Lincoln Electric LN-9, SVM127-A User Manual

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. [phone]

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

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

to

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5.e. Also see item 1.b.

LN-9 Wire Feeder

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

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

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

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

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

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

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

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

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

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

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

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

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.

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

For optimum performance with the LN-9, 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

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

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

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

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

A-14 A-14

NOTES

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LN-9 Wire Feeder

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

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

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

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.

or

• The trigger is again depressed and released.

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LN-9 Wire Feeder

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

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

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

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.

1.

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

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

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