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Lincoln Electric LN-9 SVM127-A User's Manual

1. A 3 Attaching the Wire eri d et Erb un dee A 3 2 Mo nting the eects dete tgs eol aeneae idid aa dadia aina A 3 Installing the LN 9F 2 Roll and 4 Roll A 3 Mounting the Wire Feed Unit ennemi snnt 3 Mounting the Control 3 Connecting the Wire Feed Unit to the Control A 3 Routing the Electrode Aa 4 Electrical Connections LN 9 and LN 9F 4 Power Input Cable 2 Enea a arenes 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 98 A 5 E Connecting the Power Input Cable Assembly to the A 6 e Connecting the Power Input Cable Assembly to Power Sources A 7 Machine ge 12 Work Cable Connection 12 Direct Work Cable Connection 0240 0 0 12 Connecting the Gun Cable to the Wire
2. GENERAL DESCRIPTION The LN 9 2 Roll and 4 Roll semiautomatic wire feeder models feature the precise set and forget digital pro cedure 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 volt age 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 avail able for the same electrode sizes as the 2 roll feeders RECOMMENDED PROCESSES AND EQUIPMENT When combined with the broad selection of quality welding equipment and accessories the LN 9 pro vides a versatile precision welding system to meet the specific needs of Outershield In
3. B 20 Security of Weld Procedure Settings sse eene B 20 uer n Section C Auxiliary Equipment Contacts sss nennen intent etri nnne nnns C 2 Optional Equipment and Accessories sssssssssssssssseeee seen ener nennen C 2 Malnteman CO 0 Routine 4 4 D 2 Periodic C D 2 Gun and Cable Maintenance tene o teed dee ur Ee D 3 Theory of Operation 1 7 1iccuireerur ei iet reine e Len ka kac mm Dua rana magic x usen cu Section E Troubleshooting and Repair eene nennen nennen Section F Electrical DIagrams treten iei d P 127 LN 9 Wire Feeder LINCOLN 5 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION 5 lice Section 5 Technical Specifications rire ree rh tt EFE ERR Re NER RR Rude A 2 Installing the LN 9N and LN 9S 2 Roll and 4 Roll
4. 1 634 VOLTS CONTROL 520 10 00 V IS TRIGGER INTERLOCK ON TRIGGER INTERLOCK OFF HOT COLD INTERLOCK SWITCH C522 v ZA SHUTDOWN BYPASS TABS 631 5 B O R222 4 R2 USED ON LN 9 BELOW CODE 9131 s so 9 su sis B SET ACTUAL LN 9 ABOVE CODE 9131 AND LN 9F POWER CIRCUIT 005 MFD 047 MFD F101 1 2 A SLOW BLOW FUSE 047 MFD 022 MFD R101 01 MFD R102 100K OHM 50 MFD R103 330 OHM 150 MFD R104 1K OHM 2 7 MFD R105 10K OHM 15 MFD R106 100K OHM 005 MFD R107 10 OHM 005 MFD R108 2 2K OHM 02 MFD R109 15K OHM 02 MFD 022 MFD CR101 3PDT 24 VDC 022 MFD 40 OHM 12 W SCR101 124 400V SCR102 12A 400V Q101 2N5655 Q102 2 5655 1A 1000V 0103 5 92 1A D116 PT101 1 1 1 PULSE TRANS 02101 15V 5W TP101 TRANSIENT PROT
5. 3 Return to Section Return to Master TOC o D g 5 F 68 F 68 TROUBLESHOOTING amp REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT continued 15 With the slot head screw driver remove the 19 three screws lock washers flatwashers and insulators holding the drive motor to the gear box assembly See Figure F 28 16 Carefully remove the motor and spacer plate 20 REASSEMBLY 17 Attach the drive motor and spacer plate to the gear box assembly Use the insulators 21 and mounting hardware from step 15 99 above 18 Attach the glastic mounting board and mylar insulator to the gear box assembly with the four 1 2 bolts and washers On four roll units install the 1 2 bolt for the reed switch copper energizer 24 From the right side slide the motor and gear box assembly into the LN 9 Attach the glas tic mounting to the floor with the screws Four roll units have nuts and washers Connect motor leads 626 627 539 541 527 and 528 to their terminals Attach the green motor ground lead Install any cable ties cut earlier or tape the harness as needed Attach the top motor plate with two screws Install the insulator and tach PC board hous ing with two screws Install the tach PC board and rotating di n 9 Dd he ach PC Board Removal Replacement procedure Install the 9
6. PEN 2 2 2 cc 1 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 Tape up bolted connection Connect the LN 9 control cable ground lead to the frame terminal marked 7 near the power source terminal strip The power source must be properly grounded The LN 9 voltage control jumpers must be connected as follows White jumper on voltage board to pin S Blue jumper on voltage board Later units only or on start board Earlier units to pin B 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 Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master
7. A 13 o 7 Return to Master LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o Fie 8 nl ele 2 1 Return to Section Return to Master TOC 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 20 C to 40 C 4 F to 104 F 40 C to 40 C 40 F to 104 F Recommended Maximum Rated STORAGE 40 C to 85 C 40 F to 185 F WIRE DIAMETERS Solid Electrode Cored Electrode Aluminum 030 through 3 32 0 8 through 2 4 mm 045 through 120 1 2 through 3 0 mm 035 through 1 16 0 9 through 1 6 mm PHYSICAL DIMENSIONS LN 9 2 Roll LENGTH 12 15 in 808 4 mm 11 56 in 293 4 mm HEIGHT 12 19 in 809 4 mm TOTAL WEIGHT LESS ELECTRODE 36 Ibs 16 3 kg LN 9 4 Roll 12 15 in 308 4 mm 11 56 in 293 4 mm 12 19 in 309 4 mm 38 17 2 kg LN 9F Control Box 10 4 in 264 mm 6 17 in 156 6 mm 11 26 in 293 4 mm See Total Weight Below LN 9F Wire Drive 2 Roll 8 79 in 223 3 mm 9 7
8. Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section Return to Master TOC F 63 F 63 TROUBLESHOOTING amp REPAIR TACH PC BOARD REMOVAL AND REPLACEMENT continued FIGURE F 24 TACH COMPONENT ASSEMBLY USE SPACERS SO DISC ROTATES FREELY IN SENSOR WINDOW TACH PC BOARD REASSEMBLY 9 Use the 3 8 wrench to hold the nut in place Attach the rotating disc with the phillips 8 Upon reassembly the spacers must be used screw to assure that the disc rotates freely and smoothly within the sensor window on the 10 Attach leads 510 525 and 555 to the printed circuit board See Figure F 24 Note control PC board that the tach PC board must be held in place _ 11 Secure the tach assembly cover with two when aligning the rotating disc in the sensor slot head screws window Press down on the tach PC board with your finger to simulate the cover 12 Replace the left side case cover and secure with phillips screws LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE o o 2 3 Return to Section Return to Master TOC o g
9. a GENERAL INFORMATION LABELS FILE 5211 45 1 RCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER E1537 SUPPLY VOLTAGE 777 FRAME CONNECTION HE INTERCHANGEABILITY A COMPLETE BOARD CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED R CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DIODES 1 400V UNLESS OTHERWISE SPECIFIED COMMON CONNECTION COMPONENTS OR CIRCUITRY ON A PRINTED C POWER SUPPLY SOURCE POINT EARTH GROUND CONNECTION THE LINCOLN ELECTRIC CO Type _LN 9 amp LN 9F METRIC ON 3 PLACE DECIMALS IS 002 s CLEVELAND U S A METER BOARD SCHEMATIC ON ALL ANGLES IS 5 OF A DEGREE SCALE __ NONE MATERIAL TOLERANCE t TO AGREE E SHT WITH PUBLISHED STANDARDS DR FM DATE 9 24 93 CHK SUP S D G No S 21145 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not WKN available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of
10. o 8 E Return to Section Return to Master TOC o O P N 9 2 tc F 20 F 20 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION STARTING PROBLEMS The output voltage is too low to 1 Check the welding cables 1 Check the voltage control start the weld loose or faulty connections potentiometer R3 and the associated leads See the Put the Lincoln power source in Wiring Diagram the Machine Control mode Jumper the BYPASS pins on 2 The voltage PC board may be the LN 9 voltage PC board faulty Replace Adjust the weld voltage from the power source for the process being used If the correct volt age cannot be set the power source may be faulty Check for correct control cable connections to the power source The control cable may be faulty Check or replace The start trimmer on the LN 9 voltage PC board ma low See Starting Characteris tics lin the Operation section of this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353
11. 4 Mount the meter PC board onto the meter assembly with four nuts olo O o Fle S PEN 9 gt 918 5 5 1 DIGITAL METER REMOVAL 5 Install the meter enclosure panel using two PROCEDURE screws at the top left and right of the meter 1 Using the phillips head screw driver remove panel assembly the meter shield frame and bezel assembly 2 With the 5 16 nut driver remove the two nuts screws and lockwashers holding the digital meter to the cover assembly 3 Carefully remove the digital meter Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 53 53 TROUBLESHOOTING 4 REPAIR REED SWITCH CR2 REMOVAL AND REPLACEMENT Return to Section TOC Return to Master TOC 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 troubleshoot rir ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD 55 olg a gt 99 c
12. 5 F 64 TROUBLESHOOTING amp REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT 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 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will help the technician remove the drive motor for repair or replacement MATERIALS NEEDED Slot head screw driver 3 8 Wrench Phillips head screw driver LN 9 Wire Feeder LINCOLN 5 F 64 65 65 TROUBLESHOOTING REPAIR e 3 DRIVE MOTOR REMOVAL AND REPLACEMENT continued 5 5 FIGURE F 25 MOTOR PLATE SCREWS 2 2 ES GROUND LEAD 5 SCREWS Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o D g 5 OPPOSITE SIDE TOP PLATE
13. N UAE 3 Lift the right side cover assembly 4 Carefully remove the meter enclosure panel Note the limited lead length See Figure F 13 FIGURE F 13 METER REMOVAL WITH SHORT LEADS O10 515 gt 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 F 52 F 52 TROUBLESHOOTING amp REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT continued FIGURE F 14 METER PC BOARD REMOVAL Return to Section TOC Return to Master TOC 4 MOUNTING NUTS Return to Section TOC Return to Master TOC 5 Using the 5 16 nut driver remove the four REPLACEMENT PROCEDURE nuts mounting the meter PC board to the 1 With the 5 16 nut driver fasten the digital meter assembly See Figure F 14 meter to the cover assembly with two screws 6 Unplug the meter PC board from the wiring lockwashers and nuts harness 2 Using the phillips head screw driver reattach 7 Remove the meter PC board Note insulation the meter shield frame and bezel assembly placement for reassembly Also be sure that the plug on the back of the board plugs into 3 Position the insulation removed in step 7 the prongs on the meter when you reassem above Plug the digital meter into the meter ble PC board and into the wiring harness
14. Security of Weld Procedure Settings c ccceccececeeeeeeeeeeeeeaeeeeeeeeeeeaeeeeeeeeeeaeeeseaeeeseeeeeeaeeee B 20 Q 0 5 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HE 9 o 8 5 Return to Section Return to Master TOC o g 5 2 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 e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause 1e fire or explosion Keep flammable material away Q ARC RAYS can burn Wear eye ear and body protection 3Z LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 7 g 5
15. The wire feed coasts when the gun trigger is released The inter lock switch is OFF Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 Make sure the gun trigger is not sticking RECOMMENDED COURSE OF ACTION 1 The relay 1CR be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O P 0 9 2 tc F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines 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 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 TRO
16. amphenol and the R1 resis tor Be sure to position the resistor insula tors properly Close and fasten the left cover assembly with screws FIGURE F 28 DRIVE MOTOR REMOVAL FROM GEAR BOX MOUNTING SCREWS AND INSULATORS LN 9 Wire Feeder LINCOLN 5 GEAR BOX ASSEMBLY Return to Section Return to Master TOC Return to Section TOC O10 Fle 515 15 1 Return to Section Return to Master TOC Return to Master TOC F 69 F 69 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest the LN 9 wire feeder If it fails any test and the test requires removing or replacing any mechanical part that could affect the wire feeder s electrical characteristics OR If you repair or replace any electrical compo nent The wire feeder must meet the following standards under retest Wire Feed Speed LN 9 ssssssssssssseeesss senten nenne nennen nensis nnns nennen 50 600 IPM Wire Feed Speed icon n hse tot tenet vn ca atat rn 80 960 IPM E ai Refer Wire Speed 0444444242 2 1 Refer 10 Meter Circuit Accuracy Test Gas Solenoid If Must function when gun trigger is activated Voltage control and Refer to
17. 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 20 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 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 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 lt is very important that only new or properly reclaimed flux be put in the tank particles and
18. WIRE FOR ALL OTHER DIMENSIONS SEE DIAGRAM ABOVE 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 A Diameter Hole to be Concentric to Wire Size 749 747 Dia Within 008 7 64 amp 120 152 24 Drill 068 Thru 3 32 125 1 8 Drill 1 16 or 062 078 5 64 Drill 045 amp 052 062 1 16 Drill 030 amp 035 055 54 Drill All dimensions in inches and millimeters FIGURE D 2 SWITCH REQUIREMENTS 1 2 Amp AC 24 Volts Inductive 1 2 Amp DC 24 Volts Inductive Connect Leads to Pins A amp 12024 1 L E Part No Amphenol AN3057 10 or equiv 512020 6 L E Part No Amphenol MS 3106A 18 11P or equiv LN 9 Wire Feeder LINCOLN 5 FIGURE 0 3 GENERAL COMPONENT LOCATIONS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC CONTROL PC BOARD TRIGGER PC BOARD T1 TRANSFORMER POWER PC BOARD BOX ASSEMBLY DRIVE IDLE ROLL ASSEMBLY GEAR BOX DRIVE MOTOR TACHOMETER VOLTAGE PC BOARD LOCATED UNDER RIGHT COVER LEFT COVER ASSEMBLY WIRE SPEED VOLTAGE CONTROL BOX RIGHT COVER ASSEMBLY DIGITAL METER 1 2 3 4 5 6 7 8 9 0 O10 Fle 515 5 1 Return to Section Return to Master TOC
19. CONTROL CABLE EN E POWER SOURCE O 9 WORK 0 N o Return to Section TOC Return to Master TOC NEGAT N B amp N C ELECTRODE CABLE TO WIRE FEED UNIT WORK 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 Tape up bolted connection Connect the control cable ground lead to the frame terminal marked 77 near the power source terminal strip The power source grounding terminal marked located near the power source input power connections must be properly connected to elec trical ground per the power source Operating Manual O o Fle PEN 2 2 2 21 Connect control leads t terminal strip as follows LN 9
20. 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 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 LN 9 Wire Feeder LINCOLN 5 F 41 F 41 TROUBLESHOOTING amp REPAIR METER CIRCUIT ACCURACY TEST continued Test 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 Return to Section TOC Return to Master TOC NOTE The coating will have to be removed from the test points 3 With the meter in SET M MIN adjust the speed con trol 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 olo Replace the meter PC board O o 515 9 2 METRIC MODEL METRIC RANGE SET M MIN READING TEST VOLTMETER 2 READING ele LN 9 or LN 9F LO 8 89 LEAD 560 3 50
21. He o o 2 3 Return to Section Return to Master TOC o 0 g 5 F 48 F 48 TROUBLESHOOTING amp REPAIR GENERAL POWER SUPPLY TESTS continued TEST PROCEDURE 5 1 Remove input power to the LN 9 wire feeder Apply power 115VAC to the wire feeder at the correct pins See the Wiring Diagram 6 Perform the power supply checks as 2 Using the phillips head screw driver remove the screws from the left side cover assembly 3 Lift the left side cover assembly described in the table below If any of the readings are incorrect out of range or miss ing the power PC board may be faulty 4 Locate the power PC board and the control NOTE Do NOT unplug the Molex connector PC board in the wire feeder main assembly 7 Also perform the 71 Transformer Test locate the voltage PC board in the left side cover A 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 LN 9 Wire Feeder LINCOLN 5 o 2 5 2 TROUBLESHOOTING amp REPAIR F 49 olo GENERAL POWER SUPPLY TESTS continued 0 2 o o 2 2
22. LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O P 7 9 2 tc F 21 F 21 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION STARTING PROBLEMS Voltage seems to be too high or the Adjust the start trimmer on the 1 The LN 9 voltage PC board may arc flares at the start of weld voltage PC board It should be be faulty Replace Welding is good only slightly higher than the weld voltage Ses Branting teristios n the Operation section of this manual 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 volt age cannot be set the power source may be faulty Check for correct control cable connections to the power source A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 253
23. Out of Voltage Range Shut Down fest LN 9 Wire Feeder LINCOLN 5 70 5 LN 9 Wire Feeder LINCOLN 5 F 70 NOL 0 NOL DOL J91Se N 01 DOL J91Se N 0 DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes Return to Master TOC Return to Master TOC o 7 Return to Master 2 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAM SECTION Electrical Diagram Section 2 0400021 Section G Wirlng Diagram EET G 2 a Foe eed eek tention 6 3 Meter Board 16687 000000 nnne G 4 Trigger Board M13861 G 5 Tachometer Board Schematic cccceeeecceceeeceeeneeeeeneeeeeaaeeceeeeeeaaaeseneeeesaaeeseaeeeenceeeenaeessas G 6 LN 9 Wire Feeder LINCOLN 5 G 1 5 LN 9 Wire Feeder LINCOLN 5 NOL 0 NOL DOL J91Se N 01 DOL J91Se N 0 DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes G 2 ELECTRICAL DIAGRAMS G 2 Wiring Diagram LN 9 SET ACTUAL SWITCH VOLTS SPEED SEL
24. POWER EXTENDED WIRE DRIVE K392 Permits extending gun and cable up to 80 feet from the K357 LN 9 code 8180 and higher 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 hous ing and a hand crank 50 and 60 Ib reels can be used EXTENSION ASSEMBLY K307 or K308 For LN 9NE or LN 9SE K307 is a 22 ft 6 9 m extension cable K308 is 45 ft 13 7 m Permits weld ing 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 LN 9 Wire Feeder LINCOLN 5 ACCESSORIES TABLE C 2 DRIVE ROLL AND GUIDE TUBE KITS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 ica 2 Roll m 4 Roll 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 6 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
25. 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 assem bly 3 Lift the cover assembly 4 With the slot head screwdriver and the 3 8 wrench remove the R1 2 ohm resistor Note the position of the insulators for reassembly 5 Using the Phillips head screwdriver remove the 9 pin amphenol connector LN 9 Wire Feeder LINCOLN 5 Remove the ta Set the resistor and the amphenol connector aside as far as the lead lengths will allow This is necessary to gain access to one of the three screws that mount the glastic base to the floor assembly h PC board and rotating disc the Tach PC Board Removal and Replacement procedure Remove the two screws from the tach PC board housing Remove the insulator Remove the two screws from the top motor plate and remove the plate Remove it from the other side See Figure F 25 F 66 F 66 TROUBLESHOOTING amp REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT continued FIGURE F 26 GLASTIC MOUNTING SCREWS Return to Section TOC Return to Master TOC NUTS AND WASHERS 4 ROLL lt FEEDERS Return to Section TOC Return to Master TOC 11 Remove the three screws that hold the glas 12 Remove motor leads 626 627 539 tic mounting to the LN 9 floor assembly 541 527 and 528 from their terminal See Figure F 26 lo
26. Return to Section TOC Return to Master TOC o He o o 2 3 Return to Section Return to Master TOC o 0 g 5 32 32 INSTALLATION WIRE DRIVE MOTOR AND TACH FEEDBACK TEST continued 6 Apply 115 VAC power 8 With the LN 9 at idle gun trigger NOT acti A WARNING ELECTRIC SHOCK can kill With power applied there are high voltages e inside the wire feeder Do not reach into the 9 wire feeder or touch any internal part of the wire feeder while power is applied 7 With the gun trigger activated or the gun ter minals jumpered together see the Wiring Diagram check the motor armature volts at leads 541 and 539 Normal 15 5 to 95VDC depending on the wire feed speed setting As the armature voltage is increased the wire feed speed should increase LN 9 Wire Feeder LINCOLN 5 vated 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 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 moto
27. 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 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 vari ables 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 pres sure and then back off per the particular instruc tions 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
28. 05VDC at c HI 15 2 LEAD 561 6 00 4 07VDC LN 9H or LN 9FH LO 8 28 LEAD 560 2 00 05VDC HI 24 8 LEAD 561 6 00 07VDC O10 Fle 515 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 F 42 F 42 TROUBLESHOOTING amp 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD 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 Return to Section TOC Return to Master TOC O o Fle 5 5 gt 2 2 eo 5 5 1 Return to Section Return to Maste
29. 5 F 40 TROUBLESHOOTING amp 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 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 set tings 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 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 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 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 set tings in the table below Test Meter PC Board Accuracy
30. 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 3 64 1 2 mm KP503 3 64A KP546 3 64A 1 16 1 6 503 1 16 KP546 1 16A Section D 1 Section D 1 TABLE OF CONTENTS o P MAINTENANCE 8 pins Section 0 gt Routine Maintenarice Erie D 2 Drive Rolls and Guide D 2 2 Wire Reel Mounting 50 and 60 Ib Coils D 2 Wire Reel Mounting Readi Reels and D 2 Periodic MaintenamGe A D 2 CONTOLBOK O D 2 Wire Drive Motor and Gear ian eei D 2 Gun and Cable D 3 Gun Cable Connector nennen nennen D 3 Return to Master TOC Q 7 Return to
31. Ato75 Bto77 1078 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 NOTE For proper pulse welding operating with LN 9 The LN 9 must have an L6084 3 or higher superseding part number voltage board installed Standard above code 9100 The Pulse Power Filter board must be installed and connected in the LN 9 per instructions provided with the kit The pulse current sensor assembly with looped copper energizer must be installed Standard above code 9100 Feeder conversion kits are available for all LN 9 model codes below 9100 and above 9100 Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC olo O o Fle S PEN 5 5 1 Return to Section Return to Master TOC Return to Master TOC 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 B
32. DC 400 and DC 600 be sure it is properly set for the welding process being used See the topic Making a Test Weld the Operation section of this manual For terminal strip connections using the K196 power input cable connect the input cable to the power source exactly as specified on the appropriate LN 9 model connection diagram Figure A 5 for DC 250 DC 400 and CV 400 CV 500 Figure A 6 for DC 600 Figure A 7 for DC 1000 Figure A 8 for Pulse Power 500 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 connect ed for use with the DC 250 DC 400 400 500 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 LN 9 Wire Feeder LINCOLN 5 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 connect ing the wire feeder 0 eje qq Only qualified persons should install can kill use or service this machine Return to Section TOC Return to Master TOC w POWER SOURCE CONTROL CABLE TO LN 9 INPUT CABLE PLUG Ea Return to Sectio
33. FIGURE 21 TACH ASSEMBLY COVER SCREWS SCREWS TACH ASSEMBLY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PROCEDURE 3 Lift the cover assembly 1 Remove input power to the LN 9 wire feeder 4 Using the slot head screwdriver remove the two screws from the tach assembly cover 2 Using the Phillips head screw driver remove See Figure F 21 Remove the cover the screws holding the left side cover assem bly O10 515 10 gt 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 62 62 TROUBLESHOOTING amp REPAIR TACH PC BOARD REMOVAL AND REPLACEMENT continued 5 Remove control PC board leads 510 525 and 555 See Figure F 22 FIGURE F 22 CONTROL PC BOARD LEADS LEADS 510 525 555 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 6 Hold the nut in place with the 3 8 wrench 7 Carefully remove the rotating disc and tach With the phillips head screw driver remove PC board together Note the spacer washers the locking screw from the rotating disc See underneath the disc Figure F 23 FIGURE 23 REMOVAL OF ROTATING DISK LOCKING SCREW PHILLIPS SCREW DISC NUT O o Fle 5 5 gt 2 2 5 5 1 BOARD
34. Feed Rolls and Guide Tubes for 2 Roll Wire Feeders B 9 Setting the Idler Roll Spring Pressure 2 Roll Wire B 10 5 Changing Wire Feed Rolls and Guide Tubes for 4 Roll Wire Feeders B 11 Setting the Idler Roll Pressure 4 Roll Wire B 11 NEC 14 Loading and Feeding Readi Reels 5 B 14 Loading 22 to 30 Ib Readi Reel Package B 14 Loading a 15 10 30 Ib iit cta rte ta 15 Loading 50 and 60 Ib Coils and Brake B 16 Loading and Feeding 13 14 Innershield 20 B 17 Making a Test Weld and Adjusting Response and Starting Characteristics B 18 T Adjust the Power SOUEFCe 1 idea eee EE Donee ape De lees B 18 e tin ete 19 5 Voltage Control 000 nnne nns 19 gt Starting Characteristics a 19 ces B 20 E Procedure at End Of Coll rtt EFE aaa B 20
35. GENERAL POWER SUPPLY CHECKS 515 9 9 CHECKPOINT TEST CONNECTOR LEAD NO NORMAL LOCATION DESCRIPTION PLUG PIN NO ACCEPTABLE VOLTAGE READING CONTROL P C CHECK 525 BOARD 15VDC ooo CONNECTOR SUPPLY FROM 2 PLUG POWER 525 13 5 15 5 VDC BOARD 510 510 10 515 BOARD 9 Ole 9 gt CONTROL 10 VDC 252555150 g 8 BOARD SUPPLY FROM 000047 2 500 9 2 10 8 VDC E 2 PLUG BOARD TO 510 510 c CONTROL 14 BOARD 9 525 VOLTAGE 2 BOARD UPPER 15 VDC did di CONNECTOR SUPPLY FROM PLUG NEXT POWER ift 525 13 5 15 5 VDC F AND 5 BOARD TO 510 510 isl PINS VOLTAGE 4 ate BOARD 6 VOLTAGE P C yr 8 BOARD UPPER T 5 CONNECTOR pq 510 cle PLUG NEXT TO 5 5 S CHECK 10 VDC 68 PINS SUPPLY FROM POWER 500 9 2 10 8 VDC BOARD TO VOLTAGE NES BOARD LOWER BOARD CONNECTOR 500 PLUG NEXT TO 4 PLASTIC COVERED RELAY 9 o 5 LN 9 Wire Feeder LINCOLN 5 F 50 F 50 TROUBLESHOOTING amp REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performe
36. Master LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o He o o 2 E Return to Section Return to Master TOC o 0 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 sec tion Clean it as necessary Do not use a solvent for cleaning the idle rolls s because it may wash the lubri cant 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 dam age to the wire to a minimum should wire feeding prob lems occur When drive rolls are interchanged leave the three socket head screws of the roll assembly loose until it is re assembled on the d
37. NONE WITH PUBLISHED STANDARDS 2 10 95D DR JRH pate 12 20 90 SUP S D G E NO 5 20031 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LN 9 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 0 5 ele 2 Return to Section Return to Master TOC G 6 ELECTRICAL DIAGRAMS G 6 TACHOMETER SCHEMATIC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result CA
38. PC board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 10 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION TRIGGER INTERLOCK FUNCTION PROBLEMS Return to Section TOC Return to Master TOC The wire feeds when the interlock 1 Check to see if the reed switch 1 Check the 2CR reed switch for switch is in the ON position No 2CR is stuck closed sticking and associated leads welding or gun trigger activation 529 and 628 for shorts The power PC board may be faulty Replace With the interlock switch the 1 Check leads 529 and 628 for 1 The 2CR reed switch may be ON position the wire feed stops loose or faulty connections faulty Check to see if it closes when the gun trigger is released between the 2CR reed switch when welding Board 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
39. POSITION OR COLD INCH OPTION WHEN LOADING WHEN INCHING WITH A HOT GUN TRIGGER THE ELEC TRODE 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 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
40. S FUNCTION PROBLEMS 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 Check the 5 amp circuit breaker Reset if tripped The F101 1 2 amp fuse located on the power PC board may be blown The wire drive motor may be over heated and the thermal protector has tripped Let unit cool TROUBLESHOOTING GUIDE 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 Check for loose or faulty con nections on leads 527 and 528 between the wire drive motor and the power PC board Perform the 1 Transformer Replace if faulty The power PC board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo O o 8 nl 2 2 2 1 Return to Section Return to Master TOC 5 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS
41. SHIPPED CONNECTED TO og 1 32A 10 gt gt 525 524 lt 15 N C RESISTOR USED ON CODES 9131 AND BELOW UTOR 2 xe 540 510 en 9 FOR CODES ABOVE 9131 THE GROUND LEAD 9 3 Ld 11 31 510 628 e 19 i IS CONNECTED DIRECTLY TO THE CASE o i 12 628 505 10 N D i PRESENT ON EARLIER VOLTAGE 8 45 gt 529 L549 gt gt 12 CONTROL lt mus 8 Lo L 531 17 eT P C BOARD TRIGGER N E JUMPER PLUG IS REMOVED WHEN THE 4 Eze j 22KQ 09 J 623 lt CONNECTOR OPTIONAL PULSED POWER P C BOARD Sis 538 524 ONE MAGNETICALLY 0 HARNESS PLUG IS CONNECTED THE D 602 6 4 601 TIGHTLY COUPLED TURN E VOLTAGE P C BOARD REPLACE THE JUMPER YELLOW LT PLUG IF THE OPTION I8 DISCONNECTED aA NOT PRESENT ON ALL CODES INPUT 621 CONNECTOR 620 81 BLACK ELECTRICAL SYMBOLS PER E1537 x CONNECTOR CAVITY NUMBER GROUNDING CONNECTIONS AS VIEWED FROM BACK OF RHEOSTATS STUD CONNECTION FOR D C TYPE POWER SOURCES FOR OTHER POWER 529 0 41 SOURCES 835 SAM AND SAF OR SA WITH 224 SEE OPERATING MANUAL WELD CURRENT E REED SWITCH CR2 67 13 14 147 14710 1411013 INPUT CABLE GUN CABLE 24 25 258 258 2581 14 36 369 36912 3691215 CAVITY NUMBERING L L COMPONENT SIDE OF BOARD 5 24 96 ELECTRIC CLEVELAND OHIO U S A 17197 NOTE This dia
42. TOC O o ci PEN 2 2 2 21 Return to Section Return to Master TOC A 10 A 10 INSTALLATION FIGURE A 7 CONNECTION OF LN 9 TO DC 1000 POWER SOURCES A WARNING Turn off input power to the welding power source using the disconnect switch at the fuse box before connect ing the wire feeder Only qualified persons should install kill use or service this machine N F w TO LN 9 INPUT CABLE PLUG POWER SOURCE CONTROL 70 N H NEGATIVE POSITIVE ELECTRODE CABLE TO WIRE FEED UNIT WORK 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 Extend lead 21 using 14 or larger insulated wire physically suitable for the installation an 516586 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 wor
43. 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 The Above For Gasoline Engines Return to Master TOC Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS Return to Master TOC o 7 Return to Master FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 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 refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fu
44. control PC board This voltage is depen dent upon motor speed Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 F 34 F 34 TROUBLESHOOTING amp 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD 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 Return to Section TOC Return to Master TOC O o Fle 5 5 gt 2 2 eo 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
45. 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 out put 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 elec trically 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 con nects to the power source 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 th
46. 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock 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 AN
47. 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 This alternate connection cannot be used with the DC 250 or CV 500 power sources 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 RE
48. o Fle 5 5 gt 2 2 eo 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o He o 2 3 Return to Section Return to Master TOC o 0 g 5 F 45 F 45 TROUBLESHOOTING amp REPAIR OUT OF VOLTAGE RANGE SHUT DOWN TEST continued FIGURE F 11 VOLTAGE PC BOARD WITH JUMPERS BYPASS PINS TEST PROCEDURE 5 1 Remove input power to the LN 9 wire feeder 2 Using the phillips head screw driver remove 6 the screws from the left side cover assembly 3 Lift the left side cover assembly 4 Locate the voltage PC board Jumper togeth er the BYPASS pins on the LN 9 voltage PC board See Figure F 11 On older voltage 7 boards these pins may be labeled B This should disable the shut down circuit WARNING ELECTRIC SHOCK 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 LN 9 Wire Feeder LINCOLN 5 1 8 AMP FUSE Connect to a Lincoln Electric CV power source per connection diagram See the Installation section of this manual Start welding and
49. observe the ACTUAL volt age reading on the LN 9 digital meter The actual voltage must match the SET voltage within 0 5V If it does NOT the LN 9 is designed to shut down If the LN 9 continues to shut down with the BYPASS pins jumpered together the volt age PC board may be faulty Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o o 2 3 Return to Section Return to Master TOC o g 5 F 46 F 46 TROUBLESHOOTING amp REPAIR OUT OF VOLTAGE RANGE SHUT DOWN TEST continued 8 If the ACTUAL voltage reading is zero the sensing leads may be faulty Check the con tinuity zero ohms of leads 21 and 67 Lead 21 must have continuity to the work piece and 67 must have continuity to the electrode Also check the 1 8 amp fuse on the voltage PC board Check the polarity switches in the LN 9 and the Lincoln power source and their associat ed leads Set the switches to the same polarity as the electrode See the Wiring Diagram 10 If the ACTUAL voltage reading is different 11 LN 9 Wire Feeder LINCOLN 5 from the SET voltage reading the power source may not be capable of producing the required arc voltage the control cable may be faulty or misconnected or the LN 9 volt age PC board may be faulty After all tests are complete remove
50. 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 2 Connect 21 control lead to the work polarity ter PULSE POWER 500 DC650 PRO minal 21 or 21 at the terminal strip matching the same polarity as the work cable connection Refer to each machine Instruction Manual The LN 9 requires the K442 1 Pulse Power Filter Kit For LN 9 3 Set toggle switch to Output Control Remote codes below 9100 use kit K442 2 See the Accessories section of this manual 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 Set the toggle switch to Remote 4 Install voltage triangle to a position as close as possible to desired arc voltage See Shutdown n the Operation section NOTE Since the LN 9 cannot control the fixed OCV of R3S power sources starting diffi culties may be experienced when striking the arc of processes which use a low volt age or a narrow voltage range The fol lowing steps should remedy this difficulty 1 The electrode stickout when starting should be 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 LINCOLN 5 Return to Section R
51. push the electrode into the drive roll A WARNING USE THE COLD TRIGGER SWITCH POSITION OR COLD INCH OPTION WHEN LOADING WHEN INCHING WITH A HOT GUN TRIGGER THE ELEC TRODE AND DRIVE MECHANISM ARE ALWAYS HOT TO WORK AND GROUND AND COULD REMAIN HOT SEVERAL SECONDS AFTER THE GUN TRIGGER IS RELEASED 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 90 so 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 position with the left hand 6 Apply a downward pressure to the id
52. 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 514543 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 elec trode SPINDLE FOR READI REELS 2 1 0 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 Innershield 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 K162 30lb 13 6 kg M14573 Mounting instructions K162H 60 Ib 27 2 kg M15241 Mounting instructions A CAUTION DO NOT USE COILS OR SPOOLS HEA
53. the Voltage Board and Start Board where used according to the appropriate power source connection diagram 4 Reassemble STARTING CHARACTERISTICS SELECT ACCELERATION The LN 9 models can provide optimum starting for dif ferent 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
54. the electrode through the system LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 5 MAKING TEST WELD AND ADJUSTING LN 9 RESPONSE AND STARTING CHARACTERISTICS ADJUST THE POWER SOURCE 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 IShutdown in the Operation section of this manual DC 250 DC 400 or DC 600 SAM 1 Connect electrode lead to terminal of desired 1 polarity 2 Settoggle switch to same polarity as the electrode cable connection Set toggle switch to Output Control Remote Set mode switch to the desired position for the process to be used DC 600 codes 8288 and above are preferred CV 400 500 1 Connect electrode lead to terminal of desired polarity Set Electrode Polarity switch to the appropriate Constant Voltage or Variable Voltage position of the desired polarity for the process being used on the SAM 400 or set desired polarity on the SAM 650 Set the toggle switch to Constant Voltage Set the Constant Voltage Control rheostat to Number 5 for Innershield and other open arc
55. to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 9 o 8 E Return to Section Return to Master TOC O 4 0 9 2 tc F 15 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS When the gun trigger is activated the drive rolls turn but the wire will not feed or wire feeding is rough Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FEEDING PROBLEMS Check or replace the gun cable It may be kinked clogged or twisted Make certain the drive rolls and guide tubes are correct for the wire being used Check or replace the gun con tact tip 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 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical
56. with the later removal of the coil tie wires See Figure B 6 FIGURE B 6 LOADING A 50 OR 60 LB COIL SPINNER M COVER PLATE CARDBOARD COIL LINER TIE WIRE SPRING LOADED ARM 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 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 The mount for standard 50 and 60 pound electrode coi
57. 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 adjust ed 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 set ting 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 continu ously 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 ihe topic later in this section of the manual SET ACTUAL PUSHBUTTON After the weld has been started the ACTUAL voltage or wire speed ca
58. 00 833 9353 WELD DESCRIPTION The following procedure will help the technician remove the T1 Transformer for repair or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED Soldering iron Phillips head screw driver Slot head screw driver Needle nose pliers 5 16 wrench 11 32 wrench olo O o Fle S PEN 9 gt 918 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section Return to Master TOC F 56 F 56 TROUBLESHOOTING amp REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT continued FIGURE 16 PRIMARY LEAD 31 AT R1 RESISTOR LEAD 31 LEAD 532 PROCEDURE 4 Disconnect primary lead 532 from the power PC board terminal 1 Remove input power to the LN 9 5 Disconnect the primary lead 31 from the R1 2 Using the phillips head screw driver remove 2 ohm resistor See Figure F 16 Upon the screws holding the left side cover assem reassembly this lead will have to be soldered bly onto the R1 resistor 3 Lift the cover LN 9 Wire Feeder LINCOLN 5 57 F 57 TROUBLESHOOTING amp REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT continued 6 Disconnect leads 526 and 527 from the power PC board termina
59. 1 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 22 F 22 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O v 2 tc PROBLEMS SYMPTOMS The arc voltage appears to rise too slowly or stubs or blasts at the start of a weld Once started the weld ing is good NOTE Pulse Power 500 operation with a filter kit may exhibit these symptoms POSSIBLE AREAS OF MISADJUSTMENT S STARTING PROBLEMS Check the welding cables for loose or faulty connections Adjust the start trimmer on the voltage PC board It should be slightly higher_than the weld voltage See Starting Charac teristics n the Operation section of this manual Put the Lincoln power source 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 f the symptoms persist the power source may be faulty Check for correct control cable connections to the power source 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 star
60. 120 for 120 and 7 amp 3 0 and 2 8 mm 450 amps K115 3 32 for 2 2 4 mm 450 amps K115 5 64 for 068 1 7 2 0 mm 450 amps 9 K116 120 for 120 and 3 0 and 2 8 mm 600 amps 116 3 32 for 2 4 mm 600 amps 1 9 K206 062 gt 1 6 2 4 mm Innershield 350 amps K2899 068 120 1 7 3 0 mm Innershield 500 amps 309 062 1 6 2 4 mm Innershield 250 amps 5 5 9 Submerged Arc K112 1 6 mm solid 500 amps K113 1 2 0 mm 600 amps K113 2 2 4 mm 600 amps K 114 Or 2 4 or 2 0 mm solid 600 amps 9 K466 1 connector kit required 2 K489 Fast Mate Adapter required Linconditioner guns are recommended for locations where smoke accumulation is a problem and conven 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 olo O o Fle 515 PEN 9 gt 818 5 3 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O o Fle 515 PEN 2 2 5 5 cc 1 Return to Section Return to Master TOC Return to Master TOC C 5 5 ACCESSORIES WIRE FEEDER ACCESSORIES BURNBACK DELAY KIT K202 Provides a precise control of the electrode burnback at the end of the weld Prevents
61. 7 in 248 2 mm 13 76 in 349 5 mm 67 Ibs 30 4 kg Total Package Weight LN 9F Wire Drive 4 Roll 8 79 in 223 3 mm 9 77 in 248 2 mm LINCOLN 5 13 76 349 5 72 Ibs 32 7 kg Total Package Weight Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 o o 2 G 3 Return to Section Return to Master TOC o 2 5 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 posi tion 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 a K163 undercarriage See the Accessories section for details A K178 1 swivel platform is available for mounting the LN 9 to the power sou
62. 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC O10 Fle 515 5 1 Return to Section Return to Master TOC Return to Master TOC 7 A 6 INSTALLATION If using welding currents over 450 amperes con nect 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 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 leav ing 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 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 22 1 2 feet long ti
63. BUTTON WIRE FEEDER WIRE SPEED CONTROL METER READING SWITCH HOT COLD TRIGGER INTERLOCK SWITCH CIRCUIT GROUNDING LEAD BREAKER PROTECTOR GLP RESET SWITCH AT 4 PIN CONTROL CABLE BREAKER RESET TACH FEEDBACK CONNECTOR 9 PIN MS TYPE CONNECTOR 14 MS TYPE CONNECTOR INPUT CABLE TO POWER SOURCE CONTROL CABLE TO WIRE FEED HEAD LN 9F CONTROL BOX BOTTOM VIEW LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o Et o 2 3 Return to Section Return to Master TOC o 5 CIRCUIT BREAKER AND GROUNDING LEAD PRO TECTOR GLP RESET SWITCH These protection circuit INGEN ICES are located on iront rail of the LN 9 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 9mod els 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
64. CONNECTION ELECTRICAL SYMBOLS PER E1537 OR SIGNAL SOURCE POINT REMOVABLE CONNECTION THRU SOURCE POINT CIRCUIT LOCATION SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT LEAD COLOR CODING BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM NOT SHOW THE EXACT B nED COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER U BLUR W WHITE ON HOLE SIZES PER E2056 THE LINCOLN ELECTRIC CO tyre LN 9 AND LN 9F METRIC 2 PLACE DECIMALS IS 202 PLACE DECIMALS IS 4002 ON ALL ANGLES IS 45 OF A DEGREE CLEVELAND OHIO U S A OPERATING SCHEMATIC MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS SCALE_NONE SUPSD 5155 No G 1702 CHK REF 1592 LN 9 6 4 ELECTRICAL DIAGRAMS on METER BOARD L6687 SCHEMATIC 514 515 ACTUAL 510 5108 Return to Section Return to Master TOC TO DIGITAL METER A 518 562 TP4 5100 510 5V 5V REESE ERS eo 4 9 5 4 J4 J14 J4 14 J4 J J4 JM dt e Return to Section TOC Return to Master TOC O10 Fle 515 0 5 ele 2
65. Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O P N 9 2 tc F 14 F 14 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The LN 9 shuts down while weld Make sure the power source 1 Perform Out of Voltage Range ing Upon retriggering the gun the and wire feeder polarity switch Shutdown Test unit will weld again for a period of es are set correctly for the time process being used 2 The control cable may be faulty Check or replace Make certain the voltage control switch on the Lincoln CV power source is set in the Remote position Make sure the 21 lead in the control cable has continuity to the work piece 3 The voltage PC board may be faulty Replace Check the 1 8 amp fuse on the LN 9 volage PC board Replace if faulty 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 CAUTION If for any reason you do not understand the test procedures or are unable
66. Do not reach into the 531 and 32 if the secondary voltage is missing or low the T2 transformer may be wire feeder or touch any internal part of the wire faulty Replace the T2 transformer feeder while power is 10 After the test is completed disconnect the applied 115VAC from the T2 transformer primary leads 531 and 432A Reconnect lead 32 to the circuit breaker Re attach the Protection Circuit Troubleshooting name 7 Insulate the T2 transformer primary leads plate Close the right and left side cover assemblies and replace all previously 531 and 432A and apply 115 VAC power See the Wiring Diagram and removed screws Electric Shock can kill olo O o E 515 PEN 9 gt 818 5 5 a Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 30 F 30 TROUBLESHOOTING amp 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con
67. E DRIVES ERS o change drive rolls on a 4 roll wire feeder refer to Figure B 4 B nd perform the following steps 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 col lar 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 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 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
68. ECTOR 02102 10V 5W TP102 TRANSIENT PROTECTOR C105 AND PT101 PRIMARY ARE SHOWN SECTION 022 1022 MFD 18 4 7 MED 0033 MFD MED 18 MED 4 MFD 047 MFD 4 7 MED 15 MFD 1022 MFD 1022 MFD 4 7 MFD 18 MFD 100pf 022 MFD 6 8V 1K OHM 270 OHM 500 OHM TRIMMER CONTROL CIRCUIT R204 1 00 OHM 1 4W 1 2 94K OHM 1 4W 1 15K OHM 10K OHM 100K OHM TRIMMER 33K OHM 10K OHM 5 6K OHM 15K OHM 47K OHM 15K OHM 100K OHM 1K OHM 1K OHM 1K OHM 33K OHM 50K OHM TRIMMER 15K OHM 10K OHM TRIMMER 33K OHM 100K OHM 1K OHM 10K OHM 6 8K OHM 10K OHM 20K OHM TRIMMER 27K OHM 15 OHM NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 100 OHM 6 8K OHM 2 7K OHM 10K OHM 15K OHM REGULATOR TACHOMETER QUAD OP AMP QUAD OP AMP 2N4123 2N4125 2N4123 2N5816 2N6027 METER CIRCUIT 500 MFD 4 7 MFD 27 MFD 022 MFD 1A VOLTAGE REGULATOR DIGITAL METER 24 3K OHM 1 4W 1 2K OHM TRIMMER 2 80K OHM 1 4W 1 7 68K OHM 1 4W 1 1K OHM TRIMMER 102K OHM 1 4W 1 10K OHM TRIMMER FOR VOLTMETER P C BOARDS L6687 1 OR HIGHER USE 521145 SCHEMATIC FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS v sHUTDOWN CIRCUIT VOLTAGE CIRCUIT FOR VOLTAGE P C BOARDS L6084 4 OR HIGHER USE 18388 SCHEMATIC FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS C501 1 MFD F501 18 AMP FAST 517 1K OHM 005 MED BLO
69. ECTOR SWITCH CONTROL RHEOSTAT PLUG WIRE SPEED CONTROL Return to Section TOC Return to Master TOC 634 x e 3 mue RHEOSTAT lozg noes 635 lt 10 en i 10 ono e 636 1 9 WHITE NA 631 144 3 Ba T 9 633 5108 L 12 JUMPER 5 i i Hd IH 514 c e 7 632 lt 632 1987 5263 515 1 1 i 633 x 7 1 525 1 lt lt 4 I dle dL 9 561 517 d Z E N D 634 1 91 560 BOARD 510 L lt e 6 BLUE 635 4 61 635 PLUG E J 5108 lt lt 8 JUMPER i i i 636 1 8L o 5 X 22 2 s 667 xe 11 ddo 636 K aa 634 BURNBACK 2541 500 ice 5 R i p eae 2 P C BOARD OPTIONAL 5 Ki i i VOLTS CONTROL A 53 531 504 27502 METER 4 i 5 021 9 it 4 4 i M E E go 1521A LA L J JUMPER CONNECTOR IS REMOVED AND ja i PANEL 876593412 5126391248 7 1110 i viv 1 1
70. EL STANDS AND MOUNTINGS 50 60 LB WIRE REEL MOUNTING STAND K303 The assembly includes a framework to which is attached the 50 60 Ib 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 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 Ib 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 Ib spools with 2 I D LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE o 2 3 Return to Section Return to Master TOC o g 5 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 con nect 1 Remove the three 3 8 in hex head bolts from the back of the wire feed unit 2 Place the wire reel mounting
71. K377 C 3 Small Mounting Stand for 13 14 Innershield Coils 78 C 3 50 60 Ib Wire Reel Assembly for Customer Mounting 299 C 3 8 Gun and Cable Assemblies C 4 Wire Feeder Accessories 2 221 5 Burnback Delay 202 202240 0 0 5 Dual Process 5 Dual Process Kit K318 resi 5 Dual Procedure Kit 319 22222 0 enne 5 Pulse Power Filter Conversion Kit 442 000000 C 5 3 Swivel Platformv IKT78 1 tek 6 5 Undercarriage 163 0 00204 24 0 0 1 000 an snnt 6 8 Continuous Flux Feed Tank 320 C 6 9 K320 Flux Tank uestri e ua C 6 S Flux Screen K310 assess ada nette teo c Dc dna C 6 E Magnetic Separator 58 enne nennen nnns C 7 Mechanized Hand Travel Unit K110 sse C 7 SQUIMMODIS 7 Mechanized Travel
72. LN 9 Wire Feeder LINCOLN 5 Section 1 Section 1 TABLE OF CONTENTS o THEORY OPERATION SECTION 5 Theory Section 9 2 5 Power 2 d Trigger and Shutdown 3 Arc Voltage Wire Speed Control and 0000 E 4 Printed Circuit Board Functions enne E 5 VOLTAGE CONTROL WORK VOLTAGE SENSING ELECTRODE VOLTAGE SENSING POLARITY SWITCH WIRE SPEED CONTROL o 0 5 POWER SOURCE OUTPUT TRIGGER 2 844 WIRE SPEED CONTROL a 1 1 1 TRIGGER BOARD i gt 15 00 CIRCUIT CONNECTOR 1 BREAKER C 24 5 1 1 EN TRIGGER SIGNAL INPUT ao CONNECTOR R1 1 1 1 1 1 1 1 1 9 5 i U T d CONTROL w BOARD 2 To ANNI c VOLTAGE INS INN BOARD D METER 10 28VAC BOARD Q Mo n VOLTAGE NC 1 SWITCH VOLTAGE 1 BOARD i TRIGGER SIGNAL ______________ _________ _ 1 GROUND LEAD PROTECTOR FIGURE E 1 LN 9 BLOCK LOGIC DIAGRAM Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Retu
73. NADA FRANCE AUSTRALIA 69961 S NOTES NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER THIS SHEET CONTAINS PROPRIETARY Ch ge Sht No GENERAL INFORMATION LABELS ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 1A 400V UNLESS OTHERWISE SPECIFIED Fu FRAME CONNECTION SUPPLY VOLTAGE POWER SUPPLY SOURCE POINT EARTH GROUND CONNECTION COMMON CONNECTION INFORMATION OWNED BY 5 15 92N THE LINCOLN ELECTRIC CO fee __ LN 9 TACHOMETER THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A E SCHEMATIC AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMI SSI ON SCALE __ NONE OF THE LINCOLN ELECTRIC CO LINCOLN P SHT DR MW pare 3 8 91 CHK SUP S D G 0 5 19852 in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LN 9
74. NDARY LEADS 601 AND 602 AT LEAD SPLICES Return to Section TOC Return to Master TOC Return to Section Return to Master TOC 6 Using the volt ohmmeter check for 10VAC at 7 With 115VAC applied to the primary leads secondary leads 601 and 602 Typically 532 and 31 if either or both of the sec these leads are yellow Place the probes at ondary voltages are missing or low the T1 the lead splices See Figure F 2 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 O10 Fle 515 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 F 26 F 26 TROUBLESHOOTING amp REPAIR T2 TRANSFORMER TEST A 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are un
75. O10 Fle 515 5 8 1 Return to Section Return to Master TOC F 35 F 35 TROUBLESHOOTING amp REPAIR VOLTMETER ACCURACY TEST continued FIGURE F 8 VOLTMETER CONNECTION POINT CONDUCTOR BLOCK TEST PROCEDURE Perform the following checks with the LN 9 wire 1 Lift the right side cover assembly feeder connected to a Lincoln CV welding power 2 Connect the test meter see Materials Source according to the proper connection dia Needed between the brass conductor block gram See the Installation section of this man on the wire feeder and the work piece ual See Figure F 8 for this test LN 9 Wire Feeder LINCOLN 5 36 36 TROUBLESHOOTING amp REPAIR VOLTMETER ACCURACY TEST continued 3 With the LN 9 gun trigger closed or the gun A WARNING terminals jumpered together see the Wiring Diagram the test meter reading should ELECTRIC SHOCK can kill match the LN 9 ACTUAL volts reading within 0 5 volts If it does not check the integri With power applied there are High voltages inside ty and placement of the voltage sensing leads 9 9 21 and 67 Perform the Meter Circuit the wire feeder Do not reach into the wire feeder or touch any internal part 4 Remove the test voltmeter and while weld of the wire feeder while ing compare the SET volts and ACTUAL volts power is applied meter readings Depending upon
76. Power 161 7 Gas Solenoid Ea 7 Power Extended Wire Drive 392 C 7 Enclosed Reel Mounting 304 2 7 Extension Assembly K307 or 308 000 0080 88 C 7 5 licae 7 Hedge pm 7 Drive Roll and Guide Tube Kits Table 2 C 8 2 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 5 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 A 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 termi nals marked 32 and 7 which come through the rec tangular hole in the control section sheet
77. SI 287 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 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 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and ca
78. SVM127 A LN 9 Wire Feeder November 1996 For use with machines having Code Numbers 9134 9842 9958 10316 10327 Return to Master TOC View Safety Info 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info o 9 gt 9 o z 2 gt o O i o s 5 tc SERVICE MANUAL LINCOLN amp 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 Return to Master TOC View Safety Info SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm 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 Diesel Engines ARC
79. TER READING DRIVE ROLL READING SPEED MODEL IN MIN M MIN RPM IN MIN M MIN LN 9 158 4 0 30 1 2 158 2 04 0 1 e e 316 8 0 60 1 316 2 08 0 1 LN 9F 8 LN 9H 161 4 1 30 1 2 161 04 1 1 2 322 8 2 60 1 322 3 08 2 1 LN 9FH ala amp 2 515 mio gt Se LN 9 Wire Feeder LINCOLN 5 F 44 F 44 TROUBLESHOOTING amp REPAIR OUT OF VOLTAGE RANGE SHUT DOWN 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the out of voltage range shut down circuitry is functioning prop erly MATERIALS NEEDED Phillips head screw driver Volt ohmmeter multimeter Jumper wire Return to Section TOC Return to Master TOC O
80. TROL WIRE SPEED CONTROL 15VDC TRIGGER SIGNAL 2 VOLTAGE CONTROL VOLTAGE TRIGGER SIGNAL GROUND LEAD PROTECTOR The normally closed relay located on the voltage board is in series with the trigger signal If an out of voltage range signal or a ground fault condition should occur the CR501 on voltage board relay contacts would open and the trigger signal path would be interrupt ed This would cause the wire feeder to shut down until the gun trigger is released or the ground fault pro tector is reset NOTE Unshaded areas of Block Logic Diagram are the subject of discussion LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o Fire ci 8 nl ele ES 2 1 Return to Section Return to Master TOC E 4 VOLTAGE CONTROL POLARITY SWITCH E 4 THEORY OF OPERATION FIGURE E 4 ARC VOLTAGE WIRE SPEED CONTROL AND METERING gem PS INPUT TRIGGER SIGNAL CONNECTOR TO VOLTAGE BOARD 28VAC 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 com pared to the reference preset voltage that is set by the voltage control The voltage board determines what
81. UBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION The 1CR relay on the power PC board may be faulty Check or replace Check resistor R1 Normal resistance is 2 ohms See the Wiring Diagram 3 Perform the Transformer T2 Test Perform the Trigger Board Test Perform the If the wire drive motor is OK then the power PC board or the control PC board may be faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC O 4 7 9 2 tc PROBLEMS SYMPTOMS The wire feeds when the gun trig ger is activated but there is no arc voltage POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make sure the inch switch is in a Wire Hot position Check the welding cables for loose or faulty connections Put a jumper wire from 2 to 4 on the power source terminal str
82. VIER THAN 30 LBS ON THE ORIGINAL K162 SPINDLE READI REEL ADAPTERS K363 P Adapts Lincoln Readi Reel coils of electrode 30 Ib and 22 Ib to a 2 spindle One piece construc tion 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 Ib 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 Ib 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 han dling up to 30 Ib 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 Ib Innershield 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 INNER SHIELD COILS K378 This assembly includes t
83. W FUSE 270 OHM t 001601 OPTO ISOLATOR 47 MFD 56K OHM 022 MFD 9501 28423 330K OHM 0502 2N4857 022 MFD 22K OHM 4 7K OHM X501 LC QUAD OP AMP 4 7K OHM X502 1 QUAD OP AMP 22K OHM 22K OHM 501 TRANSIENT PROTECTOR 22K OHM 2 2K OHM 44 2K OHM 1 4W 1 500 OHM TRIMMER 27K OHM 100K OHM 4 75K OHM 1 4W 1 100K OHM 27K OHM 27K OHM 10K OHM 15K OHM 100 OHM 022 MFD 10K OHM ik OHM 270 OHM 2 2K OHM 26 S P D T 24VDC 27K OHM PRIN 5K OHM TRIMMER 2k OHM TRIMMER 5 6K OHM 2 7MEG OHM 20V 1W 5 6K OHM 15V iW 1 8K OHM 54V 100K OHM D509 AND 501 B THIS SHEET CONTAINS PROPRIETARY INFORMATIQN UNLESS OTHERWISE SPECIFIED TOLERANBEN ge OWNED BY THE LINCOLN ELECTRIC CO AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED CONTACTS ARE SHOWN WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO COMPONENTS NOT ON P C BOARD COMPONENTS CIRCUIT 2 OHM SOW 10K OHM 2W POT 10K OHM 2W POT 22K OHM 0 1 OHM gt WELD CURRENT REED SWITCH G L P REED SWITCH SPST TRIGGER SWITCH DPDT HOT COLD CENT OFF INTERLOCK SWITCH DPDT POLARITY SWITCH SPST G L P RESET SWITCH DPDT SET ACTUAL SWITCH 3 POLE VOLTS SPEED SELECTOR SWITCH DPDT DIRECTION SWITCH POWER SUPPLY TRANSFORMER TRIGGER SUPPLY TRANSFORMER 70 gt gt 150VAC TRANSIENT PROTECTOR ve METER CIRCUIT KEY TO SYMBOLS INPUT CABLE
84. Y 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 con trol 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 man ner 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 in
85. able to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD 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 Return to Section TOC Return to Master TOC olo O o Fle S PEN 9 gt 918 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section Return to Master TOC F 27 F 27 TROUBLESHOOTING amp REPAIR T2 TRANSFORMER TEST continued FIGURE F 3 PROTECTION CIRCUIT TROUBLESHOOTING NAMEPLATE PROTECTION CIRCUIT TROUBLESHOOTING NAMEPLATE cult TEST PROCEDURE 1 Remove input power to the LN 9 wire feed 4 er 2 Using the phillips head screw driver remove the screws holding the left side cover assembly LN 9 Wire Feeder LINCOLN 5 3 Lift the right side cover assembly 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 wil
86. age 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 sig nals 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 ini tiate 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 meter board contains signal scaling and power supply circuitry for the digital meter NOTE Unshaded areas of Block Logic Diagram are the subject of discussion LN 9 Wire Feeder LINCOLN 5 6 5 LN 9 Wire Feeder LINCOLN 5 E 6 NOL 0 NOL DOL J91Se N 01 DOL J91Se N 0 DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes Section F 1 Section F 1 TABLE OF CONTENTS S TROUBLESHOOTING amp REPAIR SECTION 5 3 Troubleshooting amp Repair Section 4 2 2 Section F How to Use Troubleshooting F 2 PC Board Troublesho
87. ason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o 5 F 19 F 19 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION METER FUNCTION PROBLEMS SET volts and actual volts readings 1 Put the Lincoln power source in 1 Check the voltage sensing match within a few tenths of a volt the Machine Control mode leads for continuity zero ohms while welding However both read Check to see if the power Lead 21 should have continu ings are inaccurate source can be set for the arc ity to the work piece and lead voltage required for the process 67 should have continuity to If not the power source may be the brass conductor block See faulty the Wiring Diagram The control cable may be faulty 2 Perform the Meter Circuit Check or replace Accuracy Test The voltage board may be faulty Re
88. ave other health effects which are now not known 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 4 2 Never coil the electrode lead around your body 2 8 3 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 LN 9 Wire Feeder LINCOLN 5 Return to Master TOC Return to Master TOC o 7 Return to Master 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
89. cations Remove the green motor ground lead See Figure F 25 Free the leads from NOTE Four roll drive units have nuts and wash ers also Screw heads are located under the Mylar insulator the harness to allow movement of the motor Cut or untape any necessary harness ties O10 Fle 515 15 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 67 67 TROUBLESHOOTING amp REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT continued FIGURE F 27 MOTOR AND WIRE DRIVE REMOVAL Return to Section TOC Return to Master TOC 2 2 E MYLAR 8 INSULATOR 5 Ele 5 8 ele GLASTIC MOUNTING BOARD e E MOUNTING 5 8 BOLTS 4 918 a gt E 13 Lift the right side cover assembly 14 Using the 1 2 wrench remove the four bolts S 5 fully lift and slide the motor and wire drive and associated washers holding the glastic 9 assembly partially out of the LN 9 box mounting board and mylar insulator to the E assembly See Figure F 27 gear box assembly NOTE Four roll drive units will require the removal of a 1 2 bolt mounting the reed switch copper energizer to the glastic plate Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2
90. cher simultan ment les parties sous ten sion des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines 1 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais 2 enroule le c ble lectrode autour de n importe quelle partie du 5 3 3 Un coup d arc peut tre plus s v re qu un coup soliel donc 4 a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnementde l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 6 les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie tincelle
91. correction signal needs to be sent to the Lincoln weld ing power supply This voltage control signal is cou pled 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 WIRE FEED MOTOR THERMOSTAT VOLTAGE CONTROL VOLTAGE GROUND LEAD PROTECTOR 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 con trol The control board determines what correction is needed and sends the appropriate signal to the power board The power board then adjusts the motor arma ture voltage to comply with the command from the con trol 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 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o g 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
92. d 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 brush es give all information from the motor nameplate LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 9 o 8 c E Return to Section Return to Master TOC o 5 GUN AND CABLE MAINTENANCE For instructions on periodic maintenance for the weld ing gun and cables refer to the manual for your specif ic 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 62 15 7 dia 3 we d 747 18 3 03 x 48 76 x 45 O62R 158 A Dia 295 7 49 ae 290 7 36 Connector mus 252 6 40 40 d 260 6 50 200 A 51 0 LN 9 CONNECTOR FOR 1 16 120 1 6 3 0 WIRE 10045 6040 l 03 45 76 x 45 Dia Hole 495 12 5 Max Dia LN 9 CABLE CONNECTOR FOR 030 052 0 8 1 3 mm
93. d 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will help the technician remove the digital meter and meter PC board for repair or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED Slot head screw driver 5 16 nut driver Phillips head screw driver olo O o Fle S PEN 9 gt 918 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 51 51 TROUBLESHOOTING amp REPAIR bly See Figure F 12 1 Remove input power to the LN 9 wire feeder 3 S DIGITAL METER AND METER PC BOARD REMOVAL AND 5 5 REPLACEMENT continued 8 METER PC BOARD REMOVAL 2 Locate and remove the two screws on the top 2 PROCEDURE left and right side of the meter panel assem FIGURE F 12 METER PANEL ASSEMBLY SCREWS MOUNTING SCREWS METER Return to Section TOC Return to Master TOC
94. e meter displays the actual speed correctly or reads EEE POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Lincoln Service local Field Contact your Authorized Facility TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 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 Perform the Wire Drive Motor The SET speed is adjustable and steady The actual speed reading is incorrect erratic or zero Check for loose or faulty con nections on leads 510 525 and 555 between the tach board and the control PC board Check to make sure the slotted disc in the tach housing is secure and aligned Perform the Tach Board Feedback Test he Board Feedback Test 5 OK the control PC board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Retu
95. e sure the con nection to the work makes tight metal to metal electri cal contact Poor work lead connections can activate the grounding lead protector and or result in poor weld ing performance TABLE A 1 WORK CABLE SIZES Current Copper Work Cable Size AWG 60 Duty Cycle Up to 50 length 50 100 length 300 Amps 0 000 400 Amps 00 0000 500 Amps 000 0000 600 Amps 000 Two 000 DIRECT WORK LEAD CONNECTION Lincoln specified procedures give voltage readings taken between the work and the gun cable brass con nection block of the LN 9 To match these voltage read ings 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 dia gram This in line connection consists of a red insulat ed 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 cor ner of the control box near the inpu
96. e two wire feeders When connected in this manner and one trigger is pressed the other elec trode will be cold to ground but hot to the other elec trode 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 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 togeth er 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 tog gle 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 mount ed over the new panel and functions in the same man ner All electrica
97. ebrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispostifis de s ret leur place LN 9 Wire Feeder LINCOLN 5 MASTER TABLE CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Lr m die eein dp eek etal penn tet eyes i iv Install tlon noto ce aha E Section Technical 2 Installing the LN 9 2 Roll and 4 Roll A 3 Installing the LN 9F 2 Roll and 4 Roll A 3 Electrical Connections LN 9 and 200404 0 0 01 A 4 Machime Grounding MERE A 12 Work Cable Connection eessssssessssssesesseeeeene einen entren nnn A 12 Connecting the Gun Cable to the Wire Feeder sss A 13 iru m Section B Safety INStrUCtONnS ERI B 2 Generali DESCIPUON EEE B 3 Recommended Processes and eene B 3 Controls and Settings tre de cite Ahi dede ee lae oec Pee t B 4 Drive Roll Installation and Pressure B 9 Wire LO AGING eec B 14 Making a Test Weld and Adjusting Response and Starting Characteristics B 18 Procedure at End of eke
98. ecommendations LN 9 Wire Feeder LINCOLN 5 Return to Master TOC Return to Master TOC o 7 Return to Master PRECAUTIONS DE SURETE 7 Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un Pour votre propre protection lire et observer toutes les instructions chauffement et un risque d incendie et les pr cautions de s ret specifiques qui parraissent dans ce 8 S assurer que la masse est connect e le plus pr s possible manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter tou jours tout contact entre les parties sous tension et la 9 peau nue ou les v tements mouill s Porter des gants Secs et sans trous pour isoler les mains b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher 10 metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse c Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder en bon et s r tat e jamais tou
99. el is spilled wipe it up and do not start engine until fumes have been eliminated 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 6 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 Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running 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 9 ELECTRIC AND MAGNETIC FIELDS N 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding h
100. eturn to Master TOC Return to Section TOC olo O o E S8 o PEN 9 gt 918 5 5 a Return to Section Return to Master TOC Return to Master TOC 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 Check that Feed Direction is set to forward Set the Trigger Interlock switch as desired 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 appropri ate 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 L 6084 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
101. field voltage for the wire drive motor The SCR circuit ry 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 cir cuitry 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 The control board also powers and processes the feed back signals from the tachometer board It compares the actual speed information to the SET speed com mand 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 con trolled by the control board as well as the SET speed and actual speed signals for the digital meter circuitry 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 volt
102. fully seated and tighten the lock ing 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 FIGURE A 9 GUN CABLE CONNECTIONS AMPHENOL CONNECTOR GUN CABLE ASSEMBLY BLOCK LN 9 Wire Feeder LINCOLN 5 14 5 LN 9 Wire Feeder LINCOLN 5 A 14 NOL 0 NOL DOL J91Se N 01 DOL J91Se N 0 DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes Section B 1 Section B 1 TABLE OF CONTENTS o P OPERATION SECTION 8 Operation 5 WAV Y B 2 2 General Description i eara Re casas ec deu t auda B 3 2 Recommended Processes and B 3 DC Constant Voltage Power Sources B 3 Controls and Settings e a e bue 4 Circuit Protection and Automatic Shutdown B 7 Avoiding Ground Lead Protector GLP Activation sess B 7 Drive Roll Installation and Pressure 0 B 9 T Changing Wire
103. g MATERIALS NEEDED 115VAC power supply Phillips head screw driver Volt ohmmeter multimeter LN 9 Wire Feeder LINCOLN 5 F 23 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle S PEN 9 gt 918 5 5 1 Return to Section Return to Master TOC F 24 F 24 TROUBLESHOOTING amp REPAIR T1 TRANSFORMER TEST continued FIGURE LEAD 532 AT POWER PC BOARD TEST PROCEDURE 1 Remove input power to the LN 9 wire feed er Using the phillips head screw driver remove the screws holding the left side cover assembly Disconnect lead 532 from the power PC board terminal See Figure F 1 A WARNING Electric Shock can kill With power applied amp 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 526 LEAD 527 T1 TRANSFORMER LEAD 532 4 Apply power 115VAC to the T1 transformer 5 LN 9 Wire Feeder LINCOLN 5 primary leads 31 and 532 See Figure F 1 and the Wiring Diagram 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 ter minals 25 25 TROUBLESHOOTING amp REPAIR T1 TRANSFORMER TEST continued FIGURE F 2 SECO
104. g bag Wear an anti static wrist strap For safety use a 1 Meg Aa ATTENTION Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe e If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent sta tic build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either conductive anti static or static dissipative 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 e If the PC Board uses protective shorting jumpers don t remove them until installation is complete e 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 prop er 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 tem perature 5 Remove the replacement PC board and substitute it with t
105. gher than the desired procedure and make a test weld 1 If the LN 9 now keeps welding change the 835 triangle setting to the next lower voltage and reset the LN 9 set point to the desired pro cedure 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 para graph below and the other possible causes previously listed 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 SET read ing 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 shut ting 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 LINCOLN 5 Pg DRIVE ROLL INSTALLATION AND 5 5 PRESSURE SETTING 4 Remove idle roll shaft screw install idle roll 9 d Replace screw a
106. good starting for steel cored and MIG processes using or Argon CO blended 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 low ering 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 840 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 facto ry setting turn the slot CCW opposite to the labeled arrow direction NOTE f 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 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC olo O o E 5 5 o PEN 9 gt 818 5 5 a Return to Section Return to Master TOC Return to Master TOC 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 Connect the wo
107. gram is for reference only may be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside of the enclosure panels of your machine LN 9 O10 Fie amp gt 2 ple tc t Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o G 2 5 o 2 3 Return to Section o O o 9 5 tc Return to Master TOC G 3 OPERATING SCHEMATIC INPUT AND MOTOR POWER CIRCUIT A ELECTRICAL DIAGRAMS CONTROL POWER SUPPLY AND RELAY CIRCUIT MOTOR CONTROL CIRCUIT A 5 AMP CIRCUIT BREAKER WIRE FEED 57 MOTOR DIRECTION FIELD SWITCH olo MOTOR THERMOSTAT 32A 115 VAC DOF OR101 TRIGGER BOARD 622 HOT COLD 500 530 INTERLOCK SWITCH 9 BURNBACK RECEPTACLE 500 530 SHOWN WITH JUMPER PLUG INSTALLED TRIGGER SWITCH TH pick up gt 525 P C BOARD 55 VOLTAGE BOARD RECEPTACLE FOR OPTIONAL PULSE POWER FILTER P C BOARD PLUG SHOWN WITH JUMPER PLUG INSTALLED EARLIER VOLTAGE P C BOARDS DO NOT HAVE THE 4 PIN RECEPTACLE AND 521A IS 521 Y TRIGGER AND TACH CIRCUIT 1500 NIH S
108. he 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 feed ing and to avoid bird nesting by allowing the drive roll to slip on the wire if a gun cable jam or stop page occurs If using harder or larger dia alu minum 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 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o o 2 3 Return to Section o g 5 Return to Master B 13 B 13 OPERATION FIGURE B 4 INSTALLING DRIVE ROLLS ON A 4 ROLL FEEDER CLAMPING COLLARS AND SET SCREW MIDDLE CLAMPING COLLARS DRINE GUIDE TUBE KEY AND SET SCREW ROLL KEY DRIVE ROLL CLAMPING SCREW CLAMPING OUTGOING SCREW GUIDE TUBE INCOMING GUIDE TUBE QUICK RELEASE LEVER IDLE ROLLS QUICK ROLLS QUICK RELEASE LEVER TENSION TENSION RELEASE ADJUSTMENT PINS ADJUSTMENT SCREW SCREW LN 9 Wire Feeder LINCOLN 5 OPERATION WIRE LOADING 4 Se
109. he 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 termi nal 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 PROB LEM will help avoid denial of legitimate PC board warranty claims LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O P 77 9 2 tc TROUBLESHOOTING amp REPAIR Observe Safety Guidelines 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
110. he 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 Ib wire reel spindle shaft adjustable brake insulation and mounting hardware Install the assembly according to instructions included with it LN 9 Wire Feeder LINCOLN 5 ACCESSORIES o 3 GUN AND CABLE ASSEMBLIES 6 5 A variety of standard Lincoln and Magnum gun and 12 ft and 15 ft cable lengths Choose the gun and 58 cable assemblies are available for the LN 9 in 10 ft cable assembly to suit the LN 9 welding application and wire size See Table 1 gle EJE 2 8 9 E TABLE C 1 LN 9 GUN AND CABLE ASSEMBLIES 6096 Duty Process Model Electrode Rating Gas Metal Arc Welding K497 025 045 0 6 1 14 mm solid 200 amps 200 amps K498 025 045 0 6 1 14 mm solid 200 amps 200 amps e S Magnum 470 035 0 9 2 0 mm solid 300 amps E 300 amps 9 Magnum K471 035 0 9 2 0 mm solid 400 amps lz 400 amps 8 Magnum 478 035 0 9 2 0 mm solid 300 amps S 5 300 amps c Magnum 479 035 0 9 2 0 mm solid 400 amps 400 amps Innershield K126 062 2 1 6 2 4 mm Innershield 350 amps K115
111. his manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 Check or replace gun trigger and leads Make sure the trig ger leads are not shorted to the electrode or work cables RECOMMENDED COURSE OF ACTION 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 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 Perform the Wire Drive Motor The power PC board may be faulty Replace Circuit breaker 5 amp trips when power is applied to the LN 9 Gun trigger is NOT activated 1 Disconnect any kits that may be incorporated in the LN 9 K202 K319 etc Be sure to install any necessary jumper plugs the problem is resolved the fault may be in the disconnect ed kit Disconnect lead 620 from trig ger board See the Wiring Diagram If the problem is resolved the trigger board may be faulty Replace Perform the T2 Transformer Check the harness leads 32A 31 and 531 for shorts or grounds See the Wiring Diagram The power PC board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooti
112. input power to the wire feeder and remove the jumper you placed on the BYPASS pins on the voltage PC board Reattach the left case side cover assembly F 47 F 47 TROUBLESHOOTING amp REPAIR GENERAL POWER SUPPLY TESTS A 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION These tests will help determine if the power PC board is supplying the correct voltage to the control PC board and the voltage PC board Return to Section TOC Return to Master TOC MATERIALS NEEDED Phillips head screw driver Volt ohmmeter multimeter olo O o Fle S PEN 9 gt 918 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o
113. ip Machines with 14 pin amphenols pin C to pin D the arc voltage is not present at the output terminals the power source is faulty If the arc volt age IS present the problem is in the wire feeder or control cable 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 burnback kit is installed remove and install jumper plug If the problem is solved the burnback kit is faulty Check the 2 and 4 leads in the LN 9 wiring harness for loose or faulty connections See the Wiring Diagram CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O 0 9 2 tc TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The SET speed is adjustable and steady The actual speed is uncon trollable Th
114. k lead accessory on any LN 9 which has a direct work lead jack Tape up bolted connection 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 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 The LN 9 voltage control jumpers must be connected as follows White jumper on voltage board to pin S Blue jumper on voltage board Later units only or on start board earlier units to pin B Set the DC 1000 controls as follows Set the control switch to output control remote For submerged arc processes set the mode switch to submerged arc For open arc processes set the mode switch to Innershield Alternative 500 amp positive terminal connection provided on DC 1000 models above code 9500 only LN 9 Wire Feeder LINCOLN 5 11 11 INSTALLATION FIGURE 8 CONNECTION OF LN 9 PULSE POWER 500 POWER SOURCES A WARNING Turn off input power to the welding power source using the disconnect switch at the fuse box before connect ing the wire feeder eeg Only qualified persons should install kill use or service this machine Return to Section TOC Return to Master TOC LN 9 INPUT CABLE PLUG
115. ks on the electrode If there is no waviness the pressure is set too low 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 slip page 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 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC olo O o Fle 515 o PEN 5 5 1 Return to Section Return to Master TOC Return to Master TOC OPERATION CHANGING WIRE FEED ROLLS SETTING THE IDLER ROLL PRESSURE 4 ROLL GUIDE TUBES FOR 4 ROLL WIRE FEED WIR
116. l allow See Figure F 3 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section Return to Master TOC F 28 F 28 TROUBLESHOOTING amp 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 LEAD 531 R1 RESISTOR 4 Locate the T2 transformer primary lead 5 Lift the left side cover assembly 32A connected to the 5 amp circuit break er Remove lead 32A from the circuit break er See Figure F 4 and the Wiring Diagram 6 Locate T2 transformer primary lead 531 connected to the R1 2 ohm resistor See the Wiring Diagram See Figure F 4 LN 9 Wire Feeder LINCOLN 5 F 29 F 29 TROUBLESHOOTING amp REPAIR o s 3 T2 TRANSFORMER TEST continued 8 5 FIGURE F 5 T2 SECONDARY LEADS 621 AND 620 ON TRIGGER PC BOARD 2 gle LEAD LEAD PIE 620 621 Return to Section Return to Master TOC TRIGGER PC BOARD 8 Using the volt ohmmeter check for approx A_WARNING imately 24VAC at the T2 transformer sec ondary leads 621 and 620 Place the probes where the leads connect on the trig With power applied ger PC board See Figure F 5 there are high voltages inside the ra c 9 With 115VAC applied to the primary leads
117. l connections are with plugs to speed and simplify the assembly A 15 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 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 stan dard power sources Install the kit according to instructions included LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE o o 2 3 Return to Section Return to Master TOC o g 5 ACCESSORIES SWIVEL PLATFORM K178 1 For all LN 9 wire reel stand combinations For mount ing wire feeder wire reel stand assembly on top of suit able Lincoln Idealarc power sources Recommended input cable assembly length is 10 feet 8m when using the K178 1 Bolt the platform to the lift bail according to instructions supplied with the platform M16260
118. l strip The power source grounding terminal marked L 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 White jumper on voltage board to pin S Blue jumper on voltage board later units only or on start board earlier units to pin B N G If lead 21 is to be connected to the terminal strip connect to the 21 terminal that matches work polarity This connection must be changed whenever the electrode polarity is changed Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 INSTALLATION FIGURE A 6 CONNECTION OF LN 9 TO DC 600 POWER SOURCES A WARNING Turn off input power to the welding power source using the disconnect switch at the fuse box before connect ing the wire feeder 11 4 Only qualified persons should install kill use or service this machine Return to Section TOC Return to Master TOC N G N TO LN 9 INPUT CABLE PLUG POWER SOURCE CONTROL CABLE Return to Section TOC Return to Master TOC ELECTRODE CABLE TO WIRE FEED UNIT r TO WORK 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 olo O o Fle
119. l troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HE 9 o 8 E Return to Section Return to Master TOC O 4 0 9 2 tc F 17 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Poor arc striking with sticking or blast offs The weld bead may also be ropey and display weld porosity Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Make sure the welding parame ters and techniques are correct for the welding procedure being used Check the welding cables for loose or faulty connections The gun cable may be faulty Check or replace The gun contact tip may be worn Check or replace The welding power source may be faulty Check or replace RECOMMENDED COURSE OF ACTION Jumper the BYPASS terminals on the voltage PC board 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 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repai
120. le the one with threads on its O D to the con nector on the input cable assembly 3 Remove the screws holding the cable clamp locat ed near the rear of the wire reel base Put the con trol 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 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 X GM BRASS EXTENSION BLOCK CABLE HAND CRANK WIRE REEL BASE At the wire drive unit connect the amphenol of the extension control cable to the receptacle on the back of the LN 9 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 LN
121. le DESCRIPTION 5 5 9 The following procedure will help the technician remove the reed switch for repair replace c ment MATERIALS NEEDED 3 4 Wrench Slot head screw driver 11 32 wrench olo O o E 5 5 o PEN 9 gt 918 5 5 aja Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o g 5 F 54 F 54 TROUBLESHOOTING amp REPAIR REED SWITCH CR2 REMOVAL AND REPLACEMENT continued FIGURE F 15 CR2 REED SWITCH LOCATION AND COMPONENTS LEAD 529 SELF TAPPING COPPER SCREW PROCEDURE 1 Remove input power to the LN 9 wire feeder 2 Lift the right side cover assembly 3 Locate the CR2 reed switch See Figure 15 With the 3 4 wrench remove the bolt mount ing the copper reed switch energizer to the conductor block This step is optional but it makes disassembly easier on 4 roll models Using the slot head screwdriver remove the self tapping screw holding the reed switch into the copper energizer Locate and untape the splices from leads 529 and 628 to the reed switch leads Using the slot head screw driver and 11 32
122. lectrode 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 con nectors of the control cable to the mating MS type receptacles on the bottom of the control box See Figure A 4 later in this section for the location of this connection LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 5 INSTALLATION ROUTING THE ELECTRODE The electrode supply may be either from reels Readi Reels 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
123. ler roll pres sure arm with the right hand Maintain this pres sure and start cranking the wire through the sys tem Keep the conductor cable as straight as pos sible 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 WARNING The electrode is HOT to ground while inching with the gun trigger 7 Push the plastic of the hand crank to the in posi tion and shift the ingoing guide tube to the forward position LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE o 2 3 Return to Section Return to Master TOC o g 5 LOADING 50 AND 60 LB COILS AND BRAKE ADJUSTMENT K299 or K303 Wire Reel Stand 1 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 elec trode 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
124. ls See Figure F 17 FIGURE F 17 LEADS 526 AND 527 AT POWER PC BOARD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 7 Disconnect yellow leads 601 and 602 from the lead splices See Figure F 18 FIGURE 18 LEADS 601 AND 602 AT LEAD SPLICES Jc n O10 515 10 gt 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 58 58 TROUBLESHOOTING amp REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT continued 8 Remove the two phillips head screws from the 10 Remove the clip holding the 1CR relay then control PC board mounting panel unplug the relay from the power PC board 9 Using the 11 32 wrench remove the nut and SPEME E IA screw from the top of the PC board mounting panel Return to Section TOC Return to Master TOC FIGURE 19 1CR RELAY REMOVAL NUT AND SCREW CONTROL PC BOARD Return to Section TOC Return to Master TOC PHILLIPS SCREWS O10 515 gt 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE o 2 3 Return to Section Return t
125. ls 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 fric tion fit LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE o o 2 3 Return to Section Return to Master TOC o g 5 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 elec trode 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 A WARNING USE THE COLD TRIGGER SWITCH
126. n 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 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 trig ger 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 pus NO If this fuse blows the LN 9 arc voltage 2 vill be opened See the topic Automatic Shutdown below MOTOR THERMAL PROTECTION The temperature sensing thermal protector mounted in the motor frame opens the control circuit if the motor overheats Exce
127. n TOC Return to Master TOC CV OUTPUT TERMINALS ON DC 250 NEGATIVE POSITIVE ELECTRODE CABLE TO WIRE FEED UNIT 1 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 O o Fle PEN 2 2 2 21 Welding cables must 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 weld ing 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 421 on the terminal strip Note that this is not the preferred connection because it adds error to the wire feeder voltmeter reading Tape up bolted connection if lead 21 is extended Connect the control cable ground lead to the frame terminal marked 7 77 near the power source termina
128. n to Master TOC Return to Section TOC Return to Master TOC o HE o 2 Return to Section Return to Master TOC o D g 5 7 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
129. n to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 5 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 rela tively 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 magne
130. nd tighten 2 S SEE EUMD OUDE NOTE The Aluminum Wire Drive Roll Kits have o 9 TUBES FOR TWO ROLL WIRE FEEDERS one piece drive rolls and idle rolls with a larger 2 change drive idle rolls on two roll wire feeder chamfer on one side instead of gear teeth This refer to Figure and perform the following steps larger chamfer side must face the gearbox when installed The side with the smaller chamfer and 1 Loosen idle spring pressure screw wire size stencil must be installed facing out 2 Remove clamping collar from the drive shaft 5 Remove the large ingoing guide from rear brass 3 Install drive roll and replace clamping collar block by loosening screw Tighten screw 9 S FIGURE B 3 2 ROLL WIRE FEED MECHANISM 5 5 dE SHANG NGONG GUIDE Tune LOCKING olo INGOING GUIDE 912 gt 212 IDLE ROLL IDLE IDLE ROLL SPRING SHAFT SCREW ROLL PRESSURE SCREW 22 dc Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC O10 Fle 515 5 1 Return to Section Return to Master TOC Return to Master TOC B 10 OPERATION 6 Loosen the ingoing guide tube clamping screw Install the all steel guide tube through the rear brass block Tigh
131. nershield or sub merged 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 Innershield cored electrode Rated wire speed range 50 through 600 inches per minute 1 27 through 15 2 meters per minute DC CONSTANT VOLTAGE POWER SOURCES The following welding system power sources are avail able 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 K442 1 Pulse Power Filter Kit SAM power sources may also be used LN 9 Wire Feeder LINCOLN Return to Section Return to Master TOC Return to Section TOC O10 Fle 515 15 1 Return to Section Return to Master TOC Return to Master TOC 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 shown in Figure 2 Refer to these figures and the fol lowing 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 s
132. ng 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 con ducted 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 sub ject 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 elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A CAUTION 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 f
133. ng assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o E ci 8 nl 2 cc 1 Return to Section Return to Master TOC F 13 F 13 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines 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 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 TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 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 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed
134. nks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 CYLINDER may explode 16 If damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators de
135. 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 arcis extinguished by quickly pulling the gun away from the work or The trigger is again depressed and released LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o o 2 3 Return to Section Return to Master TOC o g 5 FIGURE 1 WIRE FEEDER CONTROLS FOR LN 9N S SE VOLTS SS CONTROL READING SWITCH DIGITAL METER SET ACTUAL PUSHBUTTON CIRCUIT BREAKER CIRCUIT BREAKER GROUNDING LEAD PROTECTOR GLP RESET SWITCH HOT COLD TRIGGER ELECTRODE INTERLOCK POLARITY SWITCH SWITCH WIRE FEED DIRECTION SWITCH LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 gt 1 Return to Section Return to Master TOC OPERATION FIGURE B 2 WIRE FEEDER CONTROLS FOR LN 9F WIRE FEED ELECTRODE POLARITY SWITCH DIRECTION SWITCH VOLTS NCOLN CONTROL SET ACTUAL LNOF PUSH
136. o HARNESS CONNECTOR IS PLUGGED INTO PLUG y Y Y Y 900 lt 3 tt HH E O OPTIONAL CONTACTOR DROP OUT asa l 8 AMP FAST Lr DELAY P C BOARD 54 3 2 1 6 8545 SESS 1 1 1 1 BLOW FUSE cls IA ti mp e tpe B pem MEUM vov Y Sas A 28 a p D 4 J By S BY 82 _ o 5 AMP 3 3 22 E 7 POLARIV 32A 590 CIRCUIT BREAKER olz METER PANEL L METER 32A 531 504 4 2A 502 ROLARITY 6268 7 DIRECTION 32A ASSEMBLY BOX e SWITCH 534 GROUND GND 7 1 GLP ER 626 1 H c 59 93 RESET REED N F CASE GND 3 3 ML i eor CH CR4 I HOT COLD INTERLOCK 530 SWITCH 0 ot 24 522 2A enc 500 A 32 1 2 SLOW BLOW FUSE 555 5 SP POWER 1 502 K 631 xes 644 PICK UP P C BOARD 15 5 gt 1 504 xe 6 ARM NOTES P C BOARD i 46 4 Spe BLACK ORNA 688 MM uU ME N A VOLTAGE P C BOARD WHITE JUMPER TO 539 4 gt 521 i Lp BLUE LO 54 TEE 524 BE M SHIPPED CONNECTED TO i i JUMPER olo l gt 5 gt gt 500 510A 144 8 os VOLTAGE P C BOARD BLUE JUMPER TO D EE e dex 511 6 3 BEM SHIPPED CONNECTED TO PIN Lem O 627B x lt 6 i 512 46 2 gt x i N B CONTROL P C BOARD JUMPER TO BE S 7 90 510 520 xe 1 T
137. o Master TOC o g 5 59 11 12 13 14 59 TROUBLESHOOTING amp REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT continued FIGURE F 20 TERMINAL STRIP MOUNTING TL 2 e T4 NS tt TERMINAL TRANSFORMER 55 ede STRIP MOUNTING A SCREWS 0 Using the 5 16 wrench remove the nuts and lockwashers mounting the terminal strip to the mounting panel See Figure F 20 Remove the terminal strip and set it aside Using the 5 16 wrench remove the two nuts and washers from the T1 transformer mounting screws Remove the transformer mounting screws and the T1 transformer This may require gently prying up the control PC board mounting panel Be sure to clear all leads REPLACEMENT 15 16 Position the T1 transformer and use the 5 16 wrench to attach it with the two nuts and washers With the 5 16 wrench mount the terminal strip 9 20 21 22 23 LN 9 Wire Feeder LINCOLN 5 ee 0 Sig 9 Plug the 1CR relay into the power PC board and attach the clip See Figure F 19 Mount the power PC board mounting panel with the two phillips head screws and 11 32 nut Connect leads 601 and 602 at the lead splices See Figure F 18 Connect leads 526 AND 527 at their_ter minals on the power PC board See Figure 17 Solder lead 31 to
138. oltage PC board Check the resistance of the voltage control potentiometer When measured from the wiper lead 635 to lead 634 the resis tance should vary smoothly from 0 to 10 000 ohms when the shaft is rotated The voltage PC board may be faulty Replace The field fuse F101 located on the power PC board repeatedly fails 1 Very rapid and repetitive gun triggering can possibly cause the field fuse to fail Perform the T1 Transformer Perform the Wire Drive Motor Disconnect the meter board the problem is resolved the meter board may be faulty The power PC board may be faulty Replace CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o 5 F 12 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Circuit breaker 5 amp repeatedly trips when the gun trigger is acti vated Observe Safety Guidelines detailed in the beginning of t
139. on Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o g 5 39 F 39 TROUBLESHOOTING amp REPAIR METER CIRCUIT ACCURACY TEST continued FIGURE F 10 METER PC BOARD TEST POINTS 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 If the display is NOT lit and the correct DC volt age 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 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE o 2 3 Return to Section Return to Master TOC o g
140. or electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC olo O o 515 PEN 9 gt 918 cic 5 5 a Return to Section Return to Master TOC Return to Master TOC F 3 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK 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 prob lems 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 board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing 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 shieldin
141. 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 open ings and be put through a magnetic separator The K310 vibrated Flux Screen and K58 Magnetic Separator are available for this purpose The screen in the funnel supplied with the tank has much larger openings and its only purpose is to keep paper and slag out of the tank Screw the tank cap back on and tighten it hand tight Reconnect the incoming air line to the tank There will always be a small amount of air and possi ble 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 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 pres sure 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 dis connect 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 LN 9 Wire Feeder LINCOLN 5 Retur
142. ot 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 shut down circuit will activate This protection circuit imme diately returns the LN 9 control to idle state within a few seconds after the arc voltage discrepancy occurs Typical causes for the activation of this protective shut down 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 Los
143. oting Procedures ccccccsssssssssececscecsesesesesesesesecacseseseseseseeececseseseseseees F 3 E Troubleshooting Guide cct cta tieni ui tese nated F 4 F 22 Test Procedures T1 Transtormoer TeSt ice ee ete Le EORR AR ER ERE UNE F 23 T2 Transformer Test aiunt Feb red F 26 Wire Drive Motor and Tach Feedback 30 Voltmeter Accuracy 04 44 0000000 34 Meter Circuit Accuracy 20404 0 00000 37 Wire Speed Accuracy 24 40 001 00 0 0 ennt nnn entres nnns nene F 42 Out of Voltage Range Shut Down F 44 General Power Supply 1 2 nennen nennen nnne nns F 47 5 Replacement Procedures a Digital Meter and Meter PC Board Removal and F 50 Reed Switch CR2 Removal and F 53 2 T1 Transformer Removal and F 55 S Tach PC Board Removal and F 60 Drive Motor Removal and F 64 Retest Alter Er 69 This Troubleshooting section is specific to
144. p 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 5 connector on the bottom of the LN 9F trol 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 elec trical tape FIGURE A 4 LN 9F CONTROL BOX BOTTOM VIEW CIRCUIT GLP BREAKER RESET A b d NS 9 PIN MS TYPE CONNECTOR 14 PIN MS TYPE CONNECTOR INPUT CABLE TO POWER SOURCE CONTROL CABLE TO WIRE FEED HEAD 4 PIN CONTROL CABLE TACHFEEDBACK CONNECTOR LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 o o 2 3 Return to Section Return to Master TOC o g 5 INSTALLATION CONNECTING THE POWER INPUT CABLE ASSEMBLY TO 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 fol lows 1 If using a multipurpose source such as the DC 250
145. place The actual volts reading does NOT 1 Make sure the shutdown If the actual reading is the prob match the SET volts reading within BYPASS pins are NOT lem check the actual volts a few tenths of a volt while welding jumpered together on the LN 9 switch and associated leads One reading may be erratic The voltage PC board If the SET reading is the prob LN 9 does NOT shut off Check the voltage sensing lem check the set volts switch NOTE Pulse Power Filter kit may leads for continuity zero ohms and the associated leads slow down the shutdown feature Lead 21 should have continu ity to the work piece and lead 67 should have continuity to the brass conductor block See 4 The voltage PC board may be the Wiring Diagram faulty Replace Check the Volts Speed selec tor switch and associated leads 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 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9
146. r TOC LN 9 Wire Feeder LINCOLN 5 F 43 F 43 TROUBLESHOOTING amp REPAIR O 3 WIRE SPEED ACCURACY TEST continued 8 8 TEST PROCEDURE B Check for the proper drive roll revolutions 9 8 a Perform the following checks with the LN 9 wire E feeder connected to a Lincoln welding power 1 Adjust the LN 9 wire speed control for the S5 source according to the proper connection dia LN 9 actual speed meter readings given E 9 gram See the Installation section of this manu in the table below al 2 Compare the corresponding LN 9 drive A Check for the proper wire feed inches per roll RPM counted revolutions in 60 sec revolution of the drive roll onds and LN 9 SET speed meter read ings with the table below The numbers 1 Set the LN 9 wire speed control for should match If not perform the Meter between 50 and 120 IPM 1 27 to 3 17 Circuit Accuracy Test meter M MIN 2 Measure the precise length of wire fed by gt exactly 10 revolutions of the drive rolls E This measured length should be 53 0 B 2 8 inches 1 35 02 meters If 9 9 there may be a problem with the wire o the wire feed path See the 8 P5 Troubleshooting Guide Feeding S 5 Problems in this section of the manual tio Also check for correct drive roll tension a adjustment MODEL ACTUAL SPEED METER MEASURED SET SPEED ME
147. r is running at high speed and the armature voltage is high and uncontrollable proceed with the Tach Feedback Test 33 33 TROUBLESHOOTING 4 REPAIR WIRE DRIVE MOTOR AND TACH FEEDBACK TEST continued FIGURE F 7 LEADS 525 510 555 ON CONTROL PC BOARD LEAD LEAD LEAD 525 910 555 Return to Section Return to Master TOC o 2 5 o 2 G E Return to Master ojo 5 TACH FEEDBACK TEST If the feedback voltage is missing or does 2 PROCEDURE not vary with motor speed the tach PC board be faulty 1 Locate tach PC board leads 510 525 and olg 1 555 on the control PC board See Figure 4 After the wire drive motor and tach feedback E F7 tests are completed remove the jumper t from the gun terminals if used and close ojo 2 Check leads 525 to 510 for the pres the left case side cover assembly and re ence of 15VDC This is the supply voltage attach the screws 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 General 3 With gun trigger activated or the gun termi nals 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
148. rce See the tion for details 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 gear box 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 45 angle 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 4 Roll wire feed unit It contains two keyhole slots and one slot for mounting Mount the box at some conve nient 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 e
149. rive 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 See the Operation Section for drive roll installation instructions See Table C 2 in the Accessories section for drive roll and guide tube kits 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 Figure D 3 tbr compo 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 Flui
150. rk 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 Be sure the welding power source and the shield ing gas supply if used are turned on Position the electrode over the joint The end of the electrode should be slightly over the joint Lower the welding helmet close the gun trigger and begin welding Hold the gun so that the con tact tip to weld distance gives the correct electrical stickout as required for the procedure being used 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 pro cedure 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 Uncouple the gun conductor cable from the wire drive unit Lay the cable out straight Using pliers to grip the wire pull it out of the cable from the connector end Do not pull it from the gun end Put the conductor cable back on the wire drive unit after the electrode has been removed Load a new reel of wire and feed it through the cable as described earlier in this section SECURIT
151. rn to Master TOC O o Fie 8 nl ele ES i 1 Return to Section Return to Master TOC 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 lated to the preset condition When the LN 9 is cou pled to an appropriate Lincoln constant voltage power source the arc voltage is also regulated to match the preset voltage FIGURE E 2 POWER INPUT CIRCUITS VOLTAGE CONTROL WORK VOLTAGE SENSING POWER SOURCE OUTPUT TRIGGER 2 844 TRIGGER TRIGGER BOARD CONNECTOR CIRCUIT BREAKER INPUT CONNECTOR TO VOLTAGE BOARD POWER INPUT CIRCUITS The 115VAC 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 trig ger transformer and the T1 transformer O WIRE FEED MOTOR THERMOSTAT ELECTRODE VOLTAGE SENSING POLARITY SWITCH WIRE SPEED CONTROL WIRE SPEED CONTROL TRIGGER SIGNAL 00 VOLTAGE CONTROL VOLTAGE 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 feed er trigger circuitry The 28VAC produced b
152. rn to Master TOC o g 5 9 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The SET speed is erratic or not adjustable over entire range of con trol The actual speed is also errat ic like the SET speed Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Check for loose or faulty con nections on leads 631 632 and 633 between the speed control potentiometer R2 and the control PC board RECOMMENDED COURSE OF ACTION 1 Remove power to the LN 9 and disconnect the plug to the con trol PC board Check the resis tance of the speed control potentiometer R2 When mea sured from the wiper lead 632 to lead 633 the resis tance should vary smoothly from 0 to 10 000 ohms when the shaft is rotated See the Wiring Diagram The control PC board may be faulty Replace The wire continues to feed with the gun trigger open and the wire is electrically hot The interlock switch is in the OFF position Disconnect the gun trigger cable If the problem is resolved the gun trigger or cable is faulty Repair or replace Disconnect lead 530 from the trigger board See the Wiring Diagram If the problem is resolved the trigger board is faulty Replace Relay 1CR may be stuck closed Check or replace The power
153. rolls will slip If the electrode is removed from the cable there will be a slight wavi ness in the electrode for about a foot beyond the slip marks on the electrode If there is no wavi ness 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 elec trode is unusually soft or the feeding path is exces sively 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 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC O10 Fle 515 5 1 Return to Section Return to Master TOC Return to Master TOC 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 t
154. rs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O 4 0 9 2 tc F 18 F 18 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION METER FUNCTION PROBLEMS The SET and actual speed meter 1 Contact your local Lincoln 1 Check to make sure the slotted readings match within a few IPM Authorized Field Service disc in the tach housing is but both are in error Facility secure and aligned Perform the Meter Circuit Accuracy Test The control board may be faulty Replace SET speed and actual speed meter 1 Contact your local Lincoln Check the Volts Speed meter readings do NOT match within a Authorized Field Service selector switch and the associ few IPM One or both readings Facility ated wiring See the Wiring may be erratic Diagram Check the SET Actual switch and the associated wiring See the Wiring Diagram 3 Perform the Meter Circuit A CAUTION If for any re
155. s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou atres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fum es toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment roxique ou autres produits irritants defonctionnement PR CAUTIONS DE S RET POUR LES d jamais plonger le porte lectrode dans l eau pour le MACHINES A SOUDER A TRANSFOR Teo do MATEUR ET A REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la d
156. signed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s r
157. ssive loading and or very rapid trig gering may cause overheating The thermal sensor protects the motor without nuisance tripping The ther mal 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 LN 9 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 AVOIDING GROUNDING LEAD PROTECTOR GLP SHUTDOWN 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 pre vents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the gun trigger is pressed LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC olo O o E 515 o PEN gt 918 5 5 a Return to Section Return to Master TOC Return to Master TOC 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 oe Figure the circuit press the GLP Reset button See Figure 1 Figure 1 or the location of this button The following precautions are recommended to avoid GLP shutdown Do n
158. stand base Put the control cable and the electrode cable under the clamp and install the screws For cables with more than one electrode cable leave the junction between the two or more cables and the single 4 0 stub behind the clamp so that only the single electrode lead is under the clamp 3 See Figure A 1 Pass the single electrode cable through the hole provided in the back corner of the control section and fasten it to the copper strap on the wire drive unit FIGURE A 1 INPUT CONTROL CABLE AND ELECTRODE CABLE CONNECTIONS CONTROL CABLE ELECTRODE CABLE LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC O10 Fle 515 5 1 Return to Section Return to Master TOC Return to Master TOC A 5 INSTALLATION FIGURE 2 STRAIN RELIEF CLAMP CONTROL CABLE STRAIN ELECTRODE CABLE CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE 9 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 Attach the amphenol extension assembly control cab
159. t 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 out side the LN 9 control box to be connected directly to the work With either direct work lead connection method the LN 9 regulates the power source to hold the arc volt age 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 Circuit Protection and Automatic Shutdown in the Operation section of this manual LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o o 2 3 Return to Section Return to Master TOC o D g 5 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 Accessories section of this 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
160. t board may be faulty Replace The voltage PC board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE o o 2 3 Return to Section Return to Master TOC o g 5 F 23 TROUBLESHOOTING amp 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 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will aid the technician in determining if the T1 transformer is functionin
161. t 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 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 con trols are set for 29 volts and the input voltage to the 835 goes up it may not be possible for the LN 9 con trol 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 Ifthe LN 9 keeps welding change the R3S tri angle setting to the next higher voltage and reset the LN 9 set point to the desired proce dure 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 hi
162. t one of the Readi Reel inside cage wires on the slot in the retaining spring tab LOADING AND FEEDING READI REELS 5 Lower the Readi Reel to depress the retaining OR SPOOLS spring and align the other inside cage wires with LOADING A 22 TO 30 LB READI REEL PACKAGE the grooves in the molded adapter USING THE MOLDED PLASTIC K363 P 6 Slide the cage all the way onto the adapter until the ADAPTER retaining spring pops up fully Return to Section TOC Return to Master TOC 1 Make certain that the threaded locking collar is tight and securely locks the adapter on the spindle See Figure B 5 A WARNING 2 Rotate the spindle and adapter so that the retain ing spring is at the 12 o clock position 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 ELEC TRODE 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 Return to Section TOC Return to Master TOC FIGURE B 5 INSTALLING A 30 LB READI REEL PACKAGE 2 IN O D SPINDLE ADAPTER olo O o Fle S PEN 9 gt 918 5 5 1 GROOVES READI REEL INSIDE CAGE WIRES THREADED LOCKING COLLAR Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Retur
163. tact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the drive motor and tach feedback are functioning properly Return to Section TOC Return to Master TOC MATERIALS NEEDED Phillips head screw driver Analog volt ohmmeter multimeter olo O o Fle S PEN 9 gt 918 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 31 31 TROUBLESHOOTING amp REPAIR WIRE DRIVE MOTOR AND TACH FEEDBACK TEST continued FIGURE F 6 LEAD 539 541 626B AND 627B AT POWER PC BOARD TERMINAL STRIP TEST PROCEDURE 1 Remove input power to the LN 9 wire feed er Remove any electrode wire or disengage the drive rolls Using the phillips head screw driver remove the screws from the left side cover assem bly LEAD 539 LEAD 541 LEAD 626B LEAD 627B Lift the left side cover assembly Locate leads 539 541 626B and 627B at the power PC board terminal strip See Figure F 6 Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section TOC Return to Master TOC
164. ten 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 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 adjust ed 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 sur face condition lubrication and hardness The optimum idle roll setting can be determined when there 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 mar
165. termine 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 Return to Section TOC Return to Master TOC O o Fle 5 5 gt 2 2 eo 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 F 38 F 38 TROUBLESHOOTING amp REPAIR METER CIRCUIT ACCURACY TEST continued FIGURE F 9 METER PC BOARD LOCATIONS AND COVER MOUNTING SCREWS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 9 4 Apply input power to the wire feeder A WARNING ELECTRIC SHOCK can kill With power applied there are high voltages inside the wire feeder Do reach into the wire feeder or touch any internal part of the wire feeder while power is applied O o Fle 515 o PEN 5 5 1 Return to Secti
166. the LN 9 However much of this information may apply to the LN 9F model with slight adaptation Refer to LN 9F Wiring Diagram o 7 Return to Master LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE o 2 Return to Section Return to Master TOC o g 5 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 malfunc tions Simply follow the three step procedure list ed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into main categories Function Problems Feeding Problems Weldi
167. the Wiring Diagram Return to Section TOC Return to Master TOC Check the interlock switch for proper operation The power PC board may be faulty Replace O o 8 0 12 22 5 2 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O P 7 9 tc F 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE 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 Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Check for loose or faulty con nections on leads 634 635 and 636 between the voltage control potentiometer R3 and the voltage PC board RECOMMENDED COURSE OF ACTION Remove power to the LN 9 and disconnect Plug J1 from the v
168. the R1 2 ohm resistor See Figure F 16 Connect primary lead 532 to its power PC board terminal Close the left cover and re attach the screws F 60 F 60 TROUBLESHOOTING amp REPAIR TACH PC BOARD REMOVAL AND REPLACEMENT A 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will help the technician remove the Tach PC Board and related com ponents for repair or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED Slot head screw driver Phillips head screw driver 3 8 open end wrench olo O o E 5 5 o PEN 9 gt 918 5 5 aja Return to Section TOC Return to Master TOC LN 9 Wire Feeder LINCOLN 5 F 61 F 61 TROUBLESHOOTING amp REPAIR TACH PC BOARD REMOVAL AND REPLACEMENT continued
169. the arc volt age 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 5 f no further tests are required remove the jumper from the gun terminals if used and close the left case side cover assembly Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle 5 o Oo G 2 2 eo 5 5 1 Return to Section Return to Master TOC LN 9 Wire Feeder LINCOLN 5 37 37 TROUBLESHOOTING amp 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help de
170. the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LN 9 6 5 ELECTRICAL DIAGRAMS 19 TRIGGER BOARD 13861 SCHEMATIC 160006 5 Return to Section TOC Return to Master TOC TRIGGER SWITCH Return to Section TOC Return to Master TOC O10 Fle 515 0 5 ele 2 a NOTES FILE 520031 SEB GEM GENERAL INFORMATION LABELS NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER E1537 THE INTERCHANGEABILITY OF A COMPLETE BOARD CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms 1 4AW UNLESS OTHERWISE SPECIFIED POWER SUPPLY SOURCE POINT OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DIODES 400V UNLESS OTHERWISE SPECIFIED Z SUPPLY VOLTAGE FRAME CONNECTION EARTH GROUND CONNECTION 57 COMMON CONNECTION UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP ON HOLES SIZES PER E 2056 COH THE LINCOLN ELECTRIC CO Type _LN 9 TRIGGER P C BOARD ON 8 PLAGE DECIMALS 062 7 2 25 940 CLEVELAND OHIO U S A SCHEMATIC 0 GLES IS 5 OF A DEGREE NERIS TUE NE Gis 5 20 04 scale __
171. to 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 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 LINCOLN 5 Section C 1 Section C 1 TABLE OF CONTENTS o 5 ACCESSORIES a huc Section C Auxiliary Equipment Contacts 2 C 2 5 Optional Equipment and 2 Power Input Cable Assemblies K196 K595 596 C 2 Wire Reel Stands and Mountings sssssssssssssesesee ener enne nnn C 2 50 60 Ib Wire Reel Mounting Stand 303 C 2 50 60 Ib Readi Reel Mounting Stand 445 C 2 Attaching the Wire Reel C 3 Wire Reel Door Kit M 11514 sssssssssssssssseseeeeee enne nnne C 3 gt Spindle Readi Reels and 2 1 0 Spools 162 C 3 Readi Reel Adapters esses C 3 2 Small Mounting Stand for Readi Reel Coils or 2 Spools
172. troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN 5 LN 9 Wire Feeder Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 E Return to Section Return to Master TOC o O P N 9 2 tc F 16 F 16 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS The welding arc is variable 1 Make sure the welding parame 1 Put the power source in hunting ters are correct for the welding Machine Control for voltage procedure being used and check if welding perfor mance improves If the problem is resolved check or replace the control cable Or the LN 9 volt The gun cable may be faulty age PC board may be faulty Check or replace Perform the Wire Drive Motor Check cable liner for proper size Check the welding cables for loose or faulty connections The gun contact tip may be worn Check or replace The welding power supply may be faulty Check or replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrica
173. ts Remove the magnetic particles by brushing or by using an air blast WARNING WHEN USING COMPRESSED AIR BE CAREFUL TO 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 trav el speed to help the operator make better welds 10 to 25 faster than with manual travel Speed range is 7 60 ipm 18 1 5 m min Requires K161 Power Pack 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 suit able 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
174. use injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 Also see item 1 b LN 9 Wire Feeder LINCOLN 5 Return to Master TOC Return to Master TOC o 0 Return to Master SAFETY WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 249 1 and the operating information for the equipment being used 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 Do not heat cut or weld ta
175. 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 struc ture See the Accessories section for information about a K299 wire reel assembly ELECTRICAL CONNECTIONS LN 9N S AND LN 9F POWER INPUT CABLE ASSEMBLY A special cable assembly is required to connect all LN 9 models to the power source The assembly includes control cable and electrode cable Various sizes are available based on length and maximum welding cur rent 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 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 feed er 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 Figure 2 Remove the screws holding the cable strain relief clamp located near the rear of the wire reel
176. witch 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 later in this section of the manual 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 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
177. wrench remove the screws and nuts from the lead splices Note the position of the reed switch in the energizer for reassembly Carefully slide the reed switch assembly from the copper energizer 3 4 BOLT ENERGIZER REPLACEMENT 9 Slide the reed switch into the energizer 10 LN 9 Wire Feeder LINCOLN 5 Position it according to step 7 With the slot head screw driver and the 11 32 wrench connect the 529 and 628 lead splices with the screws and nuts Tape the connections With the slot head screw driver tighten the self tapping screw that holds the reed switch to the copper energizer With the 3 4 wrench mount the copper energizer to the conductor block 55 55 TROUBLESHOOTING 4 REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT A 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 8
178. y the T1 transformer secondary is applied to the power board There it is rectified and regulated to 15VDC This 15VDC powers the electron ics 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 LINCOLN 5 Return to Section Return to Section TOC O10 Fie gt ele JE i 1 Return to Section Return to Master TOC Return to Master TOC Return to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 TRIGGER AND SHUTDOWN CIRCUIT POWER SOURCE OUTPUT TRIGGER 42 844 TRIGGER T2 TRIGGER BOARD CONNECTOR CIRCUIT BREAKER INPUT CONNECTOR TO VOLTAGE BOARD VOLTS SPEED SWITCH 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 CH1 relay may also be used to energize a gas solenoid mmsov 28VAC D WIRE FEED MOTOR THERMOSTAT VOLTAGE CONTROL WORK VOLTAGE SENSING ELECTRODE VOLTAGE SENSING POLARITY SWITCH WIRE SPEED CON

Lincoln Electric LN-9 SVM127-A User's Manual

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