Section A

 

 

Technical Specifications ..............................................................................................................

A-1

 

 

Installing the LN-9GMA 2-Roll and 4-Roll Models ......................................................................

A-2

 

 

Attaching the Wire Reel stand..............................................................................................

A-2

 

 

Mounting the Unit .................................................................................................................

A-2

 

 

Installing the LN-9F GMA 2-Roll and 4-Roll Models ...................................................................

A-2

 

 

Mounting the Wire Feed Unit................................................................................................

A-2

 

 

Mounting the Control Box .....................................................................................................

A-2

 

 

Connecting the Wire Feed Unit to the Control Box ..............................................................

A-2

 

 

Routing the Electrode ...........................................................................................................

A-3

 

 

Electrical Connections - LN-9 GMA and LN-9F GMA.................................................................

A-3

 

 

Power Input Cable Assembly................................................................................................

A-3

 

 

Connecting the Power Input Cable Assembly to the LN-9 GMA Wire Feed Unit.................

A-3

 

 

Connecting the Power Input Cable Assembly to the LN-9F GMA Wire Feed Unit ..............

A-4

 

 

Connecting the Power Input Cable Assembly to Power Sources ........................................

A-4

 

 

Machine Grounding...................................................................................................................

A-12

 

 

Work Cable Connection ............................................................................................................

A-12

 

 

Direct Work Cable Connection ...........................................................................................

A-12

 

 

Connecting the Gun Cable to the Wire Feeder ........................................................................

A-13

 

 

For GMA Gun Cables .........................................................................................................

A-13

 

 

Hooking Up GMA Shielding Gas...............................................................................................

A-14

 

 

 

 

 

 

 

Operation...............................................................................................................................

Section b

 

 

Operating Instructions .................................................................................................................

B-1

 

 

Safety Precautions ......................................................................................................................

B-1

 

 

General Description ....................................................................................................................

B-2

 

 

Recommended Processes and Equipment.................................................................................

B-2

 

 

K424 LN-9 GMA 2-Roll and K568-1 LN-9 GMA 4-Roll.........................................................

B-2

 

 

K436 LN-9F GMA 2-Roll and K583-1 LN-9F GMA 4-Roll ....................................................

B-2

 

 

DC Constant Voltage Power Sources ..................................................................................

B-3

 

 

Controls and Settings..................................................................................................................

B-4

 

 

Circuit Protection and Automatic Shutdown .........................................................................

B-7

 

 

Avoiding Grounding Lead Protector (GLP) Shutdown..........................................................

B-7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

vii

vii

 

TAbLE OF CONTENTS (cont’d)

 

 

Drive Roll Installation ..................................................................................................................

B-9

 

Changing Drive Rolls for 2-Roll Wire Feeders .....................................................................

B-9

 

Changing Drive Rolls for 4-Roll Wire Feeders....................................................................

B-11

 

Wire Loading .............................................................................................................................

B-13

 

Loading a 22 to 30 lb. Reddi-Reel Package.......................................................................

B-13

 

Loading a 10 to 30 lb. Spool ..............................................................................................

B-14

 

Loading 50 and 60 lb. Coils................................................................................................

B-15

 

Loading and Feeding 13-14 lbs. Innershield Coils .............................................................

B-16

 

Idle Roll Pressure Setting .........................................................................................................

B-17

 

2-Roll Wire Feeders............................................................................................................

B-17

 

4-Roll Wire Feeders............................................................................................................

B-17

 

Making a Test Weld and Adjusting Response and Starting ......................................................

B-18

 

Adjust the Power Source ....................................................................................................

B-18

 

Adjust the LN9 GMA Controls ............................................................................................

B-18

 

Voltage Control Response..................................................................................................

B-19

 

Starting Characteristics.......................................................................................................

B-19

 

Making a Weld....................................................................................................................

B-20

 

Procedure at End of Coil .................................................................................................................

B-20

 

Security of Weld Procedure Settings...............................................................................................

B-20

Accessories ..........................................................................................................................

Section C

Auxiliary Equipment Contacts.....................................................................................................

C-1

Optional Equipment and Accessories .........................................................................................

C-1

Power Input Cable Assemblies (K196, K595, K596)............................................................

C-1

Wire Reel Stands and Mountings.........................................................................................

C-1

Gun and Cable Assemblies ..................................................................................................

C-3

Wire Feeder Accessories .....................................................................................................

C-3

Maintenance..........................................................................................................................

Section D

Routine Maintenance ..................................................................................................................

D-1

Drive Rolls and Guide Tubes ...............................................................................................

D-1

Wire Reel Mounting – 50 and 60 lb. Coils ...........................................................................

D-1

Wire Reel Mounting Readi-Reels and Spools......................................................................

D-1

Periodic Maintenance .................................................................................................................

D-1

Control Box...........................................................................................................................

D-1

Wire Drive Motor and Gear Box ...........................................................................................

D-1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

viii

viii

TAbLE OF CONTENTS (cont’d)

Gun and Cable Maintenance ......................................................................................................

D-2

Proper Speed Sensor Motor Mounting.................................................................................

D-2

Gun Cable Connector Requirements ...................................................................................

D-3

 

 

Troubleshooting....................................................................................................................

Section E

How to Use Troubleshooting Guide ............................................................................................

E-1

Troubleshooting Guide ................................................................................................................

E-2

 

 

Diagrams................................................................................................................................

Section F

LN-9 GMA Wiring Diagram..........................................................................................................

F-1

LN-9F GMA Wiring Diagram .......................................................................................................

F-2

LN-9 GMA Dimension Print .........................................................................................................

F-3

LN-9F GMA Dimension Prints .....................................................................................................

F-4

 

 

Parts.................................................................................................

P127, P125, P107 & P289 Series

A-1

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS

INPUT POWER

Supplied by power source: 115 VAC, 50/60 Hz., 350 VA

WIRE FEED SPEED

80 to 980 inches per minute (2.03 to 24.9 meters per minute)

VOLTAGE CONTROL RANGE

12.0 TO 60.0 VDC

TEMPERATURE RANGE

 

OPERATION:

- 20o C to +40o C (- 4o F to +104o F)

Recommended

 

 

- 40o C to +40o C (- 40o F to +104o F)

Maximum Rated

 

STORAGE:

- 40o C to +85o C (- 40o F to +185o F)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WIRE

DIAMETERS

 

 

 

0.023 through 1/16

 

 

Solid Electrode

 

0.045 through 5/64

 

 

Cored Electrode

 

 

 

 

 

 

 

 

 

 

 

 

PHYSICAL

 

DIMENSIONS

 

 

 

 

 

LENGTH

WIDTH

HEIGHT

TOTAL WEIGHT LESS

 

 

 

 

 

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

LN-9 GMA (2 ROLL)

 

12.15 in.

11.56 in.

12.19 in.

29.3 lbs

 

 

 

(308.4 mm)

(293.4 mm)

(309.4 mm)

(13.3 kg)

 

 

 

 

 

 

 

 

 

LN-9 GMA (4 ROLL)

 

12.15 in.

11.56 in.

12.19 in.

27.5 lbs

 

 

 

(308.4 mm)

(293.4 mm)

(309.4 mm)

(12.4 kg)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LN-9F GMA Control Box

 

10.4 in.

6.17 in.

11.26 in.

16.3 lbs

 

 

 

(264 mm)

(156.6 mm)

(293.4 mm)

(7.4 kg)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LN-9F GMA Wire Drive (2 ROLL)

8.06 in.

 

7.5 in.

12.78 in.

15.6 lbs

 

 

 

(204.6 mm)

(190.4 mm)

(324.4 mm)

(7.1 kg)

 

 

 

 

 

 

 

 

 

LN-9F GMA Wire Drive (4 ROLL)

8.06 in.

 

7.5 in.

12.78 in.

20.5 lbs

 

 

 

(204.6 mm)

(190.4 mm)

(324.4 mm)

(9.2 kg)

 

 

 

 

 

 

 

 

 

DUTY CYCLE: The amount of welding performed in a 10 minute period, expressed as a percentage.

LN-9 GMA and LN-9F GMA Wire Feeder

A-2

A-2

INSTALLATION

INSTALLING THE LN-9 GMA 2-ROLL AND 4-ROLL MODELS

ATTACHING THE WIRE REEL STAND

Both the 2-Roll and 4-Roll LN-9 GMA are shipped without the wire reel stand attached. The screws and washers for mounting the wire reel stand are included with the LN-9 GMA (fastened in their respective mounting holes). To attach the stand:

1.Remove the three 3/8" hex screws from the back of the wire feed unit.

2.Place the wire reel stand mounting bracket in position against the back of the wire feed unit.

3.Replace and tighten the screws. The long screw and plain washer go into the top hole. For 4-Roll feeders, one plain washer is used for mounting 60# wire stands and 2 plain washers for mounting 30# stands.

MOUNTING THE CONTROL bOX

The same control box is used for both the 2-Roll and 4- Roll wire feed unit. It contains two keyhole slots and one slot for mounting. Refer to the LN-9F GMA Dimension Print in the Diagrams section of this manual for the size and location of these slots. Mount the box at some convenient location close to the wire feed unit. This will enable the 16-foot control cable assembly supplied with both the LN-9F GMA 2-Roll and 4-Roll to reach between the control box and the wire feed unit.

1.Drill the required holes in the mounting surface. Partially install 1/4-20 screws.

2.Open the control box door by removing the two door screws.

3.Mount the box.

4.Tighten the screws.

5.Close the control box door and replace the door screws.

MOUNTING THE UNIT

LN-9 GMA wire feeders can be mounted directly on top of their power source as long as it is secure and level. When portability is required, the LN-9 GMA can be mounted on a K163 undercarriage See the Accessories section for details.

A K178-1 swivel platform is available for mounting the LN-9 GMA to the power source. See the Accessories section for details.

INSTALLING THE LN-9F GMA 2-ROLL AND 4-ROLL MODELS

MOUNTING THE WIRE FEED UNIT

Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gearbox. Refer to the LN-9F GMA Dimension Print in the Diagrams section of this manual for the size and location of the mounting holes. The gearbox assembly is electrically "hot" when the gun trigger is pressed. Therefore, make certain the gearbox does not come in contact with the structure on which the unit is mounted. The wire feed unit should be mounted so that the drive rolls are in a vertical plane so dirt will not collect in the drive roll area. Position the mechanism so it will point down at about a 45o angle so the wire feed gun cable will not be bent sharply as it comes from the unit.

CONNECTING THE WIRE FEED UNIT TO THE CONTROL bOX

Both the LN-9F GMA 2-Roll and 4-Roll include the same 16 ft. control and electrode cable assembly. Connect the wire feed unit to the control box as follows:

1.Make certain the cables are protected from any sharp corners that may damage their jackets. Mount the cable assembly along the boom so the end with the female amphenol connector pins is at the wire feed unit.

2.Connect the cable connector to the receptacle on the back of the wire feed unit connection box.

3.At the same end, connect the electrode lead to the connection stud of the copper strap along the side of the wire feed unit.

4.At the control box end, connect the amphenol connector of the control cable to the mating MS-type receptacle on the bottom of the control box. (See Figure A.3, later in this section, for the location of this connection.)

LN-9 GMA and LN-9F GMA Wire Feeder

A-3

A-3

INSTALLATION

ROUTING THE ELECTRODE

The electrode supply may be either from reels, ReadiReels, spools, or bulk packaged drums or reels. Observe the following precautions:

The electrode must be routed to the wire feed unit so that the bends in the wire are at a minimum. The force required to pull the wire from the reel into the wire feed unit must be kept at a minimum.

The electrode is "hot" when the gun trigger is pressed and must be insulated from the boom and structure.

If more than one wire feed unit share the same boom, their wire and reels must be insulated from each other and insulated from their mounting structure.

See the Accessories section for information about mounting a K299 wire reel assembly.

ELECTRICAL CONNECTIONS - LN-9 GMA AND LN-9F GMA

POWER INPUT CAbLE ASSEMbLY

A special cable assembly is required to connect all LN- 9 GMA models to the power source. The assembly includes control cable and electrode cable. Various sizes are available, based on length and maximum welding current. The following power source cable assemblies are available:

K196 for Terminal Strip control connection and output terminal.

K595 for 14-Pin receptacle and output terminal.

K596 for 14-Pin receptacle and Twist-Mate" connection.

NOTE: Use of an LN-9 GMA with a Pulse Power 500, Invertec V300 or a DC650 PRO requires a K442-1 Pulse Power Filter Kit.

CONNECTING THE POWER INPUT CAbLE ASSEMbLY TO THE LN-9 GMA WIRE FEED UNIT

The K196, K595, or K596 cable assembly consists of an electrode cable and multiconductor control cable. The control cable has a polarized plug on the wire feeder end. To install:

1.See Figure A.1. Connect the polarized plug of the control cable to the mating connector on the back of the wire feeder.

2.See Figure A.2. Remove the screws holding the cable strain relief clamp located near the rear of the wire reel stand base. Put the control cable and the electrode cable under the clamp and install the screws.

For 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 that only the single electrode lead is under the clamp.

3.See Figure A.1. Pass the single electrode cable through the hole provided in the back corner of the wire section and fasten it to the conductor block of the copper strap along the side of the wire drive unit.

FIGURE A.1 – INPUT CONTROL CAbLE AND

ELECTRODE CAbLE CONNECTIONS

LN-9 GMA and LN-9F GMA Wire Feeder

Lincoln Electric LN-9F GMA, IM355-C, LN-9 GMA User Manual

A-4

 

 

 

 

 

 

 

 

A-4

 

 

 

 

 

 

 

 

 

 

 

 

 

INSTALLATION

 

FIGURE A.2 – STRAIN RELIEF CLAMP

 

 

FIGURE A.3 – LN-9F GMA CONTROL bOX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

bOTTOM VIEW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONNECTING THE POWER INPUT CAbLE

ASSEMbLY TO POWER SOURCES

WARNING

CONNECTING THE POWER INPUT CAbLE ASSEMbLY TO THE LN-9F CONTROL bOX

1.See Figure A.3. Connect the polarized plug of the K196, K595, or K596 control cable to the mating MS-type connector on the bottom of the LN-9F GMA control box.

2.Bolt the electrode lead from the power source to the electrode lead to the wire feed unit using the nut and bolt supplied. Insulate the connection with electrical tape.

Turn input supply power to the power source OFF before connecting the LN-9 GMA or LN-9F GMA wire feeder.

Connect to an appropriate Lincoln power source as follows:

1.If using a multipurpose source (such as the DC250, DC-400 and DC-600), be sure it is properly set for the welding process being used. See the topic "Making a Test Weld," in the Operation section of this manual.

For terminal strip connections using the K196 power input cable, connect the input cable to the power source exactly as specified on the appropriate LN-9 GMA model connection diagram:

Figure A.4 for DC-250, DC-400 and CV-400, CV-500 l

Figure A.5 for DC-600

Figure A.6 for DC-1000

Figure A.7 for Pulse Power 500

Figure A.8 for R3S-400, R3S-600, R3S-800

LN-9 GMA and LN-9F GMA Wire Feeder

A-5

A-5

INSTALLATION

Figure A.9 is a connection diagram for connecting the LN-9 GMA to V300 power sources. The connection is made with a K596 cable assembly, which has an amphenol connection rather than a terminal strip connection at the power source.

Depending on the power source and process you are using, the jumpers on the LN-9 GMA voltage board may have to be changed. As shipped, the LN-9 GMA is connected for use with the DC-250 DC-400, CV-400, CV-500-I and DC-600. For other power sources, refer to the appropriate connection diagram.

NOTE: If you are using the Pulse Power 500, DC650 Pro, or V300 power source, the K442-1 Pulse Power Filter Kit must be installed in the LN-9 GMA. See the instructions included with the kit. If you are using the Invertec V300, the K608-1 Adapter must also be installed according to the connection diagram and instructions provided in the Invertec Manual.

LN-9 GMA and LN-9F GMA Wire Feeder

A-6

A-6

INSTALLATION

FIGURE A.4 – CONNECTION OF LN-9 GMA TO DC-250, DC-400, and CV/CVI POWER SOURCES

ELECTRIC SHOCK can kill.

WARNING

Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder

Only qualified persons should install, use or service this machine.

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the power source and position the switch on power source to proper polarity.

* 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 AWG 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 #21 lead should be taped to the welding work lead. (If the length of 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 if lead #21 is extended.

 

N.D. Connect the control cable ground lead to the frame terminal marked

near the power source terminal strip. The power source

grounding terminal (marked

and located near the power source input power connections) must be properly connected to elec-

trical ground per the power source operating manual.

N.F. The LN-9 GMA voltage control jumpers must be connected as follows:

White jumper on voltage board to pin “S”.

Blue jumper on voltage board (later units only), or on start board (earlier units), to pin “B”.

*N.G. If lead #21 is to be connected to the terminal strip, connect to the #21 terminal that matches work polarity. This connection must be changed whenever the electrode polarity is changed.

LN-9 GMA and LN-9F GMA Wire Feeder

A-7

A-7

INSTALLATION

FIGURE A.5 – CONNECTION OF LN-9 GMA TO DC-600 POWER SOURCES

ELECTRIC SHOCK can kill.

WARNING

Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder

Only qualified persons should install, use or service this machine.

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the power source and position the switch on power source to proper polarity.

For optimum performance with the LN-9 GMA, DC-600’s with codes 8288 and above are preferred.

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 #21 lead 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-9’s which have a direct work lead jack.)

N.D. Tape up bolted connection.

 

N.E. Connect the LN-9 GMA control cable ground lead to the frame terminal marked

near the power source terminal strip. The

power source must be properly grounded.

 

N.G. The LN-9 GMA voltage control jumpers must be connected as follows:

White jumper on voltage board to pin “S”.

Blue jumper on voltage board (Later units only) or on start board (Earlier units) to pin “B”.

N.H. For DC-600 Codes below 8200 connect a jumper from “N” to “P” on LN-9 GMA only. There is no NPS terminal strip on codes above 8200.

LN-9 GMA and LN-9F GMA Wire Feeder

A-8

A-8

INSTALLATION

FIGURE A.6 – CONNECTION OF LN-9 GMA TO DC-1000 POWER SOURCES

ELECTRIC SHOCK can kill.

WARNING

Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder

Only qualified persons should install, use or service this machine.

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the power source, position the positive - negative switch on power source to correspond to the polarity of the electrode cable connection.

N.A. Welding cables must be 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 separate from the welding work cable connection to work piece. For convenience, this extended #21 lead should be taped along the welding work cable. (This extended #21 lead connection replaces the need to employ the remote work lead accessory on any LN-9 GMA which has a direct work lead jack).

N.C. Tape up bolted connection.

N.D. Connect the LN-9 GMA control cable ground lead to the frame terminal marked power source must be properly grounded.

near the power source terminal strip. The

N.E. If using an older automatic control cable with leads #75, #76, #77; connect lead #75 to #75 on terminal strip, connect lead #76 to #74 on terminal strip, connect lead #77 to #73 on terminal strip.

N.F. The LN-9 GMA voltage control jumpers must be connected as follows:

White jumper on voltage board to pin “S”.

Blue jumper on voltage board (Later units only) or on start board (earlier units) to pin “B”.

N.G. Set the DC-1000 controls as follows:

Set the control switch to “output control remote”. For submerged arc processes, set the mode switch to “C.V. submerged arc”. For open arc processes, set the mode switch to “C.V. Innershield”.

N.H. Alternative 500 amp positive terminal connection provided on DC-1000 models above code 9500 only.

LN-9 GMA and LN-9F GMA Wire Feeder

A-9

A-9

INSTALLATION

FIGURE A.7 – CONNECTION OF LN-9 GMA TO PULSE POWER 500 POWER SOURCES

ELECTRIC SHOCK can kill.

WARNING

Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder

Only qualified persons should install, use or service this machine.

75 76 77 78

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the power source and properly set the feeder 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 AWG 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 #21 lead should be taped to the welding work lead.

N.C. Tape up bolted connection.

N.D. Connect the control cable ground lead to the frame terminal markednear the power source terminal strip. The power source grounding terminal (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. Connect control leads t terminal strip as follows:

LN-9: A to 75 B to 77 C to 78

N.F. The LN-9 GMA voltage control jumpers must be connected as follows: White jumper on voltage board to pin “S”.

Blue jumper on voltage board is not connected to any pin. (Secure loose jumper clear of any possible interference.)

NOTE: For proper pulse welding operating with LN-9:

1.The LN-9 GMA must have an L6084-3 (or higher superseding part number) voltage board installed. (Standard above code 9100.)

2.The Pulse Power Filter board must be installed and connected in the LN-9 per instructions provided with the kit.

3.The pulse current sensor assembly (with looped copper energizer) must be installed. (Standard above code 9100.) Feeder conversion kits are available for all LN-9 GMA model codes (below 9100 and above 9100).

LN-9 GMA and LN-9F GMA Wire Feeder

A-10

A-10

INSTALLATION

FIGURE A.8 – CONNECTION OF LN-9 GMA TO IDEALARC R3S-400, R3S-600, R3S-800 POWER SOURCES

ELECTRIC SHOCK can kill.

WARNING

Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder

Only qualified persons should install, use or service this machine.

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the power source and reverse the “control switch” at the power source, and the “polarity switch” on the LN-9 GMA.

Connect the 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 grounded properly.

 

N.A. On earlier R3S-400, -600 & 800 machines, #67 & #1 terminals 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 AWG 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 #21 lead 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-9’s which have a direct work lead jack.)

N.E. Upper terminal strip (#75, #76 & #77) may not appear on older R3S machines, and therefore is not compatible for use since there will be no adjustment of voltage by the LN-9 GMA.

N.F. The LN-9 GMA voltage control jumpers must be connected as follows:

White jumper on voltage board;

To pin “F” for open arc process or

To pin “S” for submerged arc process.

Blue jumper on voltage board (later units only), or on start board (earlier units), to pin “A”.

LN-9 GMA and LN-9F GMA Wire Feeder

A-11

A-11

INSTALLATION

FIGURE A.9 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES

ELECTRIC SHOCK can kill.

WARNING

Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder

Only qualified persons should install, use or service this machine.

N.A. Welding cable must be sized for current and duty cycle of application.

N.B. Diagram shows electrode positive. To change polarity, turn power “OFF”, reverse electrode and work cable at power source. Set meter polarity switch on rear of invertec to coincide with polarity used. Set LN-9 GMA polarity switch also.

N.C. Install K608-1 adapter in line with P10 to LN-9 GMA voltage board and secure to adjacent harness with wire tie provided. Turn “start” trimmer on voltage board per instructions in V300 manual.

N.D. For GMAW welding, install Pulse Power Filter Kit K442-1 in LN-9 GMA.

LN-9 GMA and LN-9F GMA Wire Feeder

A-12

A-12

INSTALLATION

MACHINE GROUNDING

LN-9 GMA wire feeders are grounded to the power source through the input cable. The power source grounding cable must be properly connected to electrical ground. See your power source operating manual for details.

WORK CAbLE CONNECTION

Connect a work lead of sufficient size and length between the proper output terminal on the power source and the work. See Table A-1. Be sure the connection to the work makes tight metal-to-metal electrical contact. Poor work lead connections can activate the grounding lead protector and/or result in poor welding performance.

TAbLE A.1 – WORK CAbLE SIzES

Current

Copper Work Cable Size, AWG

 

 

60% Duty Cycle

Up to 50' length

50'-100' Iength

 

 

 

300 Amps

0

00

 

 

 

400 Amps

00

000

 

 

 

500 Amps

00

000

 

 

 

600 Amps

000

0000

DIRECT WORK LEAD CONNECTION

Lincoln specified procedures give voltage readings taken between the work and the gun cable brass connection block of the LN-9 GMA. To match these voltage readings, the connection diagrams show the #21 lead being extended and connected directly to the work instead of #21 on the power source terminal strip (or Dual Process Kit terminal strip). This extended lead must be connected directly to the work. When using a Dual Process Kit, you must extend the lead individually for each LN-9 GMA.

As an alternative, LN-9 GMA models are provided with a quick-connect terminal splice connection in the #21 lead between the input Amphenol connector of the LN9 GMA and its polarity switch. See the LN-9 GMA wiring diagram. This in-line connection consists of a red insulated male and female .250 x .032 terminal pair located in the lead harness. It runs along the right side of the wire feed motor inside the control section of the LN-

9 GMA models and in the lead harness at the lower left corner of the control box (near the input Amphenol) of the LN-9F models. You may also open this #21 lead and connect your own direct work lead equipped with a

.250 x .032 female quick-connect terminal to the male side of the splice. This direct work lead connection must be tape insulated, strain-relieved, and routed outside the LN-9 GMA control box to be connected directly to the work.

With either direct work lead connection method, the LN-9 GMA regulates the power source to hold the arc voltage constant, even with voltage drops in the electrode lead, work lead, or work lead connection. If the direct work lead becomes disconnected from the work, the LN-9 GMA wire feeder will stop welding shortly after the arc is struck. See the topic "Circuit Protection and Automatic Shutdown" in the

Operation section of this manual.

LN-9 GMA and LN-9F GMA Wire Feeder

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