Lincoln Electric LN-9, SVM127-A User Manual

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LN-9 Wire Feeder

For use with machines having Code Numbers: 9134, 9842, 9958, 10316, 10327

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.

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SVM127-A

November, 1996

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SERVICE MANUAL

World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Sales and Service through subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

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i i

SAFETY

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

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 W elding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. AFree 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.

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

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 weld-

ing 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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LN-9 Wire Feeder

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ii 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 below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b.

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

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

5.d. Read and understand the manufacturer’s instructions for this

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

vapors

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5.e. Also see item 1.b.

LN-9 Wire Feeder

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iii iii

SAFETY

WELDING 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.

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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.

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LN-9 Wire Feeder

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iv iv

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 ten-

sion 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-inflammables.

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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LN-9 Wire Feeder

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v v

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

RETURN TO MAIN INDEX

Safety.................................................................................................................................................i-iv

Installation .............................................................................................................................Section A

Technical Specifications..............................................................................................................A-2

Installing the LN-9 2-Roll and 4-Roll Models ..............................................................................A-3

Installing the LN-9F 2-Roll and 4-Roll Models............................................................................A-3

Electrical Connections - LN-9 and LN-9F...................................................................................A-4

Machine Grounding ...................................................................................................................A-12

Work Cable Connection............................................................................................................A-12

Connecting the Gun Cable to the Wire Feeder ........................................................................A-13

Operation...............................................................................................................................Section B

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-3

Recommended Processes and Equipment.................................................................................B-3

Controls and Settings..................................................................................................................B-4

Drive Roll Installation and Pressure Setting ...............................................................................B-9

Wire Loading.............................................................................................................................B-14

Making a Test Weld and Adjusting Response and Starting Characteristics.............................B-18

Procedure at End of Coil.................................................................................................................B-20

Security of Weld Procedure Settings...............................................................................................B-20

Page

Accessories ..........................................................................................................................Section C

Auxiliary Equipment Contacts.....................................................................................................C-2

Optional Equipment and Accessories .........................................................................................C-2

Maintenance..........................................................................................................................Section D

Routine Maintenance..................................................................................................................D-2

Periodic Maintenance .................................................................................................................D-2

Gun and Cable Maintenance......................................................................................................D-3

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair................................................................................................Section F

Electrical Diagrams..............................................................................................................Section G

Parts..............................................................................................................................................P-127

LN-9 Wire Feeder

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Section A-1 Section A-1

TABLE OF CONTENTS

- INSTALLATION SECTION -

Installation................................................................................................................................Section A

Technical Specifications..............................................................................................................A-2

Installing the LN-9N and LN-9S 2-Roll and 4-Roll Models .........................................................A-3

Attaching the Wire Reel Stand.............................................................................................A-3

Mounting the Unit .................................................................................................................A-3

Installing the LN-9F 2-Roll and 4-Roll Models............................................................................A-3

Mounting the Wire Feed Unit................................................................................................A-3

Mounting the Control Box.....................................................................................................A-3

Connecting the Wire Feed Unit to the Control Box..............................................................A-3

Routing the Electrode...........................................................................................................A-4

Electrical Connections – LN-9 and LN-9F ..................................................................................A-4

Power Input Cable Assembly................................................................................................A-4

Connecting the Power Input Cable Assembly to the LN-9 or LN-9S...................................A-4

Connecting the Power Input Cable Assembly to the LN-9NE or LN-9SE ............................A-5

Connecting the Power Input Cable Assembly to the LN-9F.................................................A-6

Connecting the Power Input Cable Assembly to Power Sources........................................A-7

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

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LN-9 Wire Feeder

Page 8

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS — LN-9

INPUT POWER

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

WIRE FEED SPEED

50 to 600 inches per minute (1.27 to 15.2 meters per minute)

VOLTAGE CONTROL RANGE

12.0 TO 60.0 VDC

TEMPERATURE RANGE

OPERATION: - 20oC to +40oC (- 4oF to +104oF) Recommended

- 40oC to +40oC (- 40oF to +104oF) Maximum Rated

STORAGE: - 40oC to +85oC (- 40oF to +185oF)

WIRE DIAMETERS

.030 through 3/32" (0.8 through 2.4 mm) Solid Electrode

.045 through .120" (1.2 through 3.0 mm) Cored Electrode .035 through 1/16" (0.9 through 1.6 mm) Aluminum

PHYSICAL DIMENSIONS

LENGTH WIDTH HEIGHT TOTAL WEIGHT LESS

ELECTRODE

LN-9 (2 Roll) 12.15 in. 11.56 in. 12.19 in. 36 lbs

(308.4 mm) (293.4 mm) (309.4 mm) (16.3 kg)

LN-9 (4 Roll) 12.15 in. 11.56 in. 12.19 in. 38 lbs

(308.4 mm) (293.4 mm) (309.4 mm) (17.2 kg)

LN-9F Control Box 10.4 in. 6.17 in. 11.26 in. See Total Weight

LN-9F Wire Drive (2 Roll) 8.79 in. 9.77 in. 13.76 in. 67 lbs (30.4 kg)

LN-9F Wire Drive (4 Roll) 8.79 in. 9.77 in. 13.76 in. 72 lbs (32.7 kg)

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(264 mm) (156.6 mm) (293.4 mm) Below

(223.3 mm) (248.2 mm) (349.5 mm) Total Package Weight

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A-3 A-3

INSTALLATION

INSTALLING THE LN-9N and LN-9S 2-ROLL AND 4-ROLL MODELS

ATTACHING THE WIRE REEL STAND

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

MOUNTING THE UNIT

LN-9N model 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 can be mounted on a K163 undercarriage See the

Accessories

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

section for details.

Accessories

sec-

INSTALLING THE LN-9F 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. 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 45oangle so the wire feed gun cable will not be bent sharply as it comes from the unit.

MOUNTING THE CONTROL BOX

The same control box is used for both the 2-Roll and 4Roll wire feed unit. It contains two keyhole slots and one slot for mounting. 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 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.

CONNECTING THE WIRE FEED UNIT TO THE CONTROL BOX

Both the LN-9F 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 connectors to the receptacles 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 connectors of the control cable to the mating MS-type receptacles on the bottom of the control box. (See

Figure A.4,

this connection.)

later in this section, for the location of

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LN-9 Wire Feeder

Page 10

A-4 A-4

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 K299 wire reel assembly.

Accessories

section for information about a

ELECTRICAL CONNECTIONS LN-9N, S AND LN-9F

CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE LN-9N or

LN-9S WIRE FEED UNIT

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

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

2. See

3. See Figure A.1. Pass the single electrode cable

Figure A.2.

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.

through the hole provided in the back corner of the control section and fasten it to the copper strap on the wire drive unit.

Remove the screws holding the

POWER INPUT CABLE ASSEMBLY

A special cable assembly is required to connect all LN9 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" connec-

tion. NOTE: Use of an LN-9 with a Pulse Power 500 or a

DC650 PRO requires a K442-1 Pulse Power Filter Kit.

FIGURE A.1 – INPUT CONTROL CABLE AND

ELECTRODE CABLE CONNECTIONS

CONDUCTOR

BLOCK

CONTROL

CABLE

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ELECTRODE

CABLE

LN-9 Wire Feeder

Page 11

A-5 A-5

INSTALLATION

FIGURE A.2 – STRAIN RELIEF CLAMP

CONTROL

CABLE

ELECTRODE

CABLE

STRAIN RELIEF

CLAMP

3. Remove the screws holding the cable clamp locat-

ed near the rear of the wire reel base. Put the control cable and the electrode cable under the clamp and install the screws. (On cables with more than one electrode cable, leave the junction between the cables and the single 4/0 stub behind the clamp so that only the single electrode lead is under the clamp.) Connect the electrode cable of the input cable assembly to the brass block on the hand crank.

4. Insert the connector on the conductor sheath of the

extension assembly into the brass block of the hand crank assembly. Tighten the locking screw with a 3/16 hex allen wrench.

FIGURE A.3 – LN-9NE/SE INPUT CONTROL

CABLE AND ELECTRODE CABLE CONNECTIONS

WIRE DRIVE

UNIT

POLARIZED

CONNECTOR

INPUT CABLE

ASSEMBLY

CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE LN-9NE or

LN-9SE

The hand crank drive rolls will feed all the wires used on the extension. The rolls have been stenciled for identification.

1. Position the extension assembly cable so that the amphenol plug with the threads on its O.D. can be attached to the amphenol end of the power input cable. Attach the opposite end to the wire drive unit. See Figure A.3.

2. Attach the amphenol extension assembly control cable (the one with threads on its O.D.) to the connector on the input cable assembly.

EXTENSION

CABLE

BRASS BLOCK

HAND

CRANK

WIRE REEL

BASE

5. At the wire drive unit, connect the amphenol of the extension control cable to the receptacle on the back of the LN-9.

6. Remove the ingoing guide tube from the rear brass block and then plug the connector of the conductor sheath into the brass block. Tighten the locking screw with a 3/16" hex allen wrench. The guide tube removed is not used when the extension assembly is installed.

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LN-9 Wire Feeder

Page 12

A-6 A-6

INSTALLATION

7. If using welding currents over 450 amperes, connect a length of 1/0 cable between the brass block on the hand crank and the input strap located in the wire drive unit. Tape this cable to the extension assembly. Proper cable lengths are as follows:

22-1/2 ft. extension 26’ M5906-106 45 ft. extension 46’ M5906-104

8. A handle is provided and is mounted to the wire drive unit in the following manner:

Remove the two self-tapping screws that hold the hinge pin in captivity. Push the hinge pin out, leaving the covers intact. Place the handle into the slots provided. Push the hinge pin back into the assembly, making sure that the pin goes through the holes in the handle. Put the two self-tapping screws back into their respective positions and tighten.

9. If the extension is being used with a K306 Wire Reel Flux Tank Assembly, the hose attached to the bottom of the flux tank may have to be shortened.

This hose is 64 feet long and is the correct length for use with the 45 foot extension. If a 22-1/2 foot extension is used, cut off 22-1/2 feet of the flux hose to give the correct length of 41-1/2 feet. (The conductor cable of the extension assembly is 221/2 feet long, tip to tip, and can be used to measure the length cut off.) If you tape the flux hose to the extension cables or the gun cable, be careful not to deform or collapse the flux hose.

CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE LN-9F

CONTROL BOX

1. See Figure A.4. Connect the MS-type plug of the K196, K595, or K596 control cable to the mating MS-type connector on the bottom of the LN-9F 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.

FIGURE A.4 – LN-9F CONTROL BOX

BOTTOM VIEW

CIRCUIT

BREAKER

9-PIN MS-TYPE CONNECTOR INPUT CABLE TOPOWER SOURCE

GLP

RESET

4-PIN CONTROL CABLE

TACHFEEDBACK

CONNECTOR

14-PIN MS-TYPE CONNECTOR CONTROL CABLE TOWIRE FEED HEAD

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LN-9 Wire Feeder

Page 13

A-7 A-7

INSTALLATION

CONNECTING THE POWER INPUT CABLE ASSEMBLY T O POWER

SOURCES

WARNING

Turn input supply power to the power source OFF before connecting the LN-9 or LN-9F 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,"

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 model connection diagram:

in the

Operation

Depending on the power source and process you are using, the jumpers on the LN-9 voltage board may have to be changed. As shipped, the LN-9 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 or DC650 Pro, the K442-1 Pulse Power Filter Kit must be installed in the LN-9. See the instructions included with the kit.

Figure A.5 for DC-250, DC-400 and CV-400, CV-500 l Figure A.6 for DC-600 Figure A.7 for DC-1000 Figure A.8 for Pulse Power 500

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LN-9 Wire Feeder

Page 14

A-8 A-8

INSTALLATION

FIGURE A.5 – CONNECTION OF LN-9 TO DC-250, DC-400, AND CV/CVI POWER SOURCES

WARNING

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

ELECTRIC SHOCK

can kill.

• 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 voltage control jumpers must be connected as follows:

*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.

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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”.

LN-9 Wire Feeder

Page 15

A-9 A-9

INSTALLATION

FIGURE A.6 – CONNECTION OF LN-9 TO DC-600 POWER SOURCES

WARNING

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

ELECTRIC SHOCK

can kill.

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

For optimum performance with the LN-9, 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 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 voltage control jumpers must be connected as follows:

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

8200.

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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”.

LN-9 Wire Feeder

Page 16

A-10 A-10

INSTALLATION

FIGURE A.7 – CONNECTION OF LN-9 TO DC-1000 POWER SOURCES

WARNING

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

ELECTRIC SHOCK

can kill.

• 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 which has a direct work lead jack). N.C. Tape up bolted connection. N.D. Connect the LN-9 control cable ground lead to the frame terminal marked near the power source terminal strip. The power

source must be properly grounded.

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 voltage control jumpers must be connected as follows:

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

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

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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”.

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”.

LN-9 Wire Feeder

Page 17

A-11 A-11

INSTALLATION

FIGURE A.8 – CONNECTION OF LN-9 TO PULSE POWER 500 POWER SOURCES

WARNING

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

ELECTRIC SHOCK

can kill.

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 sens-

ing 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 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 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 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.)

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

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

1. The LN-9 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

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conversion kits are available for all LN-9 model codes (below 9100 and above 9100).

LN-9 Wire Feeder

Page 18

A-12 A-12

INSTALLATION

MACHINE GROUNDING

LN-9 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

60% Duty Cycle

300 Amps 0 000 400 Amps 00 0000 500 Amps 000 0000

Copper Work Cable Size, AWG

Up to 50' length 50'-100' Iength

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. 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.

As an alternative, LN-9 models are provided with a quick-connect terminal splice connection in the #21 lead between the input Amphenol connector of the LN-9 and its polarity switch. See the LN-9 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-9N and S 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 control box to be connected directly to the work.

600 Amps 000 T wo 000

With either direct work lead connection method, the LN-9 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 wire feeder will stop welding shortly after the arc is struck. See the topic "

Automatic Shutdown"

this manual.

Circuit Protection and

in the

Operation

section of

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LN-9 Wire Feeder

Page 19

A-13 A-13

INSTALLATION

CONNECTING THE GUN CABLE TO THE WIRE FEEDER

A variety of gun and cable assemblies are available for the LN-9 models. See the manual.

Lay the cable out straight. Insert the connector on the welding conductor cable into the brass conductor block on the front of the wire drive unit. See Figure A.9. Make sure the connector is fully seated and tighten the locking screws with a 3/16" Allen wrench or handscrew (if provided). Keep this connection clean and bright. Connect the control cable polarized Amphenol plug into the mating 5-cavity receptacle on the front panel of the wire drive section.

Accessories

section of this

FIGURE A.9 – GUN CABLE CONNECTIONS

THUMB-

SCREW

AMPHENOL

CONNECTOR

GUN CABLE

ASSEMBLY

CONDUCTOR

BLOCK

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LN-9 Wire Feeder

Page 20

A-14 A-14

NOTES

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LN-9 Wire Feeder

Page 21

Section B-1 Section B-1

TABLE OF CONTENTS

- OPERATION SECTION -

Operation.................................................................................................................................Section B

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-3

Recommended Processes and Equipment.................................................................................B-3

DC Constant Voltage Power Sources..................................................................................B-3

Controls and Settings..................................................................................................................B-4

Circuit Protection and Automatic Shutdown.........................................................................B-7

Avoiding Ground Lead Protector (GLP) Activation...............................................................B-7

Drive Roll Installation and Pressure Setting ...............................................................................B-9

Changing Wire Feed Rolls and Guide Tubes for 2-Roll Wire Feeders................................B-9

Setting the Idler Roll Spring Pressure (2-Roll Wire Drives) .........................................B-10

Changing Wire Feed Rolls and Guide Tubes for 4-Roll Wire Feeders...............................B-11

Setting the Idler Roll Pressure (4-Roll Wire Drives).....................................................B-11

Wire Loading.............................................................................................................................B-14

Loading and Feeding Readi-Reels or Spools.....................................................................B-14

Loading a 22 to 30 lb. Readi-Reel Package ................................................................B-14

Loading a 15 to 30 lb. Spool ........................................................................................B-15

Loading 50 and 60 lb. Coils and Brake Adjustment...........................................................B-16

Loading and Feeding 13-14 lb. Innershield Coils ...............................................................B-17

Making a Test Weld and Adjusting Response and Starting Characteristics.............................B-18

Adjust the Power Source....................................................................................................B-18

Adjust the LN-9 Controls ....................................................................................................B-19

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

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LN-9 Wire Feeder

Page 22

B-2

OPERATION

SAFETY INSTRUCTIONS

Read and understand this entire section of operating instructions operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

B-2

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

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LN-9 Wire Feeder

Page 23

B-3 B-3

OPERATION

GENERAL DESCRIPTION

The LN-9 2-Roll and 4-Roll semiautomatic wire feeder models feature the precise "set and forget" digital procedure control. They are designed to achieve higher quality control and weld quality levels more easily . The arc voltage and wire feed speed can be set on a digital meter before the arc is struck and the procedure remains precisely set day in and day out.

The wire feed speed and arc voltage can be "SET" before or during welding, and the "ACTUAL" values can be read during welding. Wire feed speed and arc voltage will be held virtually constant regardless of input voltage variation, feeding force, loading of the power source, ambient temperature changes or a voltage drop in the electrode or ground circuit.

• Two drive rolls (driven) are used with calibrated idle roll pressure setting. Rolls are available for feeding .030 thru 3/32" solid and .045 through .120" flux cored steel electrodes, as well as .035 through 1/16 aluminum wires.

• Four drive rolls (driven) are available and they work on a "quick release"mechanism for easy access to drive rolls and guide tubes. Drive roll kits are available for the same electrode sizes as the 2-roll feeders.

DC CONSTANT VOLTAGE POWER SOURCES

The following welding system power sources are available for use with all LN-9 models:

The Idealarc®DC-250, DC-400, CV-400 and DC-600 are recommended for use with any LN-9 model. The Pulse Power 500 and DC650 Pro can also be used with the LN-9 with the installation of the optional K4421 Pulse Power Filter Kit.

SAM power sources may also be used.

RECOMMENDED PROCESSES AND EQUIPMENT

When combined with the broad selection of quality welding equipment and accessories, the LN-9 provides a versatile precision welding system to meet the specific needs of Outershield®, Innershield®or submerged arc welding processes. The capabilities of the LN-9 2-Roll and 4-Roll wire feeders are:

Rated wire size range:

.030 through 3/32" solid wire electrode. .045 through .120" Outershield®cored electrode. .062 through 7/64" lnnershield®cored electrode.

Rated wire speed range:

50 through 600 inches per minute. (1.27 through 15.2 meters per minute).

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LN-9 Wire Feeder

Page 24

B-4 B-4

OPERATION

CONTROLS AND SETTINGS

Operator controls for LN-9N, NE, S and SE models are shown in Figure B.1. Controls for LN-9F models are shown in Figure B.2. Refer to these figures and the following descriptions of the controls.

ELECTRODE POLARITY SWITCH: The polarity switch is located inside the wire drive section on the LN-9 model and on the front panel of both the LN-9F 2-Roll and 4-Roll control box. Set the switch to the same polarity as the electrode lead connection to the power source. If the switch is not set for the correct polarity, the wire feeder will stop welding shortly after the arc is struck. See the topic

Shutdown"

WIRE FEED DIRECTION SWITCH: The direction

switch is located inside the wire drive section on the LN-9 model and on the front panel of both the LN-9F 2-Roll and 4-Roll control box. This switch permits the wire to be fed in either direction when the trigger is pressed or when using the cold inch switch feature of the K202 Burnback kit. Be sure this switch is set for forward feed when you are ready to weld.

later in this section of the manual.

"Automatic

HOT-COLD TRIGGER INTERLOCK SWITCH: This

switch is located on the front rail on the LN-9 model and on the front panel of both the LN-9F 2-Roll and 4-Roll control box. The three-position switch serves a dual purpose:

1. "Hot-Cold" Wire Feed - In the center position the wire will be electrically cold when feeding with the gun trigger. In either the up or down positions the wire will be "hot" when feeding with the gun trigger.

2. Trigger Interlock Function - In the down position the trigger interlock will be OFF, allowing the gun trigger to function in the normal mode. This stops wire feed and welding when the trigger is released. In the up position the trigger interlock will be ON. The trigger interlock feature functions as follows:

a) When you are not welding, the trigger will function

in the normal mode, which feeds only when the trigger is closed.

b) Once the welding arc has been struck, the gun

trigger may be released. Welding will continue until one of the following occurs:

• The arc is extinguished by quickly pulling the gun

away from the work.

• The trigger is again depressed and released.

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LN-9 Wire Feeder

Page 25

B-5 B-5

OPERATION

FIGURE B.1 – WIRE FEEDER CONTROLS FOR LN-9N, NE, S, SE

CIRCUIT BREAKER

GROUNDING LEAD PROTECTOR(GLP) RESET SWITCH

HOT-COLD TRIGGER INTERLOCK SWITCH

VOLTS CONTROL

WIRE SPEED CONTROL

METER READING SWITCH

DIGITAL METER

SET-ACTUAL PUSHBUTTON

ELECTRODE POLARITY SWITCH

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WIRE-FEED DIRECTION SWITCH

LN-9 Wire Feeder

Page 26

B-6 B-6

OPERATION

FIGURE B.2 – WIRE FEEDER CONTROLS FOR LN-9F

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LN-9F CONTROL BOX BOTTOM VIEW

LN-9 Wire Feeder

Page 27

B-7 B-7

OPERATION

CIRCUIT BREAKER AND GROUNDING LEAD PROTECTOR (GLP) RESET SWITCH: These protection

circuit devices are located on the front rail of the LN-9 model and bottom panel of the LN-9F models. See the topic

"Circuit Protection and Automatic Shutdown"

later in this section of the manual. DIGITAL METER: A three-digit digital meter is provid-

ed to set and monitor the welding procedure. The arc voltage is displayed in volts and the wire feed speed is displayed in inches/minute or meters/minute.

METER READING SWITCH, VOLTS AND WIRE SPEED CONTROLS: This four-position rotary switch

is located to the right of the digital meter on LN-9models and to the left of the digital meter on LN-9F models. When set to the "Volts" position, the meter reads the arc voltage setting as adjusted by the "Volts" control. The rated setting range for all the LN-9 models is 12.0 to 60.0 volts.

The three "Wire Speed" positions include an English position, for meter readings in inches/minute; and "LO" and "HI" range metric positions for meter readings in meters/minute. The wire feed speed setting is adjusted by the "Wire Speed" control. The rated setting range for all the LN-9 models are 50 to 600 inches/minute (1.27 to 15.2 meters/minute).

When using metric meter readings, set the switch to "LO" for more precise meter readings up to 393 in/min (9.99 m/min.). For higher wire feed speeds, the "LO" position will result in an over-range meter reading of E.EE which indicates that the "HI" range, with single decimal place resolution, should be used. Similarly, EEE will be displayed on the English position if the setting exceeds 999 inches/minute.

The procedure adjustments can be made before or during the weld. This feature permits the operator to set the welding voltage and wire speed before welding and without assistance.

Once set, the control circuits of the LN-9 will continuously monitor the volts and wire speed and correct any deviation from the set value so there will be negligible change.

Should the range of the power source output voltage be such that the unit circuit cannot keep the arc voltage as set, the unit will stop welding shortly after the arc is struck. See the topic

Shutdown"

SET-ACTUAL PUSHBUTTON: After the weld has

been started, the ACTUAL voltage or wire speed can be read by pressing the pushbutton to the left of the meter. The METER READING switch must be set in the desired position. When the pushbutton is not being operated, the meter continues to read the SET value.

"Circuit Protection and Automatic

later in this section of the manual.

CIRCUIT PROTECTION AND AUTOMATIC SHUTDOWN

CIRCUIT BREAKER

The circuit breaker normally trips only when excessive loading in the wire feed cable or a defective motor or control component causes an overload. After allowing a minute for cooling, push in the circuit breaker button and weld. If it trips again, be sure the wire feed cable is clean and the proper size for the wire diameter being fed. Also look for excessive drive roll pressure and readjust if necessary. If the breaker still trips, look for a defective electrical component. When the circuit breaker is tripped, the digital meter is off and the trigger circuit will not operate.

POWER SUPPLY FUSE

The fuse on the PM power board inside the control box protects the power supply circuit. When the fuse is blown, the digital meter is off and the trigger circuit will not operate.

VOLTAGE PC BOARD FUSE

The 1/8 amp fast-blow fuse protects the LN-9 circuitry from damage that may result from a ground, or case, faulted control lead. If this fuse blows, the LN-9 arc voltage sensing lead circuit will be opened. See the topic

"Automatic Shutdown"

MOTOR THERMAL PROTECTION

The temperature sensing thermal protector mounted in the motor frame opens the control circuit if the motor overheats. Excessive loading and/or very rapid triggering may cause overheating. The thermal sensor protects the motor without nuisance tripping. The thermal protector automatically resets itself after the motor cools sufficiently (may take 10-15 minutes). Reset time can be shortened by removing supply power to the LN9 and also by cooling the motor with an air hose or fan. When the protector is tripped, the digital meter is lit but there will be zero reading. The trigger circuit will not operate.

below.

AVOIDING GROUNDING LEAD PROTECTOR (GLP)

The frames of all LN-9 wire feed units and drive motors are grounded to the frame of the power source by a lead in the control cable. An overload protector prevents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the gun trigger is pressed.

SHUTDOWN

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LN-9 Wire Feeder

Page 28

B-8 B-8

OPERATION

If such a grounding lead fault occurs, the meter will still be on and will be reading. The trigger circuit will not operate, however. To release the circuit, press the "GLP Reset" button. See location of this button.

The following precautions are recommended to avoid GLP shutdown:

• Do not allow the electrode to contact the case of the wire feeder or uninsulated part of its wire reel stand when the gun trigger is activated.

• Be sure that all work lead connections to the work make tight metal-to-metal electrical contact.

• Do not allow excess input cable or work cable to be placed closer than 3 feet to the wire feeder.

• Do not coil excess input cable assembly or use an

uncoiled assembly as shipped from the factory. Instead, loop excess length back and forth in 3 to 6 foot straight lengths. Coiling the input cable results in a transformer action between the electrode conductor cable and ground lead in the multiconductor cable and the ground lead in the multiconductor control cable. This can cause current to flow in the ground lead, which will falsely activate the GLP.

AUTOMATIC SHUTDOWN

If the LN-9 voltage control is unable to supply the SET value of arc voltage while welding, the automatic shutdown circuit will activate. This protection circuit immediately returns the LN-9 control to idle state within a few seconds after the arc voltage discrepancy occurs.

Figure B.1 or B.2

for the

the various taps. For instance, if the R3S-400 triangle tap setting is for 31 volts, the range of control from the remote circuit is approximately 7 volts, i.e., 27-1/2 to 34-1/2 volts at nominal input voltage. If the LN-9 controls are set for 29 volts and the input voltage to the R3S goes up, it may not be possible for the LN-9 control circuit to hold the 29 volts. The welding will shut down. By changing to the 27 volt triangle setting, the range will be approximately 23-1/2 to 30-1/2 volts, and at high input voltage there will be sufficient control to hold the SET arc voltage. On these machines, if the LN-9 stops welding, follow this procedure:

a) Move the LN-9 voltage set point 2 volts lower than

the desired procedure and make a test weld.

If the LN-9 still shuts down, go to Step b. below.

2. If the LN-9 keeps welding, change the R3S triangle setting to the next higher voltage and reset the LN-9 set point to the desired procedure. R3S is now set properly unless there is a significant change in input voltage. Skip the following step.

b) Move the LN-9 voltage set point 2 volts higher than

the desired procedure and make a test weld.

1. If the LN-9 now keeps welding, change the R3S triangle setting to the next lower voltage and reset the LN-9 set point to the desired procedure. R3S is now set properly unless there is a significant change in input voltage.

2. If the LN-9 still shuts down, refer to the paragraph below and the other possible causes previously listed.

Typical causes for the activation of this protective shutdown circuit are as follows:

a) SET value of arc voltage is outside the power

source range. b) Power source voltage control not set for REMOTE. c) Misconnection of LN-9 control cable leads to

power source. d) Incorrect weld polarity connections, or settings, at

the LN-9 or the power source. e) Lost connection of LN-9 voltage sensing leads

(#67 and #21) between the arc and voltage control,

or a blown 1/8 amp fuse on the Voltage PC board. Although out of range shutdown can occur with all

power sources when working with very low or very high arc voltages, it is most likely to occur when using the R3S models with somewhat limited voltage range of

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In some cases, it is also possible to hold the ACTUAL button pressed while starting the arc. Before the LN-9 shuts down, the actual arc voltage can be read on the digital meter. Comparing this reading to the SETreading will tell what change in the range controls of the power source is required to supply the desired voltage. Should the meter read zero, check the connections of LN-9 sensing leads #21 and #67. Should the meter read a minus (-) voltage, the polarity connections or settings at the LN-9 or power source are wrong.

The same general procedure can be used on other power sources. For example, if the LN-9 keeps shutting down and the other possible causes have been checked, adjust the SET voltage higher and/or lower than the desired voltage. Then you can determine what change in the range controls of the power source is required to supply the desired voltage.

LN-9 Wire Feeder

Page 29

B-9 B-9

OPERATION

DRIVE ROLL INSTALLATION AND PRESSURE SETTING

CHANGING WIRE FEED ROLLS AND GUIDE TUBES FOR TWO-ROLL

To change drive or idle rolls on a two-roll wire feeder, refer to Figure B.3 and perform the following steps:

1. Loosen idle roll spring pressure screw.

2. Remove clamping collar from the drive shaft.

3. Install drive roll and replace clamping collar.

Tighten screw.

WIRE FEEDERS

FIGURE B.3 – 2 ROLL WIRE FEED MECHANISM

4. Remove idle roll shaft screw - install idle roll. Replace screw and tighten.

NOTE: The Aluminum Wire Drive Roll Kits have one-piece drive rolls and idle rolls with a larger chamfer on one side, instead of gear teeth. This larger chamfer side must face the gearbox when installed. The side with the smaller chamfer and wire size stencil must be installed facing out.

5. Remove the large ingoing guide from rear brass block by loosening screw.

OUTGOING

GUIDE TUBE

LOCKING

SCREW

CLAMPING

COLLAR

SCREW

IDLE ROLL

SHAFT SCREW

DRIVE

ROLL

IDLE

ROLL

INGOING GUIDE TUBE

CLAMPING SCREW

GUIDE

TUBE

SCREW

IDLE ROLL SPRING

PRESSURE SCREW

INGOING

GUIDE

TUBE

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LN-9 Wire Feeder

Page 30

B-10 B-10

OPERATION

6. Loosen the ingoing guide tube clamping screw. Install the all steel guide tube through the rear brass block. Tighten the locking screw.

7. Replace the large ingoing guide tube into rear brass block.

8. Install the outgoing guide tube with its plastic insert through front brass block. Tighten the locking screw so its dog point goes into the groove in the O.D. of the guide tube.

NOTE: The drive rolls and guide tubes are stamped with the wire size ranges (in inches and mm) for which they are designed. If a wire size other than that stamped is to be used, the drive rolls and guide tubes will have to be changed. Drive rolls stamped with a "(C)" or "(H)" suffix to the wire size range are recommended specifically for use with cored wires.

SETTING THE IDLER ROLL SPRING PRESSURE (2-ROLL WIRE DRIVES)

For Steel Wire, the idle roll pressure should be adjusted as follows:

The idle roll pressure indicator should be set to the proper wire size indication shown on the appropriate "solid" or "cored" side of the idler roll spring pressure nameplate. This setting is a starting point and may have to be changed depending upon type of wire surface condition, lubrication, and hardness.

For Aluminum Wire, the idle roll pressure should be adjusted as follows:

1. With low idle roll pressure, load the feeder so it’s ready for welding.

2. Run the feeder at a slow speed (about 100 IPM) and reduce the idle roll pressure until the idler roll stops rotating.

3. Slowly increase idle roll pressure until the idle roll just starts to rotate consistently with the drive roll without slippage, then add an extra 1/4 to 1/3 turn more idle roll pressure.

This pressure setting should be optimum for feeding and to avoid "bird-nesting" by allowing the drive roll to slip on the wire if a gun cable jam or stoppage occurs. If using harder or larger dia. aluminum wires, more idle roll pressure, if necessary, can be tolerated. However, if the pressure required to properly feed the aluminum wire also permits "bird-nesting," or if excessive slippage results in aluminum pickup in the drive roll groove, the loading on the wire by the gun-cable or wire reel should be inspected and adjusted.

The optimum idle roll setting can be determined when there are wire stoppages. If the wire "bird nests" between the drive roll and the guide tube, the idle roll spring pressure is set too high. When set, during a stoppage the drive rolls will slip. If the electrode is removed from the cable there will be a slight waviness in the electrode for about a foot beyond the slip marks on the electrode. If there is no waviness, the pressure is set too low.

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LN-9 Wire Feeder

Page 31

B-11 B-11

OPERATION

CHANGING WIRE FEED ROLLS AND GUIDE TUBES FOR 4-ROLL WIRE FEEDERS

To change drive rolls on a 4-roll wire feeder, refer to

Figure B.4

1. Release both quick release levers.

2. Remove clamping collars from both drive shafts.

3. Install one drive roll and replace clamping collar. Tighten screw.

4. Slide the middle guide tube into place. Do not tighten set screw.

5. Install second drive roll and replace clamping collar. Tighten screw. (Note: The middle guide tube may need to be pushed up tight against the first drive roll to allow room for installing the second roll.)

6. Center the middle guide tube and lock in place with its set screw.

7. Remove the idle roll quick release pins - install idle rolls. Replace pins.

NOTE: The aluminum wire drive roll kits have onepiece drive rolls and idle rolls with a larger chamfer on one side, instead of gear teeth. This larger chamfer side must face the gearbox when installed. The side with the smaller chamfer and wire size stencil must be installed facing out.

8. Loosen the ingoing guide tube clamping screw. Install the all steel guide tube. The guide tube should be slid in until it almost touches the drive rolls. Tighten the locking screw.

9. Install the outgoing guide tube with its plastic insert through the front brass block. Tighten the locking screw so its dog point goes into the groove in the O.D. of the guide tube.

NOTE: The drive rolls and guide tubes are stamped with the wire size ranges (in inches and mm) for which they are designed. If a wire size other than that stamped is to be used, the drive rolls and guide tubes will have to be changed. Drive rolls stamped with a “(C)” suffix to the wire size range are recommended specifically for use with cored wires.

and perform the following steps:

SETTING THE IDLER ROLL PRESSURE (4-ROLL WIRE DRIVES)

Because every feeding situation is different, the 4-roll wire drive does not have graduated markings with wire sizes indicated on it. A recommended starting pressure is indicated below for each applicable wire size and type. Depending on the particular application, these starting pressures may need to be adjusted up or down. Some of the variables that affect tension settings are type and brand of electrode, surface condition, lubrication, harness, type and length of cables and conduits, routings of cables and conduits, and drive roll wear.

In most applications, the front and rear drive roll pressures should be adjusted the same. To adjust, start by releasing both "quick release" arms. Tighten the tension adjusting screws to full pressure and then back off per the particular instructions for your electrode size and type as outlined below.

For Steel Wire

1. .030-.052" solid-----------4 turns from maximum .045-.052" cored--------12 turns from maximum

The optimum pressure setting can be determined when there are wire stoppages. If the wire "birdnests" between the rolls and guide tubes, the pressure is too great. When properly set, during a stoppage the drive rolls will slip. If the electrode is removed from the cable there will be a slight waviness in the electrode for about a foot beyond the slip marks on the electrode. If there is no waviness, the pressure is too low.

2. 1/16" solid-----------2 to 4 turns from maximum .062" cored----------7 to 8 turns from maximum

These settings should be accurate unless the electrode is unusually soft or the feeding path is excessively long or curved.

3. .068-3/32" solid----8 to 10 turns from maximum .068-.120" cored----6 or 7 turns from maximum

Larger wire settings are accurate for nearly all applications. Some unusual circumstances will require "fine tuning."

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LN-9 Wire Feeder

Page 32

B-12 B-12

OPERATION

For Aluminum Wire Each set of rolls should have their pressure set

independent of the other. To do this, release and open the other quick release arm while making each adjustment. Follow the procedure below for each adjustment.

1. With low idle roll pressure, load the feeder so it’s ready for welding.

2. Run the feeder at a slow speed (about 100 IPM) and reduce the idle roll pressure until the idle roll stops rotating.

3. Slowly increase idle roll pressure until the idle roll just starts to rotate consistently with the drive roll without slippage, then add an extra 1/4 to 1/3 turn more idle roll pressure.

This pressure setting should be optimum for feeding and to avoid "bird-nesting" by allowing the drive roll to slip on the wire if a gun cable jam or stoppage occurs. If using harder or larger dia. aluminum wires more idle roll pressure, if necessary, can be tolerated. However, if the pressure required to properly feed the aluminum wire also permits "bird-nesting," or excessive slippage results in aluminum pickup in the drive roll groove, the loading on the wire by the gun-cable or wire reel should be inspected and adjusted.

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LN-9 Wire Feeder

Page 33

B-13 B-13

OPERATION

FIGURE B.4 – INSTALLING DRIVE ROLLS ON A 4-ROLL FEEDER

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LN-9 Wire Feeder

Page 34

B-14 B-14

OPERATION

WIRE LOADING

LOADING AND FEEDING READI-REELS OR SPOOLS

LOADING A 22 TO 30 LB. READI-REEL PACKAGE USING THE MOLDED PLASTIC K363-P TYPE ADAPTER:

1. Make certain that the threaded locking collar is tight and securely locks the adapter on the spindle. See Figure B.5.

2. Rotate the spindle and adapter so that the retaining spring is at the 12 o'clock position.

3. Position the Readi-Reel so that it will rotate in a clockwise direction when feeding (wire de-reels from the bottom of the coil).

4. Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab.

5. Lower the Readi-Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter.

6. Slide the cage all the way onto the adapter until the retaining spring "pops up" fully.

WARNING

CHECK TO BE SURE THE RETAINING SPRING HAS FULLY RETURNED TO THE LOCKING POSITION AND HAS SECURELY LOCKED THE READI-REEL CAGE IN PLACE. THE RETAINING SPRING MUST REST ON THE CAGE, NOT THE WELDING ELECTRODE.

2 IN. O.D. SPINDLE

BRAKE

HOLDING

FIGURE B.5 – INSTALLING A 30-LB. READI-REEL PACKAGE

ADAPTER

RETAINING SPRING

GROOVES

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READI-REEL

LN-9 Wire Feeder

INSIDE CAGE WIRES

THREADED

LOCKING

COLLAR

Page 35

B-15 B-15

OPERATION

7. To remove the Readi-Reel from the adapter, depress the retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove the adapter from the spindle.

LOADING A 15 TO 30 LB. SPOOL (12" DIAMETER):

(For 8" spools, a K468 spindle adapter must be used.)

1. Remove the locking collar and the Readi-Reel adapter shipped on the 2" diameter spindle (adapter is not required).

2. Place the spool on the spindle making certain the brake holding pin enters one of the holes in the back side of the spool. Be certain the wire comes off the reel in a clockwise direction when de-reeled from the bottom of the coil.

3. Replace and tighten the locking collar.

ELECTRODE FEEDING AND BRAKE ADJUSTMENT

1. Turn the Readi-Reel or spool until the free end of the electrode is accessible.

2. While tightly holding the electrode, cut off the bent end. Straighten the first six inches. Cut off the first inch. (If the electrode is not properly straightened, it may not feed or may not go into the outgoing guide tube, causing a "birdnest.")

3. Insert the free end through the incoming guide tube.

4. Press the gun trigger or "cold inch" (if used) and push the electrode into the drive roll.

WARNING

5. Inch the electrode through the gun. NOTE: When feeding soft jacket electrodes such as

Lincore 60-0, remove tip from the gun tube before feeding electrode through the gun. When the electrode is cut off, the start end of the electrode is usually too large to fit through the tip.

6. Adjust the brake tension with the thumbscrew on the spindle hub, until the reel turns freely but with little or no overrun when wire feeding is stopped. Do not overtighten.

WHEN USING THE EXTENSION ASSEMBLY (models LN-9NE and LN-9SE)

1. Slide the ingoing guide tube of the hand crank to the forward position.

2. Remove start end of coil from hole in wire reel cover, straighten the first six inches or so of the wire and then insert this end in the ingoing guide tube. Push a foot or so of wire through.

3. Pull the ingoing guide tube back to the rear position and rotate it 90oso that it will remain in this position during the cranking operation.

4. Pull the plastic hand crank handle to the "out" position in the arm.

5. Pull the shaft and drive roll assembly to the "out" position with the left hand.

6. Apply a downward pressure to the idler roll pressure arm with the right hand. Maintain this pressure and start cranking the wire through the system. Keep the conductor cable as straight as possible during the loading operation. This will make it much easier to crank the wire through. Crank until the wire touches the drive rolls and feed the wire the rest of the way through the cable and gun assembly.

USE THE "COLD" TRIGGER SWITCH POSITION, OR "COLD INCH" OPTION WHEN LOADING. WHEN INCHING WITH A"HOT" GUN TRIGGER, THE ELECTRODE AND DRIVE MECHANISM ARE ALWAYS "HOT" TO WORK AND GROUND AND COULD REMAIN "HOT" SEVERAL SECONDS AFTER THE GUN TRIGGER IS RELEASED.

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WARNING

The electrode is "HOT" to ground while inching with the gun trigger.

7. Push the plastic of the hand crank to the "in" position and shift the ingoing guide tube to the forward position.

LN-9 Wire Feeder

Page 36

B-16 B-16

SPINNER

NUT

COVER

PLATE

COIL

REEL

SLOTS

CARDBOARD COIL LINER

TIE WIRE

SPRING LOADED ARM

OPERATION

LOADING 50 AND 60 LB. COILS AND BRAKE ADJUSTMENT (K299 or K303 Wire Reel Stand)

1. To remove the wire reel from its shaft, grasp the spring loaded knob and pull it out. This straightens the knob so that it seats into the shaft when released. Remove the reel.

2. Lay the reel flat on the floor, loosen the spinner nut and remove the cover plate.

3. Before cutting the tie wires, place the coil of electrode on the reel so that it unwinds as the reel rotates clockwise.

a) Be sure the coil is placed so that the spring loaded

arms will not interfere with the later removal of the coil tie wires. See Figure B.6.

FIGURE B.6 – LOADING A 50 OR 60 LB. COIL

b) When loading 0.030, 0.035 and 0.045" electrode,

be certain the coil is placed on the reel so that the spring loaded arms are at the center of the slots in the cardboard coil liner. This provides the positive compression of the coil sides needed for trouble free wire feeding. See Figure B.6.

c) Put the cover plate on the reel so that the four arms

of the cover straddle and are in line with the spring loaded arm of the reel.

4. Tighten the cover as much as possible by hand. DO NOT hammer on the spinner nut arms.

5. Cut and remove only the tie wire holding the free end of the coil. Insert the free end into one of the holes in the cover and secure it by bending it back. Cut and remove the remaining tie wires.

CAUTION

Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls. Failure to do this will result in "backlashing" of the coil, which may tangle the wire. A tangled coil will not feed; therefore it must either be untangled or discarded.

6. Replace the reel on the wire feeder. Grasp the shaft knob, pull it out and swing it across the reel hub, locking the reel in place.

7. The mount for standard 50 and 60 pound electrode coils includes a two-position brake assembly. Generally the brake should be at the inner position (nearest to the wire reel shaft) for wire feed speeds below 400 in/min. It should be at the outer position for the faster wire speeds often used when feeding small diameter electrode.

To adjust the brake position, remove the wire reel. Pull the cotter pin that holds the brake shoe to the arm, move the shoe and replace the cotter pin. Do not bend the cotter pin - it is held in place by a friction fit.

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LN-9 Wire Feeder

Page 37

B-17 B-17

OPERATION

ELECTRODE FEEDING

1. Turn the reel until the free end of the electrode is accessible.

2. While tightly holding the electrode, cut off the bent end. Straighten the first 6 inches.

3. Cut off the first inch. Insert the free end through the incoming guide tube.

4. Insert the free end through the incoming guide tube.

5. Press the gun trigger or “cold inch” (if used) and push the electrode into the drive roll. (If the electrode is not properly straightened, it may not feed or may not enter the outgoing guide tube, causing a "birdnest.")

6. Inch the electrode through the gun.

WARNING

USE THE "COLD" TRIGGER SWITCH POSITION, OR "COLD INCH" OPTION WHEN LOADING. WHEN INCHING WITH A"HOT" GUN TRIGGER, THE ELECTRODE AND WIRE FEEDING SYSTEM ARE ALWAYS "HOT" TO WORK AND GROUND AND COULD REMAIN "HOT" SEVERAL SECONDS AFTER THE GUN TRIGGER IS RELEASED.

LOADING AND FEEDING 13-14 LB. INNERSHIELD COILS (K378 REEL MOUNTING STAND AND K435 SPINDLE ADAPTER)

The K378 small mounting stand for the 14 pound Innershield coil does not have an adjustable brake. It has a fixed drag built into the reel spindle.

To load a 14 pound coil:

1. Remove the snap-on lid from the plastic canister.

2. Remove the center clamping nut and the cover plate from the wire reel.

3. Unpack the 14-pound coil of wire. Be sure not to bend the side tangs of the coil liner. Straighten any tangs that may have been bent.

4. Remove the start end of the coil from its holding slot in the coil liner, cut off the bent end, straighten the first six inches, and cut off the first inch. (If the electrode is not properly straightened, it may not feed or may not go into the outgoing tube, causing a "birdnest.") Thread it through the canister wire feed liner until about four inches of electrode are exposed.

5. Place the coil onto the disc support.

6. Replace the front reel cover and center clamping nut, keep the reel from turning and tighten the clamping nut securely.

7. Thread the exposed end of the electrode into the wire feeder until it touches the drive rolls. Actuate the gun trigger, and feed the electrode through the system.

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LN-9 Wire Feeder

Page 38

B-18 B-18

OPERATION

MAKING A TEST WELD AND ADJUSTING LN-9 RESPONSE

AND

STARTING CHARACTERISTICS

ADJUST THE POWER SOURCE

DC-250, DC-400, or DC-600*

1. Connect electrode lead to terminal of desired polarity.

2. Set toggle switch to same polarity as the electrode cable connection.

3. Set toggle switch to "Output Control Remote."

4. Set mode switch to the desired position for the process to be used.

* DC-600 codes 8288 and above are preferred.

CV-400, CV-500-I

1. Connect electrode lead to terminal of desired polarity.

2. Install the R3S voltage triangle to the position higher than the desired arc voltage, provided it does not result in out of range shutdown of the LN-9 while welding. See

Shutdown

manual.

SAM

1. Set "Electrode Polarity" switch to the appropriate "Constant Voltage" or "Variable V oltage" position of the desired polarity for the process being used on the SAM-400, or set desired polarity on the SAM-

650.

2. Set the toggle switch to "Constant Voltage."

3. Set the "Constant Voltage Control" rheostat to Number 5 for Innershield and other open arc processes. (Use the maximum slope Innershield tap of SAM-650.) Set the "Constant Voltage Control" rheostat to Number 7 and the "Current Control" rheostat to 500 for CV subarc processes. (Use 300-575 tap of SAM-650.)

in the Operation section of this

Automatic

2. Connect #21 control lead to the work polarity terminal (+21 or -21), at the terminal strip, matching the same polarity as the work cable connection.

3. Set toggle switch to "Output Control Remote."

R3S-400, R3S-600, R3S-800

1. Connect electrode lead to terminal of desired polarity.

2. Set toggle switch to same polarity as the electrode cable connection.

3. Set the toggle switch to "Remote."

4. Install voltage triangle to a position as close as possible to desired arc voltage. See

Shutdown

NOTE: Since the LN-9 cannot control the fixed

in the Operation section.

OCV of R3S power sources, starting difficulties may be experienced when striking the arc of processes which use a low voltage or a narrow voltage range. The following steps should remedy this difficulty:

Automatic

PULSE POWER 500, DC650 PRO

Refer to each machine Instruction Manual. The LN-9 requires the K442-1 Pulse Power Filter Kit. For LN-9 codes below 9100, use kit K442-2. (See the

Accessories

section of this manual.)

1 . The electrode stickout when starting should be

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as close to procedural length as possible, and the tip of the electrode should be clean and held nearly touching the work.

LN-9 Wire Feeder

Page 39

B-19 B-19

OPERATION

ADJUST THE LN-9 CONTROLS

1. Set the "Electrode Polarity" switch to same polarity as the electrode lead.

2. Connect the "Direct Work Lead" if it is going to be used.

3. Check that "Feed Direction" is set to forward.

4. Set the "Trigger Interlock" switch as desired.

5. Set the "Meter Reading" switch to "Wire Speed" and adjust the "Wire Speed" rheostat so the meter reads the desired wire feed speed.

6. Set the "Meter Reading" switch to "Volts" and adjust the "Volts" rheostat so the meter reads the desired arc voltage. IMPORTANT: Make certain this setting is within the voltage output range of the power source setting.

7. Load the LN-9 with electrode.

VOLTAGE CONTROL RESPONSE

The LN-9 is provided with selectable voltage control response. Proper setting depends on the power source and process being used. Refer to the appropriate power source connection diagram for the proper connection of the jumpers located on the LN-9 Voltage PC Board and Start PC Board (only in models using L6084 Voltage PC Board).

To change the voltage control response:

1. Turn OFF the control power to the LN-9 at the power source.

2. Remove the screws holding the control section cover in place and swing open.

3. Position the jumper plugs on the Voltage Board and Start Board (where used) according to the appropriate power source connection diagram.

4. Reassemble.

STARTING CHARACTERISTICS

SELECT ACCELERA TION

The LN-9 models can provide optimum starting for different processes. The wire feeder is designed to start with two different speeds of controlled acceleration. As shipped, it is connected for fast acceleration, which is the best for most open arc procedures. However, the slower acceleration may be more desirable for Linc-Fill long stickout applications and most submerged arc

procedures. If the electrode being used does not give satisfactory starting because of "stubbing" or "blasting off," slower acceleration can be obtained by modifying the LN-9 models as follows:

1. Turn OFF the control power to the LN-9 at the power source.

2. Remove the screws holding the control section cover in place and swing it open.

3. Move the jumper plug on the Control PC board from pin "F" to pin "S."

4. Reassemble.

START VOLTAGE TRIM

The start voltage is the voltage provided by the welding power source before establishing the welding arc. This start voltage setting is a function of the open circuit voltage characteristic of the power source, the SET value of the weld voltage, and the start voltage trimmer (R41) setting on the LN-9 Voltage PC Board. As set at the factory, the start voltage trim level is typically about 20% higher than the LN-9 SET level. This generally gives good starting for steel cored and MIG processes using CO2or Argon/CO2blended shielding gas. If you are using "hotter" gases (such as Argon/Oxygen blends) and other processes (such as stainless steel MIG), arc flaring may occur at start, which requires lowering the start voltage trim as follows:

1. Turn off the control power to the LN-9 at the power source.

2. Remove the screws holding the control section cover in place and swing it open.

3. On the voltage board, locate trimmer R41 (below R40 next to the 1/8 amp fuse) and labeled START.

4. The slot on the START trimmer is marked with a red seal for factory setting. To decrease the factory setting, turn the slot CCW (opposite to the labeled arrow direction).

NOTE: If the start trim is set too low, stubbing may occur at start, requiring increasing the START trimmer by turning the slot CW (in the direction of the labeled arrow).

5. Reassemble.

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LN-9 Wire Feeder

Page 40

B-20 B-20

OPERATION

MAKING A WELD

1. Inch the electrode through the gun and cable and then cut the electrode within approximately 3/8" of the end of the contact tip for solid wire and within approximately 3/4" of the extension guide for cored wire.

2. Connect the work cable to the metal to be welded. The work cable must make good electrical contact to the work. The work must also be grounded as stated in the Safety section at the beginning of this manual.

3. Be sure the welding power source and the shielding gas supply (if used) are turned on.

4. Position the electrode over the joint. The end of the electrode should be slightly over the joint.

5. Lower the welding helmet, close the gun trigger and begin welding. Hold the gun so that the contact tip to weld distance gives the correct electrical stickout as required for the procedure being used.

6. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out.

PROCEDURE AT END OF COIL

When the wire on the reel is used up, follow this procedure for removing the old wire from the conductor cable and loading a new reel.

1. Cut the end of the electrode off at the gun end. Do not break it off by hand since this puts a slight bend in the wire and makes it difficult or impossible to pull it back through the nozzle.

2. Uncouple the gun conductor cable from the wire drive unit.

3. Lay the cable out straight.

4. Using pliers to grip the wire, pull it out of the cable from the connector end. Do not pull it from the gun end.

5. Put the conductor cable back on the wire drive unit after the electrode has been removed.

6. Load a new reel of wire and feed it through the cable as described earlier in this section.

SECURITY OF WELD PROCEDURE SETTINGS

There are two ways to prevent or limit unauthorized readjustment of the LN-9 voltage and wire feed speed controls.

1. Once the procedure is set, the security panel of the LN-9 can be locked to prevent access to the control knobs.

2. The control range of the procedure control knobs can be limited to either about 3% or about 15% of the full range control by installing a knob rotation stop screw to either or both of the control knobs. This stop screw is installed in the following manner:

a) Turn off the input power to the LN-9 unit. b) Loosen the knob set screw and remove the

control knob and the felt seal located behind the knob.

c) Remove the control potentiometer locknut and

fiber spacer, then open the control panel and remove the potentiometer from the panel.

d) Install a 1/2" long, pan or round head, #4 sheet

metal screw into the 0.10" dia. hole located .40" from the center of the potentiometer hole so that the head is on the back side of the panel (inside the control box).

e) Remount the control potentiometer with the

fiber spacer under the locknut, then close and secure the control panel.

f) Replace the felt seal around the fiber spacer

so that the #4 screw protrudes between the fiber spacer and the felt seal.

g) Turn on the input power to the LN-9 unit and

set the desired procedure by rotating the potentiometer shaft.

h) Carefully replace the control knob so that the

#4 screw inserts into the center of the shorter length channel on the back of the knob for about 3% of the total range of control, or the center of the longer length channel for about 15% of the total range of control.

i) With finger pressure on the knob against the

felt seal, carefully retighten the knob set screw.

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NOTE: Steps g) through i) will have to be repeated if

you want to change the set procedure to a value outside the selected 3% or 15% control range limit.

LN-9 Wire Feeder

Page 41

Section C-1 Section C-1

TABLE OF CONTENTS

- ACCESSORIES -

Accessories .............................................................................................................................Section C

Auxiliary Equipment Contacts.....................................................................................................C-2

Optional Equipment and Accessories .........................................................................................C-2

Power Input Cable Assemblies (K196, K595, K596)............................................................C-2

Wire Reel Stands and Mountings.........................................................................................C-2

50-60 lb. Wire Reel Mounting Stand (K303)..................................................................C-2

50-60 lb. Readi-Reel Mounting Stand (K445)................................................................C-2

Attaching the Wire Reel Stands.....................................................................................C-3

Wire Reel Door Kit (M-11514)........................................................................................C-3

Spindle for Readi-Reels and 2" I.D. Spools (K162-H) ...................................................C-3

Readi-Reel Adapters......................................................................................................C-3

Small Mounting Stand for Readi-Reel Coils or 2" I.D. Spools (K377)...........................C-3

Small Mounting Stand for 13-14 lb. Innershield Coils (K378)........................................C-3

50-60 lb. Wire Reel Assembly for Customer Mounting (K299)......................................C-3

Gun and Cable Assemblies..................................................................................................C-4

Wire Feeder Accessories.....................................................................................................C-5

Burnback Delay Kit (K202) .............................................................................................C-5

Dual Process Kit (K317) .................................................................................................C-5

Dual Process Kit (K318) .................................................................................................C-5

Dual Procedure Kit (K319).............................................................................................C-5

Pulse Power Filter Conversion Kit (K442-1) ..................................................................C-5

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Swivel Platform (K178-1)................................................................................................C-6

Undercarriage (K163) .....................................................................................................C-6

Continuous Flux Feed Tank (K320)................................................................................C-6

K320 Flux Tank Loading.................................................................................................C-6

Flux Screen (K310) ........................................................................................................C-6

Magnetic Separator (K58)..............................................................................................C-7

Mechanized Hand Travel Unit (K110) ............................................................................C-7

Squirtmobile (K62)..........................................................................................................C-7

Mechanized Travel Power Pack (K161-XX)...................................................................C-7

Gas Solenoid Kits...........................................................................................................C-7

Power Extended Wire Drive (K392)...............................................................................C-7

Enclosed Reel Mounting (K304) ....................................................................................C-7

Extension Assembly (K307 or K308)..............................................................................C-7

Fillet Guide (K70) ...........................................................................................................C-7

Linc-Fill Guides...............................................................................................................C-7

Drive Roll and Guide Tube Kits (Table C.2)...................................................................C-8

LN-9 Wire Feeder

Page 42

C-2 C-2

ACCESSORIES

AUXILIARY EQUIPMENT CONTACTS

The power for 115 volt AC auxiliary equipment can be obtained from the terminals inside the LN-9 control box. The contacts are “hot” whenever the trigger is pressed or the unit is welding. The current draw of this circuit must not exceed 1/4 ampere.

WARNING

TURN THE INPUT POWER TO THE POWER SOURCE OFF AT THE DISCONNECT SWITCH BEFORE PERFORMING THE FOLLOWING WORK.

LN-9N, NE, S, SE MODELS:

Install 1/4” quick connect terminals to the leads from the auxiliary equipment. Route the leads to the terminals marked #32A and #7 which come through the rectangular hole in the control section sheet metal near the wire feed motor.

LN-9F 2-ROLL AND 4-ROLL MODELS:

Install terminals for #6 screws to the leads from the auxiliary equipment. Route the leads to the terminals #32A and #7 on the terminal strip on the inside bottom of the control box.

NOTE: The K202 Burnback Delay kit does not delay the opening of the auxiliary equipment contacts. If you want to continue power to auxiliary equipment during the burnback time, this can be accomplished only if you are using an R3S, DC-400 or DC-600 power source. Connect the 115 volt AC auxiliary equipment leads to #4 and #31 on the power source terminal strip. The auxiliary equipment power requirements should not exceed 15 watts.

OPTIONAL EQUIPMENT AND ACCESSORIES

POWER INPUT CABLE ASSEMBLIES (K196, K595, K596)

Required to connect wire feeder to power source. Includes multiconductor control cable and the proper size electrode cable for the welding current to be used. Specify length and maximum welding current.

• K196 Input Cable Assemblies - For power sources with terminal strip wire feeder connections and stud output terminals.

• K595 Input Cable Assemblies - For power sources with MS-type (Amphenol) wire feeder receptacle and stud output terminals.

• K596 Input Cable Assemblies - For power sources with MS-type (Amphenol) wire feeder receptacle and Twist-Mate™ output connectors.

WIRE REEL STANDS AND MOUNTINGS

50-60 LB. WIRE REEL MOUNTING STAND (K303)

The assembly includes a framework to which is attached the 50-60 lb. wire reel, a mounting spindle, a dust shield, a lift bail, and a cable clamp for fastening the input cable assembly. It is easily mounted to the basic wire feed unit by three bolts. The reel mounting spindle is the pull knob type with a built-in brake.

The brake pad is adjustable for proper braking at low or high wire feed speeds.

This alternate connection cannot be used with the DC-250, CV-l, or CV- 500-I power sources.

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50-60 LB. READI-REEL®MOUNTING STAND (K445)

The assembly includes a framework to which is attached a 2" O.D. spindle with adjustable brake and 50-60 lb. Readi-Reel Adapter. Includes a lift bail and cable clamp for fastening the input cable assembly, and easily mounts to the LN-9 feeder. Does not include dust shield.

Can also be used for up to 60 lb. spools with 2" I.D.

LN-9 Wire Feeder

Page 43

C-3 C-3

ACCESSORIES

ATTACHING THE WIRE REEL STANDS

The mounting hardware for mounting the stands is included with the LN-9. Screws and washers are inserted in their respective mounting holes. To connect:

1. Remove the three 3/8 in. hex head bolts from the back of the wire feed unit.

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

3. Replace and tighten the hex head bolts. The long screw and plain washer go into the top hole.

WIRE REEL DOOR KIT (M-11514)

Mounts to K303 or to K445 equipped with an S14543 dust shield housing kit, to completely enclose wire reels against extremely dusty and dirty environments. Includes a hinged door and sliding bottom seal. Install the door according to instructions included with the kit.

Place the bottom seal panel in the forward position when using .030-1/16" electrode. Place the bottom seal in the rear position when using 5/64-.120" electrode.

SPINDLE FOR READI-REELS AND 2" I.D. SPOOLS (K162-H*)

(60 Lb. Maximum Capacity) The 2" O.D. spindle kit is for use with the K303. The

shaft for the standard 50-60 pound wire coils is removed from the mounting framework, and the K162H is installed in its place. Includes an easily adjustable friction brake for control of overrun.

When used with Readi-Reels, a Readi-Reel Adapter is required.

When used with 8" O.D. spools, a K468 Spindle Adapter is available.

14 Lb. lnnershield coils can be mounted to the spindle using the K435 Adapter.

* Replaces the K162 30 Lb. Spindle Kit. Install the spindle according to instructions included

with the kit:

READI-REEL ADAPTERS K363-P Adapts Lincoln Readi-Reel coils of electrode

(30 lb. and 22 lb.) to a 2" spindle. One-piece construction. Made from a durable molded plastic. Designed for easy loading; adapter remains on spindle for quick changeover. Included with K377 small mounting stand.

K438 Adapts 50-60 lb. Lincoln Readi-Reel coils to a K162-H spindle, or similar 2 inch spindle suitable for 60 lb. spools. Two-piece construction made from a durable flame retardant molded plastic. Designed for minimum loading downtime, the coils easily load with inside adapter half on spindle. Four twist latches lock adapter halves together. Included with K445 50-60 lb. Readi-Reel stand.

SMALL MOUNTING STAND FOR READI-REEL COILS OR 2" I.D. SPOOLS (K377)

(30 Lb. Maximum Capacity) This assembly includes a small frame to which is

attached a wire reel spindle similar to the K162 spindle. The unit is supplied with the K363 Readi-Reel Adapter for use with the Lincoln 22-30 lb. Readi-Reel Electrode Coils. Without the adapter the unit is capable of handling up to 30 lb. spools with a 2 " I.D., a 12" max. O.D., and a 4 " width. For spools with an 8" O.D., a K468 Spindle Adapter is available.

14 lb. lnnershield coils can be mounted to the spindle using the K435 Adapter. The spindle has an easily adjustable braking system.

SMALL MOUNTING STAND FOR 13-14 LB. INNERSHIELD COILS (K378)

This assembly includes the same smaller frame as used in the K377 and a fully enclosed canister system for de-reeling of the 14 pound coil. This system has a fixed brake for the 14 pound coil.

50-60 LB. WIRE REEL ASSEMBLY FOR CUSTOMER MOUNTING (K299)

This assembly is available only when ordering either the LN-9F 2-Roll or 4-Roll model. It includes a 50-60 lb. wire reel, spindle shaft, adjustable brake, insulation and mounting hardware.

K162 - 30lb (13.6 kg) – M14573 Mounting instructions K162H - 60 lb (27.2 kg) – M15241 Mounting instructions

DO NOT USE COILS OR SPOOLS HEAVIER THAN 30 LBS. ON THE ORIGINAL K162 SPINDLE.

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Install the assembly according to instructions included with it.

CAUTION

LN-9 Wire Feeder

Page 44

C-4 C-4

ACCESSORIES

GUN AND CABLE ASSEMBLIES

A variety of standard Lincoln and Magnum gun and cable assemblies are available for the LN-9 in 10 ft.,

TABLE C.1 – LN-9 GUN AND CABLE ASSEMBLIES

Process Model Electrode Rating

K498

(1)

(2)

.025-.045” (0.6-1.14 mm) solid 200 amps

(1)

(2)

.035-5⁄64” (0.9-2.0 mm) solid 300 amps

.035-5⁄64” (0.9-2.0 mm) solid 400 amps

.035-5⁄64” (0.9-2.0 mm) solid 300 amps

.035-5⁄64” (0.9-2.0 mm) solid 400 amps

K126 .062-3⁄32” (1.6-2.4 mm) Innershield 350 amps

Gas Metal Arc Welding K497

Magnum K470

Magnum K471

Magnum K478

Magnum K479

Innershield

12 ft. and 15 ft. cable lengths. Choose the gun and cable assembly to suit the LN-9 welding application and wire size. See Table C-1.

60% Duty

200 amps

300 amps

400 amps

300 amps

400 amps

K115-120 for .120” and 7⁄64” (3.0 and 2.8 mm) 450 amps K115-3/32 for 3⁄32” (2.4 mm) 450 amps K115-5/64 for .068-5⁄64” (1.7-2.0 mm) 450 amps K116-120 for 120” and 7⁄64” (3.0 and 2.8 mm) 600 amps K116-3/32 for 3⁄32” (2.4 mm) 600 amps

(3)

K206

(3)

K289

(3)

K309

Submerged Arc K112

K113-1 K113-2 K-114

(1)

K466-1 connector kit required.

(2)

K489 Fast-Mate™ Adapter required.

(3)

Linconditioner™ guns are recommended for locations where smoke accumulation is a problem and conven-

.062-3⁄32” (1.6-2.4 mm) Innershield 350 amps

.068-.120” (1.7-3.0 mm) lnnershield 500 amps

.062-3⁄32” (1.6-2.4 mm) lnnershield 250 amps

⁄ 16” (1.6 mm) solid 500 amps

⁄64” (2.0 mm) 600 amps

⁄32” (2.4 mm) 600 amps

⁄32 or 5⁄64” (2.4 or 2.0 mm) solid 600 amps

tional exhaust systems are ineffective. The available smoke removal type Innershield guns and vacuum units can be used in these locations. Instructions are shipped with the equipment.

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LN-9 Wire Feeder

Page 45

C-5 C-5

ACCESSORIES

WIRE FEEDER ACCESSORIES

BURNBACK DELAY KIT (K202)

Provides a precise control of the electrode burnback at the end of the weld. Prevents crater sticking and provides proper stickout for starting the next weld. Recommended especially when welding with small (.030-1/16") diameter wire at high wire feed speeds. Also recommended when the semiautomatic gun is mounted in a fixture or on the Squirtmobile in a way that prevents the gun from lifting from the work at the end of the weld.

Install the kit according to the instructions included with the kit.

DUAL PROCESS KIT (K317) - For Wire Feeders Using Same Polarity

This kit permits the connection of two wire feeders to a single power source. Both feeders must weld with the same electrode polarity. When the trigger of the desired wire feeder is pressed, the power source output control leads (#75, #76 and #77) will be connected to that feeder, and the procedure as set on its controls will be provided. The other connected wire feeder will not be feeding wire, but its electrode circuit will be electrically hot. The kit mounts at the power source and is connected to the power source terminal strip with the supplied leads. Standard K196 input cable assemblies are used to connect each wire feeder to the dual process control circuit while the electrode lead connects to the power source.

Install the kit according to instructions included.

NOTE: The K317 and K318 Dual Process Kits also include mode change capability, but only when using the DC-600 power source. This feature permits one feeder to weld in CV Innershield mode and the other feeder to weld in CV Submerged Arc mode, as well as both in the same mode.

When using the Pulse Power 500 power source, the K317 or K318 Dual Process Kits can be used only if the procedures are close enough to use the same mode setting. The K317 or K318 cannot switch modes on the Pulse Power 500. An LN-9 may not be used with an LN-7 or LN-8, although two LN-9s may be used together.

DUAL PROCEDURE KIT (K319)

With the use of this kit, one of two different settings of wire feed speed and voltage can be selected by a toggle switch mounted on the gun handle. The kit consists of a control panel which mounts over the standard LN-9 control rheostats. This control panel has four rheostats, a transfer relay and a polarized connector. During installation, the standard security door is mounted over the new panel and functions in the same manner. All electrical connections are with plugs to speed and simplify the assembly. A15-foot control cable with a polarized connector on one end for plugging into the new control panel is provided. On the other end of the control cable is a small selector toggle switch and a mounting bracket.

A K302 Extension Control Cable is required when using the K319 with any LN-9F model.

Install the kit according to instructions included.

DUAL PROCESS KIT (K318) - With Electrode Polarity Change Capability

Functions essentially the same as the K317 except that the kit includes two contactors to provide different polarities on the two wire feeders. When connected in this manner and one trigger is pressed, the other electrode will be "cold" to ground but "hot" to the other electrode. This kit can also be connected to provide the same polarities on each feeder, but the electrode circuit of the one not being used will be cold to work and to the other electrode.

Install the kit according to instructions included.

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PULSE POWER FILTER CONVERSION KIT (K442-1)

Required for any LN-9 to be used with a Pulse Power 500 or DC650 Pro power source. Includes a Filter Board and connection harness, easily installed in the control section and plugged into the Voltage Board. The plug must be disconnected for use with other standard power sources.

Install the kit according to instructions included.

LN-9 Wire Feeder

Page 46

C-6 C-6

ACCESSORIES

SWIVEL PLATFORM (K178-1)

For all LN-9 wire reel stand combinations. For mounting wire feeder-wire reel stand assembly on top of suitable Lincoln Idealarc power sources. Recommended input cable assembly length is 10 feet (3m) when using the K178-1.

Bolt the platform to the lift bail according to instructions supplied with the platform (M16260).

UNDERCARRIAGE (K163)

For all LN-9 wire reel stand combinations. Includes mounting frame, front casters, 10" (254 mm) O.D. rear wheels, and handle. Use when portability is required. Casters mount at the front and the wheels mount at the rear. Handle bolts to the front, which allows the LN-9 to be tilted back and wheeled like a two-wheel truck.

CONTINUOUS FLUX FEED TANK (K320)

The K320 is available to permit the LN-9 to be used for submerged arc welding using the K112 submerged arc gun and cable. Requires a supply of compressed air at 60 to 120 psi with a flow of 1.5 cubic feet per minute.

K320 FLUX TANK LOADING

Either turn off the incoming air line or remove the quick disconnect if one has been installed. Slightly loosen the tank cap and let the air in the tank escape through the holes in the side of the cap. After pressure has been released, remove the cap from the tank. Using the funnel provided, put 100 pounds of flux into the tank. It is very important that only new or properly reclaimed flux be put in the tank. Coarse particles and/or magnetic particles will stop the flux feeding process. New Lincoln flux is properly screened at the factory . All reclaimed flux must be separately screened through a vibrated screen having 0.065 - 0.075 openings and be put through a magnetic separator. The K310 vibrated Flux Screen and a K58 Magnetic Separator are available for this purpose. The screen in the funnel supplied with the tank has much larger openings, and its only purpose is to keep paper and slag out of the tank. Screw the tank cap back on and tighten it hand tight. Reconnect the incoming air line to the tank.

There will always be a small amount of air and possible drops of water coming out of the end of the tube coiled under the tank. This is an automatic disposal system in case the plant air has water and dirt in it.

The kit is a complete continuous flux feeding system including air filter, pressure regulator, gage, tank and 18 foot flux hose. It also includes a funnel for filling the tank, plus the lift bail assembly required to mount the tank and wire feeder to a K163 undercarriage. The tank can also be used as a free standing assembly.

Install the tank according to instructions included with the kit.

FLUX SCREEN (K310)

This unit is designed to fit the top of either the standard fill funnel of a continuous flux feed system or a K58 magnetic separator. The unit has a steel screen with

0.065 to 0.075 openings and an air vibrator attached to the frame. The vibrator can be used with air line pressure ranging from 20 psi to 100 psi.

For ease of handling, you should connect the incoming air line to the 1/8" pipe elbow with the aid of a fast disconnect type air coupling.

It is very important that reclaimed flux to be used in the continuous flux feeding system be passed through the K310 screen or its equivalent.

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LN-9 Wire Feeder

Page 47

C-7 C-7

ACCESSORIES

MAGNETIC SEPARATOR (K58)

The K58 is a permanent magnet type separator designed to fit the top of the standard fill funnel of the continuous flux feed system.

The purpose of the separator is to remove magnetic materials such as mill scale and any other extraneous magnetic materials which may have been recovered along with the flux to be processed.

It is important to remove these magnetic particles from the flux which is to be reused in the continuous flux feeding system. If the magnetic material is not removed, it will gather around the nozzle of the gun and impede or shut off the flux flow when making relatively long welds or when welding continuously. The magnetic particles can also cause porosity in the weld.

Fit the magnetic separator into the funnel or hopper. Pour the flux to be reclaimed into the top pan of the separator. The separator is designed so that the flux flows around three permanent magnets. The magnets remove all magnetic particles. When the magnets become covered with their full load, they automatically stop the flux flow. When the flux flow stops, remove the separator from the funnel or hopper. Turn it over and open the panel that covers the magnets. Remove the magnetic particles by brushing or by using an air blast.

WARNING

SQUIRTMOBILE ®(K62)

Self-propelled trackless carriage carries K114 gun on long welds for automatic welder economy without high fixture costs. Requires K161 power pack.

MECHANIZED TRAVEL POWER PACK (K161-CABLE LENGTH)

Includes travel mag-amp circuit required when using either a K62 Squirtmobile or K110 mechanized hand travel unit with a K114 gun. Mounts near power source. Available with 25, 50, 75 or 100’ (7.6, 15.2,

22.9 or 30.5 m) power pack to wire feeder leads. Connect to the power source for input power. (Not suitable for use with the LN-9F.)

GAS SOLENOID KITS K425 Mounts inside K357 LN-9 model above code

9131.

K437 Mounts outside all other LN-9 models.

POWER EXTENDED WIRE DRIVE (K392)

Permits extending gun and cable up to 80 feet from the K357 LN-9 (code 8180 and higher).

WHEN USING COMPRESSED AIR BE CAREFULTO PROTECT YOURSELF AND OTHERS IN THE AREA FROM FLYING PARTICLES.

NOTE: The magnetic separator is used with all Lincoln mild steel fluxes - 700 Series, 800 Series and 900 Series. Do not use the magnetic separator with any stainless steel, alloy, or hardsurfacing flux except H-535. The magnetic separator removes some of the alloying elements from these fluxes, thus changing their characteristics.

MECHANIZED HAND TRAVEL UNIT (K110)

Carries K114 Squirtgun along the joint at a preset travel speed to help the operator make better welds 10 to 25% faster than with manual travel. Speed range is 760 ipm (.18-1.5 m/min). Requires K161 Power Pack.

ENCLOSED REEL MOUNTING (K304)

Used with the LN-9SE for welding at a distance from the wire feeder. Includes a door for the wire reel housing and a hand crank. 50 and 60 lb. reels can be used.

EXTENSION ASSEMBLY (K307 or K308)

For LN-9NE or LN-9SE. K307 is a 221⁄2 ft. (6.9 m) extension cable. K308 is 45 ft. (13.7 m). Permits welding up to 60 ft. (18 m) from the wire reel.

FILLET GUIDE (K70)

Attachment simplifies horizontal fillet welding when using the Mechanized Hand Travel Unit (K110).

LINC-FILL ™ GUIDES

A complete line for submerged arc and Innershield available.

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LN-9 Wire Feeder

Page 48

C-8 C-8

ACCESSORIES

TABLE C.2 – DRIVE ROLL AND GUIDE TUBE KITS

Wire Size

Solid Steel Electrode

.030 - .035” (0.8 - 0.9 mm) KP502 - 035 KP545 - 035 .045 - 0.052” (1.2 - 1.4 mm) KP502 - 052 KP545 - 052 1/16” (1.6 mm) KP502 - 1/16 KP545 - 1/16 .068 - 3/32” (1.7 - 2.4 mm) KP502 - 3/32 KP545 - 3/32

Cored Electrode

.045 - 0.052” (1.2 - 1.4 mm) KP502 - 052C KP545 - 052C 1/16” (.062”) (1.6 mm) KP502 - 1/16C KP545 - 1/16 .068 - 3/32” (1.7 - 2.4 mm) KP502 - 3/32 KP545 - 3/32 7/64 - .120” (2.0 - 3.0 mm) KP502 - 120 KP545 - 120 7/64” Soft Jacket (2.8 mm) KP502 - 7/64H __________

Aluminum Electrode

.035” (0.9 - 1.0 mm) KP503 - 035A KP546 - 035A

2-Roll 4-Roll

Kit

3/64” (1.2 mm) KP503 - 3/64A KP546 - 3/64A 1/16” (1.6 mm) KP503 - 1/16A KP546 - 1/16A

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LN-9 Wire Feeder

Page 49

Section D-1 Section D-1

TABLE OF CONTENTS

-MAINTENANCE-

Maintenance .........................................................................................................................Section D

Routine Maintenance..................................................................................................................D-2

Drive Rolls and Guide Tubes................................................................................................D-2

Wire Reel Mounting – 50 and 60 lb. Coils ...........................................................................D-2

Wire Reel Mounting – Readi-Reels and Spools...................................................................D-2

Periodic Maintenance.................................................................................................................D-2

Control Box ..........................................................................................................................D-2

Wire Drive Motor and Gear Box...........................................................................................D-2

Gun and Cable Maintenance......................................................................................................D-3

Gun Cable Connector Requirements...................................................................................D-3

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LN-9 Wire Feeder

Page 50

D-2 D-2

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this maintenance.

• Turn the input supply power OFF at the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.

ROUTINE MAINTENANCE

DRIVE ROLLS AND GUIDE TUBES

After feeding any coil of wire, inspect the drive roll section. Clean it as necessary. Do not use a solvent for cleaning the idle rolls(s) because it may wash the lubricant out of the bearing. The drive roll(s) and guide tubes are stamped with the wire sizes they will feed. If you use a wire size other than that stamped on the rolls, the roll(s) and guide tubes must be changed.

The drive rolls using the knurled "V-groove" design have a double set of teeth so they can be reversed for additional life. Between the two knurled rolls for .068 through .120" is a shim washer which limits the damage to the wire to a minimum should wire feeding problems occur. When drive rolls are interchanged, leave the three socket head screws of the roll assembly loose until it is re-assembled on the drive shaft. Then tighten all three. Be sure the roll faces and spacer faces are thoroughly cleaned before re-assembly. Drive rolls for 1/16" and smaller solid electrodes using the smooth "V-groove" design have no teeth. They are not reversible.

WIRE REEL MOUNTING - 50 AND 60 LB. COILS

To prolong the life of the reel shaft, periodically coat it with a thin layer of grease. No maintenance of the brake assemblies is needed. If the brake shoe wears through to metal, replace the brake assembly.

WIRE REEL MOUNTING - READI-REELS AND 10 THROUGH 30 LB. SPOOLS

No routine maintenance required. Do not lubricate the 2" spindle.

PERIODIC MAINTENANCE

CONTROL BOX

Every six months open and inspect the control section. The accumulated dirt should be gently blown off all of the electrical components. See nent locations. Be sure the air that is being used is dry . Check the contacts of the large plug-in relay.

A spatter resistant shield protects the digital meter. This shield must always be installed. If it breaks or becomes damaged, replace it by removing the two screws securing its frame, installing a new shield, and reattaching the frame.

WIRE DRIVE MOTOR AND GEAR BOX

Every year examine the gearbox. Paint the gear teeth with molydisulfide-filled grease such as Non-Fluid Oil Corporation’s A-29 Special/MS Lubricant. Do not use a graphite grease.

Check the motor brushes. Replace if they are worn down to 1/4" or less. When ordering feed motor brushes, give all information from the motor nameplate.

Figure D.3

for compo-

See the instructions.

See

Table C.2

and guide tube kits.

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Operation

in the

Section for drive roll installation

Accessories

section for drive roll

LN-9 Wire Feeder

Page 51

D-3 D-3

MAINTENANCE

GUN AND CABLE MAINTENANCE

For instructions on periodic maintenance for the welding gun and cables, refer to the manual for your specific model of welding gun. Also see IM-294.

GUN CABLE CONNECTOR REQUIREMENTS TO PERMIT PROPER CONNECTION TO LINCOLN LN-9 AND LN-9F WIRE FEEDER

The following Figures D.1 and D.2 should serve as a guide to determine if a particular gun or switch can be connected to the LN-9 and LN-9F models.

FIGURE D.1 – LN-9 CONNECTORS

Wire Size .749/.747 Dia.

7/64 & .120" .152 (#24 Drill)

.068 Thru 3/32" .125 (1/8 Drill)

1/16 or .062" .078 (5/64 Drill) .045 & .052" .062 (1/16 Drill) .030 & .035" .055 (#54 Drill)

All dimensions in inches and (millimeters).

FIGURE D.2 – SWITCH REQUIREMENTS

“A” Diameter Hole

to be Concentric to

Within .008 F.I.M.

LN-9 CONNECTOR FOR 1/16-120” (1.6-3.0 MM) WIRE)

LN-9 CABLE CONNECTOR FOR .030-.052” (0.8-1.3 mm) WIRE (FOR ALL OTHER DIMENSIONS, SEE DIAGRAM

ABOVE).

1/2 Amp AC 24 Volts — Inductive

1/2 Amp DC 24 Volts — Inductive

NOTE: Connector part with .7459/.747 (19.0/18.9) diameter should be made from brass if it is to be part of the welding current carrying circuit.

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LN-9 Wire Feeder

Page 52

D-4 D-4

MAINTENANCE

FIGURE D.3 – GENERAL COMPONENT LOCATIONS

1. CONTROL PC BOARD

2. TRIGGER PC BOARD

3. T1 TRANSFORMER

4. POWER PC BOARD

5. BOX ASSEMBLY

6. DRIVE/IDLE ROLL ASSEMBLY

7. GEAR BOX

8. DRIVE MOTOR

9. TACHOMETER

10. VOLTAGE PC BOARD (LOCATED UNDER RIGHT COVER)

11 . LEFT COVER ASSEMBLY

12. WIRE SPEED/VOLTAGE CONTROL BOX

13. RIGHT COVER ASSEMBLY

14. DIGITAL METER

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LN-9 Wire Feeder

Page 53

Section E-1 Section E-1

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

Theory of Operation .............................................................................................................Section E

General Description...............................................................................................................E-2

Power Input Circuits...............................................................................................................E-2

Trigger and Shutdown Circuit................................................................................................E-3

Arc Voltage, Wire Speed Control and Metering.....................................................................E-4

Printed Circuit Board Functions .............................................................................................E-5

VOLTAGE CONTROL

VOLTAGE SENSING

WORK

ELECTRODE VOLTAGE SENSING

TACH

BOARD

WIRE SPEED CONTROL

POLARITY

SWITCH

POWER SOURCE OUTPUT TRIGGER (#2 )

GEAR

BOX

WIRE FEED

MOTOR

VOLTAGE

BOARD

INPUT

CONNECTOR

CONTROL

BOARD

METER BOARD

VOLTS SPEED

SWITCH

10VAC

CIRCUIT

BREAKER

WIRE SPEED CONTROL

TRIGGER

CONNECTOR

28VAC

BOARD

24VAC

F U S E

A R

WIRE FEED

MOTOR

THERMOSTAT

TRIGGER SIGNAL

+ 15VDC

C O

B O

N C

VOLTAGE

BOARD

GROUND

LEAD

PROTECTOR

VOLTAGE CONTROL

S H U T D O W N

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FIGURE E.1 – LN-9 BLOCK LOGIC DIAGRAM

LN-9 Wire Feeder

Page 54

E-2 E-2

THEORY OF OPERATION

GENERAL DESCRIPTION

The LN-9 is a semiautomatic wire feeder that allows the user to preset the arc voltage and wire feed speed. The wire feed speed is internally monitored and regu-

FIGURE E.2 – POWER INPUT CIRCUITS

GEAR

BOX

WIRE FEED

MOTOR

POWER SOURCE OUTPUT TRIGGER (#2 )

VOLTAGE

BOARD

INPUT

CONNECTOR

CONTROL

BOARD

METER BOARD

VOLTS SPEED

SWITCH

10VAC

CIRCUIT

BREAKER

TRIGGER

CONNECTOR

28VAC

BOARD

24VAC

lated to the preset condition. When the LN-9 is coupled to an appropriate Lincoln constant voltage power source, the arc voltage is also regulated to match the preset voltage.

VOLTAGE CONTROL

VOLTAGE SENSING

WORK

F U S E

P O

WIRE FEED

MOTOR

THERMOSTAT

TRIGGER SIGNAL

BOARD

B O A R D

TACH

ELECTRODE VOLTAGE SENSING

WIRE SPEED CONTROL

+ 15VDC

TRIGGER SIGNAL

+ 15VDC

WIRE SPEED CONTROL

C O

B O

R E F E R E N C E

V O

L T A G E

VOLTAGE

BOARD

S H U T D O W N

POLARITY

SWITCH

VOLTAGE CONTROL

POWER INPUT CIRCUITS

The 1 15VAC is applied (usually from the welding power source) via the input connector and through the circuit breaker and R1 resistor to the power board, the T2 trigger transformer, and the T1 transformer.

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GROUND

LEAD

PROTECTOR

The 24VAC developed at the T2 trigger transformer is applied to the trigger board. There it is rectified and regulated to 20VDC and used to operate the wire feeder trigger circuitry.

The 28VAC produced by the T1 transformer secondary is applied to the power board. There it is rectified and regulated to 15VDC. This 15VDC powers the electronics on the power, control, and voltage boards. The 10VAC secondary voltage is rectified, regulated, and utilized by the meter board.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

LN-9 Wire Feeder

Page 55

E-3 E-3

THEORY OF OPERATION

FIGURE E.3 – TRIGGER AND SHUTDOWN CIRCUIT

VOLTAGE CONTROL

VOLTAGE SENSING

WORK

ELECTRODE VOLTAGE SENSING

TACH

BOARD

WIRE SPEED CONTROL

POLARITY

SWITCH

POWER SOURCE OUTPUT TRIGGER (#2 )

GEAR

BOX

WIRE FEED

MOTOR

VOLTAGE

BOARD

INPUT

CONNECTOR

CONTROL

BOARD

METER BOARD

VOLTS SPEED

SWITCH

10VAC

CIRCUIT

BREAKER

TRIGGER

CONNECTOR

28VAC

BOARD

24VAC

F U S E

A R

WIRE FEED

MOTOR

THERMOSTAT

TRIGGER SIGNAL

+ 15VDC

C O

B O

N C

VOLTAGE

BOARD

GROUND

LEAD

PROTECTOR

VOLTAGE CONTROL

S H U T D O

TRIGGER AND SHUTDOWN CIRCUIT

When the gun trigger switch is activated (closed), the trigger board completes the trigger signal path. This energizes the CR1 relay located on the power board. The CR1 relay activates the wire drive motor and the #2 and #4 circuit, which then activates the Lincoln welding power source. The CR1 relay may also be used to energize a gas solenoid.

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The normally closed relay located on the voltage board is in series with the trigger signal. If an out-of-voltagerange signal or a ground fault condition should occur, the CR501 (on voltage board) relay contacts would "open," and the trigger signal path would be interrupted. This would cause the wire feeder to "shut down" until the gun trigger is released or the ground fault protector is reset.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

LN-9 Wire Feeder

Page 56

E-4 E-4

THEORY OF OPERATION

FIGURE E.4 – ARC VOLTAGE, WIRE SPEED CONTROL AND METERING

VOLTAGE CONTROL

VOLTAGE SENSING

WORK

ELECTRODE VOLTAGE SENSING

TACH

BOARD

WIRE SPEED CONTROL

POLARITY

SWITCH

POWER SOURCE OUTPUT TRIGGER (#2 )

GEAR

BOX

WIRE FEED

MOTOR

VOLTAGE

BOARD

INPUT

CONNECTOR

CONTROL

BOARD

METER BOARD

VOLTS SPEED

SWITCH

10VAC

CIRCUIT

BREAKER

TRIGGER

BOARD

TRIGGER

CONNECTOR

28VAC

24VAC

F U S E

WIRE FEED

MOTOR

THERMOSTAT

TRIGGER SIGNAL

+ 15VDC

B O

N C

VOLTAGE

BOARD

GROUND

LEAD

PROTECTOR

VOLTAGE CONTROL

S H U T D O W

ARC VOLTAGE, WIRE SPEED CONTROL AND METERING

The arc voltage, which is sensed at the work piece and motor gear box, is connected through a polarity switch to the voltage board. This actual arc voltage is compared to the reference preset voltage that is set by the voltage control. The voltage board determines what correction signal needs to be sent to the Lincoln welding power supply. This voltage control signal is coupled to the power supply through the input connector. The Lincoln power supply then adjusts the welding arc voltage to meet the demands of the preset reference voltage.

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The tach board sends motor speed information to the control board. This feedback voltage is compared to the reference command preset by the wire speed control. The control board determines what correction is needed and sends the appropriate signal to the power board. The power board then adjusts the motor armature voltage to comply with the command from the control board.

A three-digit meter is provided to read both arc voltage and wire feed speed. Either the preset or the actual welding parameters can be displayed.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

LN-9 Wire Feeder

Page 57

E-5 E-5

THEORY OF OPERATION

PRINTED CIRCUIT BOARD FUNCTIONS

POWER BOARD

The input power (115VAC) is applied to the power board, and from that the power board develops the DC field voltage for the wire drive motor. The SCR circuitry, used to control the motor armature voltage, is also contained on the power board.

The relay used to activate motor armature voltage, field voltage, auxiliary output on terminals 32A-7, and power source output (#2 and #4) is housed on the power board.

The rectified and regulated power supplies, used for the LN-9 control circuitry , are incorporated in the power board.

The shut down, start response and trigger interlock circuitry, in addition to the rectified and regulated power supplies used for the LN-9 control circuitry, is included in the power board design.

CONTROL BOARD

The control board provides a reference voltage to the wire speed control and voltage control potentiometers, allowing SET signals to be produced.

VOLTAGE BOARD

The voltage board compares the SET voltage values to the actual voltage values and makes any necessary correction by sending the appropriate signal to the Lincoln CV power source. If for any reason the arc voltage cannot be controlled to the SET voltage, the voltage board interrupts the LN-9 trigger path, and the unit shuts down. The response (Fast or Slow) to changes in arc voltage is also controlled by the voltage board, as well as the SET and actual arc voltage signals for the digital meter circuitry.

TRIGGER BOARD

The trigger transformer supplies 24VAC to the trigger board where it is rectified and regulated to 20VDC. This DC voltage is used in the gun trigger circuit to initiate the welding operation.

TACHOMETER BOARD

A square wave frequency signal, proportional to motor speed, is generated by the tachometer board and sent to the control board.

METER BOARD

The control board also powers and processes the feedback signals from the tachometer board. It compares the actual speed information to the SET speed command signal and develops firing pulses that drive the motor armature SCR circuitry, located on the power board.

Initial acceleration rates for wire feed speed are controlled by the control board as well as the SET speed and actual speed signals for the digital meter circuitry.

The meter board contains signal scaling and power supply circuitry for the digital meter.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

LN-9 Wire Feeder

Page 58

E-6 E-6

NOTES

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LN-9 Wire Feeder

Page 59

Section F-1 Section F-1

TABLE OF CONTENTS

TROUBLESHOOTING & REPAIR SECTION

Troubleshooting & Repair Section................................................................................Section F

How to Use Troubleshooting Guide.......................................................................................F-2

PC Board Troubleshooting Procedures.................................................................................F-3

Troubleshooting Guide ................................................................................................F-4 - F-22

Test Procedures

T1 Transformer Test......................................................................................................F-23

T2 Transformer Test......................................................................................................F-26

Wire Drive Motor and Tach Feedback Test...................................................................F-30

Voltmeter Accuracy Test................................................................................................F-34

Meter Circuit Accuracy Test...........................................................................................F-37

Wire Speed Accuracy Test ............................................................................................F-42

Out of Voltage Range Shut Down Test .........................................................................F-44

General Power Supply Tests.........................................................................................F-47

Replacement Procedures

Digital Meter and Meter PC Board Removal and Replacement ...................................F-50

Reed Switch (CR2) Removal and Replacement...........................................................F-53

T1 Transformer Removal and Replacement.................................................................F-55

Tach PC Board Removal and Replacement..................................................................F-60

Drive Motor Removal and Replacement.......................................................................F-64

Retest After Repair...............................................................................................................F-69

NOTE

This Troubleshooting section is specific to the LN-9. However, much of this information may apply to the LN-9F model with slight adaptation. Refer to LN-9F Wiring Diagram.

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LN-9 Wire Feeder

Page 60

F-2 F-2

TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into main categories: Function Problems, Feeding Problems, Welding Problems, Meter Problems, and Starting Problems.

Step 2. PERFORM EXTERNAL TESTS. The second column, labeled “POSSIBLE AREAS OF MISADJUSTMENT(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 the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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CAUTION

LN-9 Wire Feeder

Page 61

F-3 F-3

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK can kill.

Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts.

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC Board can be damaged by static electricity.

• Remove your body’s static charge before opening the static-shielding bag. Wear an anti-static wrist

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

Reusable Container Do Not Destroy

strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

• If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

• 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-shielding bag.

• If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete.

• If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determine if the failure symp-

tom has been corrected by the replacement PC board.

NOTE: Allow the machine to heat up so that all electri-

cal components can reach their operating temperature.

5. Remove the replacement PC board and substitute

it with the original PC board to recreate the original problem.

a. If the original problem does not reappear

by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6. Always indicate that this procedure was followed

when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the

warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

• Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.

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LN-9 Wire Feeder

Page 62

F-4 F-4

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

No wire feed when gun trigger is activated. The digital meter does NOT light. The drive rolls do not turn.

No wire feed when gun trigger is activated. The digital meter DOES light but reads zero in both (set and actual) volts and wire speed.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make sure 115VAC is being applied to the LN-9 at the input connector. Pin "C" is lead #31 and pin "D" is lead #32.

2. Check the 5 amp circuit breaker. Reset if tripped.

3. The F101 1/2 amp fuse, located on the power PC board, may be blown.

1. The wire drive motor may be over heated, and the thermal protector has tripped. Let unit cool.

RECOMMENDED COURSE OF ACTION

1. Check for loose or faulty lead connections between the input connector, the T1 transformer, and the power PC board.

2. The T1 transformer may be faulty. Perform the

Transformer Test.

1. Check for loose or faulty con-

nections on leads #527 and #528 between the wire drive motor and the power PC board.

2. Perform the

Test.

Replace if faulty.

3. The power PC board may be

faulty. Replace.

T1 Transformer

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CAUTION

LN-9 Wire Feeder

Page 63

F-5 F-5

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The wire feed "coasts" when the gun trigger is released. The interlock switch is OFF.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make sure the gun trigger is not "sticking."

RECOMMENDED COURSE OF ACTION

1. The relay 1CR may be faulty. Replace.

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CAUTION

LN-9 Wire Feeder

Page 64

F-6 F-6

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

No wire feed when gun trigger is activated. The drive rolls do not turn. The digital meter does light but reads only the SET voltage and wire speed values.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. The Ground Lead Protector may have tripped. Reset and clear possible fault between electrode circuit and feeder frame.

2. The gun trigger may be faulty.

RECOMMENDED COURSE OF ACTION

1. The 1CR relay on the power PC board may be faulty. Check or replace.

2. Check resistor R1. Normal resistance is 2 ohms. See the Wiring Diagram.

3. Perform the

Transformer T2 Test.

3. Perform the

Test.

4. Perform the

Test.

5. If the wire drive motor is OK, then the power PC board or the control PC board may be faulty.

Trigger Board

Wire Drive Motor

Trigger

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CAUTION

LN-9 Wire Feeder

Page 65

F-7 F-7

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The wire feeds when the gun trigger is activated, but there is no arc voltage.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make sure the inch switch is in a "Wire Hot" position.

2. Check the welding cables for loose or faulty connections.

3. Put a jumper wire from #2 to #4 on the power source terminal strip. (Machines with 14 pin amphenols: pin C to pin D.) If the arc voltage is not present at the output terminals, the power source is faulty. If the arc voltage IS present, the problem is in the wire feeder or control cable.

4. Check the continuity of leads #2 and #4 through the control cable. Replace if "open."

RECOMMENDED COURSE OF ACTION

1. The 1CR relay, located on the power PC board, may be faulty. Check or replace.

2. If a burnback kit is installed, remove and install jumper plug. If the problem is solved, the burnback kit is faulty.

3. Check the #2 and #4 leads in the LN-9 wiring harness for loose or faulty connections. See the Wiring Diagram.

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CAUTION

LN-9 Wire Feeder

Page 66

F-8 F-8

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The SET speed is adjustable and steady. The actual speed is uncontrollable. The meter displays the actual speed correctly or reads "EEE."

The SET speed is adjustable and steady. The actual speed reading is incorrect, erratic, or zero.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Contact your local Lincoln Authorized Field Service Facility.

1. Check for loose or faulty connections on leads #510, #525, and #555 between the tach board and the control PC board.

RECOMMENDED COURSE OF ACTION

1. While the motor is running, carefully unplug the 15 pin molex plug from the control board.

If the motor continues to run, the power PC board may be faulty. Replace.

If the motor stops, the control PC board may be faulty. Replace.

2. Perform the

Test.

1. Check to make sure the slotted disc in the tach housing is secure and aligned.

2. Perform the

Feedback Test.

Wire Drive Motor

Tach Board

3. If the

Tach Board Feedback

Test

is OK, the control PC

board may be faulty. Replace.

CAUTION

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LN-9 Wire Feeder

Page 67

F-9 F-9

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The SET speed is erratic or not adjustable over entire range of control. The actual speed is also erratic like the SET speed.

The wire continues to feed with the gun trigger open, and the wire is electrically "hot." The interlock switch is in the "OFF" position.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Check for loose or faulty connections on leads #631, #632, and #633 between the speed control potentiometer (R2) and the control PC board.

1. Disconnect the gun trigger cable. If the problem is resolved, the gun trigger or cable is faulty. Repair or replace.

RECOMMENDED COURSE OF ACTION

1. Remove power to the LN-9 and disconnect the plug to the control PC board. Check the resistance of the speed control potentiometer (R2). When measured from the wiper (lead #632) to lead #633, the resistance should vary smoothly from 0 to 10,000 ohms, when the shaft is rotated. See the Wiring Diagram.

2. The control PC board may be faulty. Replace.

1. Disconnect lead #530 from the trigger board. See the Wiring Diagram. If the problem is resolved, the trigger board is faulty. Replace.

CAUTION

2. Relay 1CR may be stuck closed. Check or replace.

3. The power PC board may be faulty. Replace.

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LN-9 Wire Feeder

Page 68

F-10 F-10

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The wire feeds when the interlock switch is in the "ON" position. No welding or gun trigger activation.

With the interlock switch in the "ON" position, the wire feed stops when the gun trigger is released.

POSSIBLE AREAS OF MISADJUSTMENT(S)

TRIGGER INTERLOCK

FUNCTION PROBLEMS

1. Check to see if the reed switch 2CR is stuck closed.

1. Check leads #529 and #628 for loose or faulty connections between the 2CR reed switch and the power PC board.

RECOMMENDED COURSE OF ACTION

1. Check the 2CR reed switch for sticking and associated leads (#529 and #628) for shorts.

2. The power PC board may be faulty. Replace.

1. The 2CR reed switch may be faulty. Check to see if it closes when welding.

2. Check the continuity (zero ohms) of leads #529 and #628 from the 2CR reed switch to the power PC board. Also check continuity of leads #530 and #522 from the power PC board to the interlock switch. See the Wiring Diagram.

CAUTION

3. Check the interlock switch for proper operation.

4. The power PC board may be faulty. Replace.

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LN-9 Wire Feeder

Page 69

F-11 F-11

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The SET voltage is erratic or not adjustable over the entire range of control. The actual voltage is also erratic like the SET voltage.

The field fuse (F101), located on the power PC board, repeatedly fails.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Check for loose or faulty connections on leads #634, #635 and #636 between the voltage control potentiometer (R3) and the voltage PC board.

1. Very rapid and repetitive gun triggering can possibly cause the field fuse to fail.

RECOMMENDED COURSE OF ACTION

1. Remove power to the LN-9 and disconnect Plug J1 from the voltage PC board. Check the resistance of the voltage control potentiometer (R3). When measured from the wiper (lead #635) to lead #634, the resistance should vary smoothly from 0 to 10,000 ohms when the shaft is rotated.

2. The voltage PC board may be faulty. Replace.

1. Perform the

Test.

2. Perform the

Test.

T1 Transformer

Wire Drive Motor

CAUTION

3. Disconnect the meter board. If the problem is resolved, the meter board may be faulty.

4. The power PC board may be faulty. Replace.

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LN-9 Wire Feeder

Page 70

F-12 F-12

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Circuit breaker (5 amp) repeatedly trips when the gun trigger is activated.

Circuit breaker (5 amp) trips when power is applied to the LN-9. Gun trigger is NOT activated.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Check or replace gun trigger and leads. Make sure the trigger leads are not shorted to the electrode or work cables.

1. Disconnect any kits that may be incorporated in the LN-9 (K202, K319, etc.). Be sure to install any necessary jumper plugs. If the problem is resolved, the fault may be in the disconnected kit.

RECOMMENDED COURSE OF ACTION

1. Disconnect lead #500 from the trigger board. If the breaker still trips when the gun trigger is activated, the trigger board may be faulty. Replace

2. Disconnect any accessory that may be connected to terminals #7 and #32A. See the Wiring Diagram. If the problem is resolved, the accessory may be faulty. Replace.

3. Perform the

Test.

4. The power PC board may be faulty. Replace.

1. Disconnect lead #620 from trigger board. See the Wiring Diagram. If the problem is resolved, the trigger board may be faulty. Replace.

2. Perform the

Test.

Wire Drive Motor

T2 Transformer

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3. Check the harness leads #32A, #31, and #531 for shorts or grounds. See the Wiring Diagram.

4. The power PC board may be faulty. Replace.

CAUTION

LN-9 Wire Feeder

Page 71

F-13 F-13

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The 1/8 amp fuse on the voltage PC board repeatedly fails.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Check to make sure the PC boards are NOT grounded to the case of the LN-9. This can happen due to metallic wire shavings build-up.

RECOMMENDED COURSE OF ACTION

1. Remove input power to the LN-

9. Replace the 1/8 amp fuse and switch the LN-9 polarity switch to the "NEG" position.

Make a resistance check from the following leads to the LN-9 case grounding screw: Lead # 500, 510, 525, 522, 526, 530, and 628.

The resistances should be above 1000 ohms. If any test is below 1000 ohms, that circuit has low resistance to case ground. Isolate the faulty leads or PC board. See the Wiring Diagram and Schematic.

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CAUTION

LN-9 Wire Feeder

Page 72

F-14 F-14

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The LN-9 shuts down while welding. Upon retriggering, the gun the unit will weld again for a period of time.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make sure the power source and wire feeder polarity switches are set correctly for the process being used.

2. Make certain the voltage control switch on the Lincoln CV power source is set in the "Remote" position.

3. Make sure the #21 lead in the control cable has continuity to the work piece.

4. Check the 1/8 amp fuse on the LN-9 voltage PC board. Replace if faulty.

5. Be sure the welding power source is compatible with the LN-9 and operating properly. Make sure duty cycle of power source is not being exceeded.

RECOMMENDED COURSE OF ACTION

1. Perform

Shutdown Test.

2. The control cable may be faulty. Check or replace.

3. The voltage PC board may be faulty. Replace.

Out of Voltage Range

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CAUTION

LN-9 Wire Feeder

Page 73

F-15 F-15

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

When the gun trigger is activated the drive rolls turn, but the wire will not feed or wire feeding is rough.

POSSIBLE AREAS OF MISADJUSTMENT(S)

FEEDING PROBLEMS

1. Check or replace the gun cable. It may be kinked, clogged, or twisted.

2. Make certain the drive rolls and guide tubes are correct for the wire being used.

3. Check or replace the gun contact tip.

4. The electrode wire may be rusty or dirty. Replace if necessary.

RECOMMENDED COURSE OF ACTION

1. If conditions are extremely dirty, install a wiper on the wire before it enters the guide tube. Use a piece of cloth saturated with "Pyroil B."

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CAUTION

LN-9 Wire Feeder

Page 74

F-16 F-16

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The welding arc is variable or "hunting."

POSSIBLE AREAS OF MISADJUSTMENT(S)

WELDING PROBLEMS

1. Make sure the welding parameters are correct for the welding procedure being used.

2. Check the welding cables for loose or faulty connections.

3. The gun cable may be faulty. Check or replace.

4. Check cable liner for proper size.

5. The gun contact tip may be worn. Check or replace.

6. The welding power supply may be faulty. Check or replace.

RECOMMENDED COURSE OF ACTION

1. Put the power source in "Machine Control" for voltage, and check if welding performance improves. If the problem is resolved, check or replace the control cable. Or, the LN-9 voltage PC board may be faulty.

2. Perform the

Test.

Wire Drive Motor

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CAUTION

LN-9 Wire Feeder

Page 75

F-17 F-17

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Poor arc striking with sticking or "blast offs." The weld bead may also be ropey and display weld porosity.

POSSIBLE AREAS OF MISADJUSTMENT(S)

WELDING PROBLEMS

1. Make sure the welding parameters and techniques are correct for the welding procedure being used.

2. Check the welding cables for loose or faulty connections.

3. The gun cable may be faulty. Check or replace.

4. The gun contact tip may be worn. Check or replace.

5. The welding power source may be faulty. Check or replace.

RECOMMENDED COURSE OF ACTION

1. Jumper the "BYPASS" terminals on the voltage PC board.

2. Put the power source in "Machine Control" and check if welding performance improves. If the problem is resolved, check or replace the control cable. Or, the LN-9 voltage PC board may be faulty.

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CAUTION

LN-9 Wire Feeder

Page 76

F-18 F-18

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The SET and actual speed meter readings match within a few IPM, but both are in error.

SET speed and actual speed meter readings do NOT match within a few IPM. One or both readings may be erratic.

POSSIBLE AREAS OF MISADJUSTMENT(S)

METER FUNCTION PROBLEMS

1. Contact your local Lincoln Authorized Field Service Facility.

RECOMMENDED COURSE OF ACTION

1. Check to make sure the slotted disc in the tach housing is secure and aligned.

2. Perform the

Accuracy Test.

3. The control board may be faulty. Replace.

1. Check the Volts - Speed meter selector switch and the associated wiring. See the Wiring Diagram.

2. Check the SET - Actual switch and the associated wiring. See the Wiring Diagram.

3. Perform the

Accuracy Test.

Meter Circuit

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CAUTION

LN-9 Wire Feeder

Page 77

F-19 F-19

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

SET volts and actual volts readings match within a few tenths of a volt while welding. However, both readings are inaccurate.

The actual volts reading does NOT match the SET volts reading within a few tenths of a volt while welding. One reading may be erratic. The LN-9 does NOT shut off.

NOTE: Pulse Power Filter kit may slow down the shutdown feature.

POSSIBLE AREAS OF MISADJUSTMENT(S)

METER FUNCTION PROBLEMS

1. Put the Lincoln power source in the "Machine Control" mode. Check to see if the power source can be set for the arc voltage required for the process. If not, the power source may be faulty.

2. The control cable may be faulty. Check or replace.

1. Make sure the shutdown "BYPASS" pins are NOT jumpered together on the LN-9 voltage PC board.

2. Check the voltage sensing leads for continuity (zero ohms). Lead #21 should have continuity to the work piece, and lead #67 should have continuity to the brass conductor block. See the Wiring Diagram.

RECOMMENDED COURSE OF ACTION

1. Check the voltage sensing leads for continuity (zero ohms). Lead #21 should have continuity to the work piece, and lead #67 should have continuity to the brass conductor block. See the Wiring Diagram.

2. Perform the

Accuracy Test.

3. The voltage board may be faulty. Replace.

1. If the actual reading is the problem, check the actual volts switch and associated leads.

2. If the SET reading is the problem, check the set volts switch and the associated leads.

3. Check the Volts - Speed selector switch and associated leads.

4. The voltage PC board may be faulty. Replace.

Meter Circuit

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3. Put the Lincoln power source in the "Machine Control" mode. Check to see if the power source can be set for the arc voltage required for the process. If not, the power source may be faulty.

CAUTION

LN-9 Wire Feeder

Page 78

F-20 F-20

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The output voltage is too low to start the weld.

POSSIBLE AREAS OF MISADJUSTMENT(S)

STARTING PROBLEMS

1. Check the welding cables for loose or faulty connections.

2. Put the Lincoln power source in the "Machine Control" mode. Jumper the "BYPASS" pins on the LN-9 voltage PC board. Adjust the weld voltage from the power source for the process being used. If the correct voltage cannot be set, the power source may be faulty.

3. Check for correct control cable connections to the power source.

4. The control cable may be faulty. Check or replace.

The start trimmer on the LN-9 voltage PC board may be set too low. See

tics

this manual.

Starting Characteris-

in the

Operation

section of

RECOMMENDED COURSE OF ACTION

1. Check the voltage control potentiometer (R3) and the associated leads. See the Wiring Diagram.

2. The voltage PC board may be faulty. Replace.

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CAUTION

LN-9 Wire Feeder

Page 79

F-21 F-21

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Voltage seems to be too high or the arc flares at the start of weld. Welding is good.

POSSIBLE AREAS OF MISADJUSTMENT(S)

STARTING PROBLEMS

Adjust the "start" trimmer on the voltage PC board. It should be only slightly higher than the weld voltage. See

teristics

of this manual.

3. Check for correct control cable connections to the power source.

Starting Charac-

in the

Operation

section

RECOMMENDED COURSE OF ACTION

1. The LN-9 voltage PC board may be faulty. Replace.

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CAUTION

LN-9 Wire Feeder

Page 80

F-22 F-22

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The arc voltage appears to rise too slowly or stubs or blasts at the start of a weld. Once started the welding is good.

NOTE: Pulse Power 500 operation with a filter kit may exhibit these symptoms.

POSSIBLE AREAS OF MISADJUSTMENT(S)

STARTING PROBLEMS

1. Check the welding cables for loose or faulty connections.

2. Adjust the "start" trimmer on the voltage PC board. It should be slightly higher than the weld voltage.

teristics

of this manual.

3. Put the Lincoln power source in the "Machine Control" mode. Jumper the "BYPASS" pins on the LN-9 voltage PC board. Adjust the weld voltage from the power source for the process being used. If the symptoms persist, the power source may be faulty.

4. Check for correct control cable connections to the power source.

See

Starting Charac-

in the

Operation

section

RECOMMENDED COURSE OF ACTION

1. If a start board is used in the LN-9, change the jumper to position "A." If the problem is solved, the start board may be faulty. Replace.

2. The voltage PC board may be faulty. Replace.

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CAUTION

LN-9 Wire Feeder

Page 81

F-23 F-23

TROUBLESHOOTING & REPAIR

T1 TRANSFORMER TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION

This test will aid the technician in determining if the T1 transformer is functioning.

MATERIALS NEEDED

115VAC power supply Phillips head screw driver Volt/ohmmeter (multimeter)

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LN-9 Wire Feeder

Page 82

F-24 F-24

TROUBLESHOOTING & REPAIR

T1 TRANSFORMER TEST (continued)

FIGURE F.1 – LEAD #532 AT POWER PC BOARD

LEAD 526 LEAD 527

T1 TRANSFORMER

LEAD 31

TEST PROCEDURE

1. Remove input power to the LN-9 wire feeder.

2. Using the phillips head screw driver, remove the screws holding the left side cover assembly.

3. Disconnect lead #532 from the power PC board terminal. See Figure F.1.

WARNING

Electric Shock can kill.

• With power applied, there are high voltages inside the wire feeder. Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied.

LEAD 532

115 VAC

4. Apply power (115VAC) to the T1 transformer primary leads #31 and #532. See Figure F.1 and the Wiring Diagram.

5. Using the volt-ohmmeter, check for 28VAC at secondary leads #526 and #527. See Figure F.1. Place the meter probes where the leads attach to the power PC board terminals.

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LN-9 Wire Feeder

Page 83

F-25 F-25

TROUBLESHOOTING & REPAIR

T1 TRANSFORMER TEST (continued)

FIGURE F.2 – SECONDARY LEADS #601 AND #602 AT LEAD SPLICES

6. Using the volt/ohmmeter, check for 10V AC at secondary leads #601 and #602. Typically, these leads are yellow. Place the probes at the lead splices. See Figure F.2.

LEAD 601

LEAD 602

7. With 115VAC applied to the primary leads #532 and #31, if either or both of the secondary voltages are missing or low the T1 transformer may be faulty. Replace the transformer.

8. After the test is completed, disconnect the 115VAC from the T1 transformer primary leads. Reconnect lead #532 to the power PC board terminal. Close the left side cover assembly and re-assemble the screws.

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LN-9 Wire Feeder

Page 84

F-26 F-26

TROUBLESHOOTING & REPAIR

T2 TRANSFORMER TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION

This test will aid the technician in determining if the T2 transformer is functioning.

MATERIALS NEEDED

115VAC power supply Phillips head screw driver Volt/ohmmeter (multimeter)

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LN-9 Wire Feeder

Page 85

F-27 F-27

TROUBLESHOOTING & REPAIR

T2 TRANSFORMER TEST (continued)

FIGURE F.3 – “PROTECTION CIRCUIT TROUBLESHOOTING” NAMEPLATE

PROTECTION CIRCUIT

TROUBLESHOOTING NAMEPLATE

TEST PROCEDURE

1. Remove input power to the LN-9 wire feeder.

2. Using the phillips head screw driver, remove the screws holding the left side cover assembly.

3. Lift the right side cover assembly.

4. Using the Phillips head screw driver, remove the two screws from the "protection circuit troubleshooting" name plate. Remove the nameplate as far as the lead length will allow. See Figure F.3.

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LN-9 Wire Feeder

Page 86

F-28 F-28

TROUBLESHOOTING & REPAIR

T2 TRANSFORMER TEST (continued)

FIGURE F.4 – T2 PRIMARY LEADS #32A AT 5 AMP CIRCUIT BREAKER AND #531 AT R1 RESISTOR

CIRCUIT BREAKER

LEAD 32A

4. Locate the T2 transformer primary lead #32A connected to the 5 amp circuit breaker. Remove lead #32Afrom the circuit breaker. See Figure F.4 and the Wiring Diagram.

LEAD 531

R1 RESISTOR

5. Lift the left side cover assembly.

6. Locate T2 transformer primary lead #531 connected to the R1 2-ohm resistor. See the Wiring Diagram. See Figure F.4.

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LN-9 Wire Feeder

Page 87

F-29 F-29

TROUBLESHOOTING & REPAIR

T2 TRANSFORMER TEST (continued)

FIGURE F.5 – T2 SECONDARY LEADS #621 AND #620 ON TRIGGER PC BOARD

LEAD

620

LEAD

621

WARNING

Electric Shock can kill.

• With power applied, there are high voltages inside the wire feeder. Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied.

7. Insulate the T2 transformer primary leads #531 and #32A and apply 115 VAC power. See the Wiring Diagram and

Figure F.4.

TRIGGER PC BOARD

8. Using the volt/ohmmeter, check for approximately 24VAC at the T2 transformer secondary leads #621 and #620. Place the probes where the leads connect on the trigger PC board. See Figure F.5.

9. With 115VAC applied to the primary leads #531 and #32A, if the secondary voltage is missing or low the T2 transformer may be faulty. Replace the T2 transformer.

10. After the test is completed, disconnect the 115VAC from the T2 transformer primary leads #531 and #32A. Reconnect lead #32 to the circuit breaker. Re-attach the Protection Circuit Troubleshooting nameplate. Close the right and left side cover assemblies and replace all previously removed screws.

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LN-9 Wire Feeder

Page 88

F-30 F-30

TROUBLESHOOTING & REPAIR

WIRE DRIVE MOTOR AND TACH FEEDBACK TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION

This test will help determine if the drive motor and tach feedback are functioning properly.

MATERIALS NEEDED

Phillips head screw driver Analog volt/ohmmeter (multimeter)

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LN-9 Wire Feeder

Page 89

F-31 F-31

TROUBLESHOOTING & REPAIR

WIRE DRIVE MOTOR AND TACH FEEDBACK TEST (continued)

FIGURE F.6 – LEAD #539, #541, #626B AND #627B AT POWER PC BOARD TERMINAL STRIP

LEAD 539 LEAD 541 LEAD 626B LEAD 627B

TEST PROCEDURE

1. Remove input power to the LN-9 wire feeder.

2. Remove any electrode wire or disengage the drive rolls.

3. Using the phillips head screw driver, remove the screws from the left side cover assembly.

4. Lift the left side cover assembly.

5. Locate leads #539, #541, #626B and #627B at the power PC board terminal strip. See Figure F.6.

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LN-9 Wire Feeder

Page 90

F-32 F-32

INSTALLATION

WIRE DRIVE MOTOR AND TACH FEEDBACK TEST (continued)

6. Apply 115 VAC power.

WARNING

ELECTRIC SHOCK can kill.

• With power applied, there are high voltages inside the wire feeder. Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied.

7. With the gun trigger activated or the gun terminals jumpered together (see the Wiring Diagram), check the motor armature volts at leads #541(+) and #539(-). Normal is 5 to 95VDC depending on the wire feed speed setting. As the armature voltage is increased the wire feed speed should increase.

8. With the LN-9 at idle (gun trigger NOT activated), check the motor field voltage at leads #626 and #627. Normal is 115VDC. When the gun trigger is activated or the gun terminals are jumpered together (see the Wiring Diagram), the field voltage polarity should reverse from the idle state. Normal is 115VDC, independent of motor speed.

9. If the above voltages are present and the motor does not operate, the motor, motor brushes or gear box may be faulty.

If the armature or field voltages are missing or not correct, the power board or 1CR relay may be faulty.

If the motor is running at high speed and the armature voltage is high and uncontrollable, proceed with the

Tach Feedback Test.

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LN-9 Wire Feeder

Page 91

F-33 F-33

TROUBLESHOOTING & REPAIR

WIRE DRIVE MOTOR AND TACH FEEDBACK TEST (continued)

FIGURE F.7 – LEADS #525, #510, #555 ON CONTROL PC BOARD

LEAD

525

LEAD

510

LEAD

555

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TACH FEEDBACK TEST PROCEDURE

1. Locate tach PC board leads #510, #525 and #555 on the control PC board. See Figure F.7.

2. Check leads #525(+) to #510(-) for the presence of 15VDC. This is the supply voltage from the control PC board to the tach PC board. If the voltage is present, proceed to the next step. If the voltage is missing, check the wiring and perform the

Power Supply Test.

3. With gun trigger activated or the gun terminals jumpered together (see the Wiring Diagram), check leads #555(+) to #510(-) for the presence of between 4.5 - 10.5VDC. (The motor must be running). This is the feedback voltage from the tach PC board to the control PC board. This voltage is dependent upon motor speed.

General

LN-9 Wire Feeder

If the feedback voltage is missing or does not vary with motor speed, the tach PC board may be faulty.

4. After the wire drive motor and tach feedback tests are completed, remove the jumper from the gun terminals (if used) and close the left case side cover assembly and reattach the screws.

Page 92

F-34 F-34

TROUBLESHOOTING & REPAIR

VOLTMETER ACCURACY TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION

This test will help determine if the LN-9 voltmeter is providing accurate readings.

MATERIALS NEEDED

Phillips head screw driver Digital volt/ohmmeter (multimeter) with at least 3-1/2 digits and +/-0.5% accuracy

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LN-9 Wire Feeder

Page 93

F-35 F-35

TROUBLESHOOTING & REPAIR

VOLTMETER ACCURACY TEST (continued)

FIGURE F.8 – VOLTMETER CONNECTION POINT

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BRASS

CONDUCTOR

BLOCK

TEST PROCEDURE

Perform the following checks with the LN-9 wire feeder connected to a Lincoln CV welding power source according to the proper connection diagram. (See the ual.)

See Figure F.8 for this test.

Installation

section of this man-

LN-9 Wire Feeder

1. Lift the right side cover assembly.

2. Connect the test meter (see Materials Needed) between the brass conductor block on the wire feeder and the work piece.

Page 94

F-36 F-36

TROUBLESHOOTING & REPAIR

VOLTMETER ACCURACY TEST (continued)

3. With the LN-9 gun trigger closed or the gun

WARNING

ELECTRIC SHOCK can kill.

• With power applied, there are high voltages inside the wire feeder. Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied.

terminals jumpered together (see the Wiring Diagram), the test meter reading should match the LN-9 ACTUAL volts reading within +/- 0.5 volts. If it does not, check the integrity and placement of the voltage sensing leads #21 and #67. Perform the

Accuracy Test.

4. Remove the test voltmeter and, while welding, compare the SET volts and ACTUALvolts meter readings. Depending upon the arc voltage characteristics of the welding process being used, the ACTUAL reading may vary somewhat around an average value. The average ACTUAL reading should match the SET reading within +/- 0.5 volts. If not, refer to the

Meter Circuit Accuracy Test.

Meter Circuit

5. If no further tests are required, remove the jumper from the gun terminals (if used) and close the left case side cover assembly.

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LN-9 Wire Feeder

Page 95

F-37 F-37

TROUBLESHOOTING & REPAIR

METER CIRCUIT ACCURACY TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION

This test will help determine if the LN-9 meter circuit is functioning properly.

MATERIALS NEEDED

Phillips head screw driver Digital volt/ohmmeter (multimeter) with at least 3-1/2 digits and ± 0.5% accuracy Slot head screw driver 3/8" Nut driver

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LN-9 Wire Feeder

Page 96

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TROUBLESHOOTING & REPAIR

METER CIRCUIT ACCURACY TEST (continued)

FIGURE F.9 – METER PC BOARD LOCATIONS AND COVER

MOUNTING SCREWS

TEST PROCEDURE

1. Remove input power to the LN-9 wire feeder.

2. Lift the right side cover assembly and remove the two screws holding the meter cover to the right side assembly. Carefully remove the meter cover. See Figure F.9.

3. Locate and gain access to the meter PC board. See Figure F.9.

4. Apply input power to the wire feeder.

WARNING

ELECTRIC SHOCK can kill.

• With power applied, there are high voltages inside the wire feeder. Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied.

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LN-9 Wire Feeder

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TROUBLESHOOTING & REPAIR

METER CIRCUIT ACCURACY TEST (continued)

FIGURE F.10 – METER PC BOARD TEST POINTS

TP5

602

601

510C

561

5. Test for AC supply to the meter PC board. Check for 8 to 11 VAC from lead #601 to

#602. See Figure F.10. Note: The coating will have to be removed

from the test points.

6. Test for DC volts on the meter PC board. Check for 4.75 to 5.25 VDC from TP5 to lead

#510C. See Figure F.10. NOTE: The coating will have to be removed

from the test points.

560

517

TP4

If the display is NOT lit and the correct DC voltage is present at TP5 to lead #510C, the digital meter may be faulty. Replace the digital meter.

If AC voltage IS present at leads #601 to #602 and the DC voltage is missing, the meter PC board may be faulty.

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LN-9 Wire Feeder

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TROUBLESHOOTING & REPAIR

METER CIRCUIT ACCURACY TEST (continued)

Test Digital Meter Accuracy. (For LN-9 models

above code 7980 with separable digital meter and meter boards only).

1. Use a test meter with at least 3-1/2 digits and +/- .5% accuracy.

2. Connect the + probe to TP4 and the - probe to lead #510C.

NOTE: The coating will have to be removed from the test points.

3. With the meter in SET volts, adjust the voltage control until the test meter matches the settings in the table below.

If the LN-9 digital meter does not match the readings, the LN-9 digital meter may be faulty. Replace the digital meter.

LN-9 SET VOLTS READING TEST VOLTMETER READING

15.0 V .150 +/- .004 VDC

30.0 V .300 +/- .004 VDC

60.0 V .600 +/- .006 VDC

Test Meter PC Board Accuracy. (All Models)

If the test meter does not match the readings, the meter PC board may be faulty. Replace the meter PC board.

LN-9 SET VOLTS READING TEST VOLTMETER READING

15.0 V 1.50 +/- .05 VDC

30.0 V 3.00 +/- .05 VDC

60.0 V 6.00 +/- .07 VDC

Test Meter PC Board Accuracy. (For LN9-H, LN-9FH Models Only)

1. Use a test meter with at least 3-1/2 digits and +/- .5% accuracy.

2. Connect the + probe to lead #519 and the probe to lead #510C.

NOTE: The coating will have to be removed from the test points.

3. With the meter in SET IN/MIN, adjust the speed control until the LN-9 meter matches the settings in the table below. If the test meter does not match the readings, the meter PC board may be faulty. Replace the meter PC board.

1. Use a test meter with at least 3-1/2 digits and +/- .5% accuracy.

2. Connect the + probe to leads #517 and the probe to lead #510C.

NOTE: The coating will have to be removed from the test points.

3. With the meter in SET volts, adjust the voltage control until the LN-9 meter matches the settings in the table below.

LN-9 SET IN/MIN READING TEST VOLTMETER READING

082 IPM 0.50 +/- .05 VDC

49 IPM 3.00 +/- .05 VDC

978 IPM 6.00 +/- .07 VDC

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LN-9 Wire Feeder

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F-41 F-41

TROUBLESHOOTING & REPAIR

METER CIRCUIT ACCURACY TEST (continued)

T est Meter PC Board Accuracy. (Metric Models Only)

1. Use a test meter with at least 3-1/2 digits and +/.5% accuracy.

2. Connect the + probe to lead called for in the table below and the - probe to lead #510C.

NOTE: The coating will have to be removed from the test points.

3. With the meter in SET M/MIN, adjust the speed control until the LN-9 meter matches the settings in the table below. If the test meter does not match the readings, the meter PC board may be faulty. Replace the meter PC board.

METRIC MODEL METRIC RANGE SET M/MIN READING TEST VOLTMETER

READING

LN-9 or LN-9F LO 8.89 LEAD #560

3.50 +/-.05VDC

HI 15.2 LEAD #561

6.00 +/-.07VDC

LN-9H or LN-9FH LO 8.28 LEAD #560

2.00 +/- .05VDC

HI 24.8 LEAD #561

6.00+/-.07VDC

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LN-9 Wire Feeder

Page 100

F-42 F-42

TROUBLESHOOTING & REPAIR

WIRE SPEED ACCURACY TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION

This test will help determine if the LN-9 is providing the proper wire feed inches per revolution of the drive roll.

MATERIALS NEEDED

Phillips head screw driver Ruler or other linear measuring device

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LN-9 Wire Feeder

Lincoln Electric LN-9, SVM127-A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

No wire feed when gun trigger is activated. The digital meter does NOT light. The drive rolls do not turn.

The SET speed is adjustable and steady. The actual speed reading is incorrect, erratic, or zero.

The wire feeds when the interlock switch is in the "ON" position. No welding or gun trigger activation.

With the interlock switch in the "ON" position, the wire feed stops when the gun trigger is released.

The field fuse (F101), located on the power PC board, repeatedly fails.

Circuit breaker (5 amp) trips when power is applied to the LN-9. Gun trigger is NOT activated.

The 1/8 amp fuse on the voltage PC board repeatedly fails.

When the gun trigger is activated the drive rolls turn, but the wire will not feed or wire feeding is rough.

The welding arc is variable or "hunting."

Poor arc striking with sticking or "blast offs." The weld bead may also be ropey and display weld porosity.

The SET and actual speed meter readings match within a few IPM, but both are in error.

SET speed and actual speed meter readings do NOT match within a few IPM. One or both readings may be erratic.

The output voltage is too low to start the weld.

Voltage seems to be too high or the arc flares at the start of weld. Welding is good.