View Safety Info 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 View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN INDEX 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.
Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 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.
Return to Master TOC iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
Return to Master TOC iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Return to Master TOC b. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety .................................................................................................................................................i-iv Installation.............................................................................................................................Section A Technical Specifications ...........................................................................................................
Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation ................................................................................................................................Section A Technical Specifications ..............................................................................................................A-2 Installing the LN-9N and LN-9S 2-Roll and 4-Roll Models .........................................................
Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS — LN-9 INPUT POWER Supplied by power source: 115 VAC, 50/60 Hz., 350 VA WIRE FEED SPEED Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 50 to 600 inches per minute (1.27 to 15.2 meters per minute) VOLTAGE CONTROL RANGE 12.0 TO 60.
Return to Master TOC Return to Section TOC A-3 INSTALLATION INSTALLING THE LN-9N and LN-9S 2-ROLL AND 4-ROLL MODELS ATTACHING THE WIRE REEL STAND Both 2-Roll and 4-Roll LN-9 model wire feeders are shipped without a wire reel stand. The screws and washers for mounting a wire reel stand are included with the LN-9 (fastened in their respective mounting holes). To attach a stand: 1. Remove the three 3/8" hex screws from the back of the wire feed unit. Return to Master TOC Return to Section TOC 2.
Return to Master TOC Return to Section TOC A-4 INSTALLATION ROUTING THE ELECTRODE The electrode supply may be either from reels, ReadiReels, spools, or bulk packaged drums or reels. Observe the following precautions: • The electrode must be routed to the wire feed unit so that the bends in the wire are at a minimum. The force required to pull the wire from the reel into the wire feed unit must be kept at a minimum.
Return to Master TOC Return to Section TOC A-5 INSTALLATION FIGURE A.2 – STRAIN RELIEF CLAMP Return to Master TOC Return to Section TOC CONTROL CABLE STRAIN RELIEF CLAMP Return to Section TOC Return to Master TOC Return to Master TOC 3. Remove the screws holding the cable clamp located near the rear of the wire reel base. Put the control cable and the electrode cable under the clamp and install the screws.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC A-6 A-6 INSTALLATION 7. If using welding currents over 450 amperes, connect a length of 1/0 cable between the brass block on the hand crank and the input strap located in the wire drive unit. Tape this cable to the extension assembly. Proper cable lengths are as follows: 22-1/2 ft. extension 45 ft.
Return to Master TOC Return to Section TOC A-7 INSTALLATION Depending on the power source and process you are using, the jumpers on the LN-9 voltage board may have to be changed. As shipped, the LN-9 is connected for use with the DC-250 DC-400, CV-400, CV-500-I and DC-600. For other power sources, refer to the appropriate connection diagram.
Return to Master TOC Return to Section TOC A-8 INSTALLATION A-8 FIGURE A.5 – CONNECTION OF LN-9 TO DC-250, DC-400, AND CV/CVI POWER SOURCES WARNING • Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ELECTRIC SHOCK • Only qualified persons should install, use or service this machine. can kill.
Return to Master TOC Return to Section TOC A-9 A-9 INSTALLATION FIGURE A.6 – CONNECTION OF LN-9 TO DC-600 POWER SOURCES WARNING • Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ELECTRIC SHOCK • Only qualified persons should install, use or service this machine. can kill. Above diagram shows electrode connected positive.
Return to Master TOC Return to Section TOC A-10 A-10 INSTALLATION FIGURE A.7 – CONNECTION OF LN-9 TO DC-1000 POWER SOURCES WARNING • Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ELECTRIC SHOCK • Only qualified persons should install, use or service this machine. can kill. Above diagram shows electrode connected positive.
Return to Master TOC Return to Section TOC A-11 INSTALLATION A-11 FIGURE A.8 – CONNECTION OF LN-9 TO PULSE POWER 500 POWER SOURCES WARNING • Turn off input power to the welding power source using the disconnect switch at the fuse box before connecting the wire feeder Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC ELECTRIC SHOCK • Only qualified persons should install, use or service this machine. can kill. Above diagram shows electrode connected positive.
Return to Master TOC Return to Section TOC A-12 INSTALLATION MACHINE GROUNDING DIRECT WORK LEAD CONNECTION 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. Lincoln specified procedures give voltage readings taken between the work and the gun cable brass connection block of the LN-9.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-13 A-13 INSTALLATION CONNECTING THE GUN CABLE TO THE WIRE FEEDER FIGURE A.9 – GUN CABLE CONNECTIONS 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC A-14 NOTES LN-9 Wire Feeder A-14
Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation .................................................................................................................................Section B Safety Instructions.......................................................................................................................B-2 General Description ...................................................................................................................
Return to Master TOC Return to Section TOC B-2 OPERATION SAFETY INSTRUCTIONS Read and understand this entire section of operating instructions operating the machine. WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes.
Return to Master TOC OPERATION GENERAL DESCRIPTION The LN-9 2-Roll and 4-Roll semiautomatic wire feeder models feature the precise "set and forget" digital procedure control. They are designed to achieve higher quality control and weld quality levels more easily. The arc voltage and wire feed speed can be set on a digital meter before the arc is struck and the procedure remains precisely set day in and day out.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section 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 are shown in Figure B.2. Refer to these figures and the following descriptions of the controls. ELECTRODE POLARITY SWITCH: The polarity switch is located inside the wire drive section on the LN-9 model and on the front panel of both the LN-9F 2-Roll and 4-Roll control box.
FIGURE B.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC B-6 OPERATION FIGURE B.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-7 OPERATION CIRCUIT BREAKER AND GROUNDING LEAD PROTECTOR (GLP) RESET SWITCH: These protection circuit devices are located on the front rail of the LN-9 model and bottom panel of the LN-9F models. See the topic "Circuit Protection and Automatic Shutdown" later in this section of the manual.
Return to Master TOC Return to Section 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 release the circuit, press the "GLP Reset" button. See Figure B.1 or B.2 for the location of this button.
Return to Master TOC Return to Section TOC B-9 OPERATION DRIVE ROLL INSTALLATION AND PRESSURE SETTING 4. Remove idle roll shaft screw - install idle roll. Replace screw and tighten. CHANGING WIRE FEED ROLLS AND GUIDE TUBES FOR TWO-ROLL WIRE FEEDERS 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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-10 OPERATION 6. Loosen the ingoing guide tube clamping screw. Install the all steel guide tube through the rear brass block. Tighten the locking screw. 7. Replace the large ingoing guide tube into rear brass block. 8. Install the outgoing guide tube with its plastic insert through front brass block.
Return to Master TOC Return to Section TOC B-11 OPERATION CHANGING WIRE FEED ROLLS AND GUIDE TUBES FOR 4-ROLL WIRE FEEDERS To change drive rolls on a 4-roll wire feeder, refer to Figure B.4 and 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. Return to Master TOC Return to Section TOC 4. Slide the middle guide tube into place. Do not tighten set screw. 5.
Return to Master TOC Return to Section TOC B-12 OPERATION For Aluminum Wire Each set of rolls should have their pressure set independent of the other. To do this, release and open the other quick release arm while making each adjustment. Follow the procedure below for each adjustment. 1. With low idle roll pressure, load the feeder so it’s ready for welding. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 2.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC B-13 OPERATION FIGURE B.
Return to Master TOC Return to Section TOC B-14 OPERATION 4. Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab. WIRE LOADING LOADING AND FEEDING READI-REELS OR SPOOLS LOADING A 22 TO 30 LB. READI-REEL PACKAGE USING THE MOLDED PLASTIC K363-P TYPE ADAPTER: 5. Lower the Readi-Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter. 6.
Return to Master TOC Return to Section TOC B-15 OPERATION 7. To remove the Readi-Reel from the adapter, depress the retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove the adapter from the spindle. 5. Inch the electrode through the gun. LOADING A 15 TO 30 LB. SPOOL (12" DIAMETER): 6.
Return to Master TOC Return to Section TOC B-16 OPERATION LOADING 50 AND 60 LB. COILS AND BRAKE ADJUSTMENT (K299 or K303 Wire Reel Stand) 1. To remove the wire reel from its shaft, grasp the spring loaded knob and pull it out. This straightens the knob so that it seats into the shaft when released. Remove the reel. 2. Lay the reel flat on the floor, loosen the spinner nut and remove the cover plate. Return to Master TOC Return to Section TOC 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-17 OPERATION ELECTRODE FEEDING 1. Turn the reel until the free end of the electrode is accessible. 2. While tightly holding the electrode, cut off the bent end. Straighten the first 6 inches. 3. Cut off the first inch. Insert the free end through the incoming guide tube. B-17 LOADING AND FEEDING 13-14 LB.
Return to Master TOC Return to Section TOC B-18 OPERATION MAKING A TEST WELD AND ADJUSTING LN-9 RESPONSE AND STARTING CHARACTERISTICS DC-250, DC-400, or DC-600* SAM 1. Connect electrode lead to terminal of desired polarity. 1. 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 SAM650. Return to Master TOC Return to Section TOC 3.
Return to Master TOC Return to Section TOC B-19 OPERATION 1. Set the "Electrode Polarity" switch to same polarity as the electrode lead. 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: 2. Connect the "Direct Work Lead" if it is going to be used. 1. Turn OFF the control power to the LN-9 at the power source. 3. Check that "Feed Direction" is set to forward.
Return to Master TOC Return to Section TOC B-20 OPERATION MAKING A WELD 1. Inch the electrode through the gun and cable and then cut the electrode within approximately 3/8" of the end of the contact tip for solid wire and within approximately 3/4" of the extension guide for cored wire. 2. Connect the work cable to the metal to be welded. The work cable must make good electrical contact to the work. The work must also be grounded as stated in the Safety section at the beginning of this manual.
Return to Master TOC Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories .............................................................................................................................Section C Auxiliary Equipment Contacts .....................................................................................................C-2 Optional Equipment and Accessories .........................................................................................
Return to Master TOC Return to Section TOC C-2 ACCESSORIES AUXILIARY EQUIPMENT CONTACTS The power for 115 volt AC auxiliary equipment can be obtained from the terminals inside the LN-9 control box. The contacts are “hot” whenever the trigger is pressed or the unit is welding. The current draw of this circuit must not exceed 1/4 ampere.
Return to Master TOC Return to Section TOC C-3 ACCESSORIES ATTACHING THE WIRE REEL STANDS READI-REEL ADAPTERS The mounting hardware for mounting the stands is included with the LN-9. Screws and washers are inserted in their respective mounting holes. To connect: K363-P Adapts Lincoln Readi-Reel coils of electrode (30 lb. and 22 lb.) to a 2" spindle. One-piece construction. Made from a durable molded plastic. Designed for easy loading; adapter remains on spindle for quick changeover.
Return to Master TOC Return to Section TOC C-4 ACCESSORIES GUN AND CABLE ASSEMBLIES TABLE C.1 – LN-9 GUN AND CABLE ASSEMBLIES Return to Master TOC Return to Section TOC Gas Metal Arc Welding Return to Master TOC Innershield Return to Section TOC ® Model 200 amps 200 amps K498(2) .025-.045” (0.6-1.14 mm) solid 200 amps 200 amps Magnum K470(1) .035-5⁄64” (0.9-2.0 mm) solid 300 amps 300 amps Magnum K471(1) .035-5⁄64” (0.9-2.0 mm) solid 400 amps 400 amps Magnum K478(2) .035-5⁄64” (0.
Return to Master TOC Return to Section TOC C-5 ACCESSORIES WIRE FEEDER ACCESSORIES BURNBACK DELAY KIT (K202) Provides a precise control of the electrode burnback at the end of the weld. Prevents crater sticking and provides proper stickout for starting the next weld. Recommended especially when welding with small (.030-1/16") diameter wire at high wire feed speeds.
Return to Master TOC Return to Section TOC C-6 ACCESSORIES SWIVEL PLATFORM (K178-1) K320 FLUX TANK LOADING For all LN-9 wire reel stand combinations. For mounting wire feeder-wire reel stand assembly on top of suitable Lincoln Idealarc power sources. Recommended input cable assembly length is 10 feet (3m) when using the K178-1. CONTINUOUS FLUX FEED TANK (K320) Either turn off the incoming air line or remove the quick disconnect if one has been installed.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC C-7 ACCESSORIES MAGNETIC SEPARATOR (K58) SQUIRTMOBILE ® (K62) The K58 is a permanent magnet type separator designed to fit the top of the standard fill funnel of the continuous flux feed system. Self-propelled trackless carriage carries K114 gun on long welds for automatic welder economy without high fixture costs. Requires K161 power pack.
Return to Master TOC Return to Section TOC C-8 C-8 ACCESSORIES TABLE C.2 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size Kit 2-Roll 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 1/16” (1.6 mm) KP502 - 1/16 KP545 - 1/16 .068 - 3/32” (1.7 - 2.4 mm) KP502 - 3/32 KP545 - 3/32 Return to Master TOC Return to Section TOC Cored Electrode .045 - 0.052” (1.2 - 1.4 mm) KP502 - 052C KP545 - 052C 1/16” (.
Return to Master TOC Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Routine Maintenance..................................................................................................................D-2 Drive Rolls and Guide Tubes................................................................................................
Return to Master TOC Return to Section TOC D-2 MAINTENANCE D-2 WIRE REEL MOUNTING - 50 AND 60 LB. COILS 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. 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.
Return to Master TOC Return to Section TOC D-3 MAINTENANCE GUN AND CABLE MAINTENANCE For instructions on periodic maintenance for the welding gun and cables, refer to the manual for your specific model of welding gun. Also see IM-294. GUN CABLE CONNECTOR REQUIREMENTS TO PERMIT PROPER CONNECTION TO LINCOLN LN-9 AND LN-9F WIRE FEEDER Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC The following Figures D.1 and D.
D-4 MAINTENANCE Return to Master TOC Return to Section TOC D-4 FIGURE D.3 – GENERAL COMPONENT LOCATIONS Return to Master TOC Return to Section TOC 13 11 10 14 12 9 Return to Master TOC Return to Section TOC 8 6 7 11. 12. 5 13. 14. Return to Master TOC 4 Return to Section TOC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATION SECTIONTheory of Operation .............................................................................................................Section E General Description ...............................................................................................................E-2 Power Input Circuits...............................................................................................................
Return to Master TOC Return to Section 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 coupled to an appropriate Lincoln constant voltage power source, the arc voltage is also regulated to match the preset voltage. FIGURE E.
E-3 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-3 FIGURE E.
E-4 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-4 FIGURE E.
Return to Master TOC Return to Section TOC E-5 THEORY OF OPERATION VOLTAGE BOARD PRINTED CIRCUIT BOARD FUNCTIONS POWER BOARD The input power (115VAC) is applied to the power board, and from that the power board develops the DC field voltage for the wire drive motor. The SCR circuitry, used to control the motor armature voltage, is also contained on the power board.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC E-6 NOTES LN-9 Wire Feeder E-6
Return to Master TOC Return to Master TOC Section F-1 Section F-1 TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ................................................................................Section F How to Use Troubleshooting Guide .......................................................................................F-2 PC Board Troubleshooting Procedures .................................................................................F-3 Troubleshooting Guide .
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Return to Master TOC Return to Section TOC F-4 TROUBLESHOOTING & REPAIR Return to Master TOC POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS No wire feed when gun trigger is activated. The digital meter does NOT light. The drive rolls do not turn. Return to Section TOC TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) F-4 1. Make sure 115VAC is being applied to the LN-9 at the input connector.
Return to Master TOC TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-5 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The wire feed "coasts" when the gun trigger is released. The interlock switch is OFF. 1. Make sure the gun trigger is not "sticking." 1. The relay 1CR may be faulty. Replace.
Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 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. 1. The Ground Lead Protector may have tripped. Reset and clear possible fault between electrode circuit and feeder frame. 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-7 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The wire feeds when the gun trigger is activated, but there is no arc voltage. 1.
Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION Return to Master TOC POSSIBLE AREAS OF MISADJUSTMENT(S) FUNCTION PROBLEMS The SET speed is adjustable and steady. The actual speed is uncontrollable. The meter displays the actual speed correctly or reads "EEE." 1. Contact your local Lincoln Authorized Field Service Facility. 1.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-9 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-9 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The SET speed is erratic or not adjustable over entire range of control. The actual speed is also erratic like the SET speed. 1.
Return to Master TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR F-10 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) TRIGGER INTERLOCK FUNCTION PROBLEMS The wire feeds when the interlock switch is in the "ON" position. No welding or gun trigger activation. 1. Check to see if the reed switch 2CR is stuck closed. 1.
Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The SET voltage is erratic or not adjustable over the entire range of control. The actual voltage is also erratic like the SET voltage. Return to Section TOC F-11 1.
Return to Master TOC Return to Section TOC F-12 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check or replace gun trigger and leads. Make sure the trigger leads are not shorted to the electrode or work cables. Return to Master TOC Return to Master TOC 1. Disconnect lead #500 from the trigger board. If the breaker still trips when the gun trigger is activated, the trigger board may be faulty. Replace 3. Perform the Wire Drive Motor Test.
Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check to make sure the PC boards are NOT grounded to the case of the LN-9. This can happen due to metallic wire shavings build-up. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The 1/8 amp fuse on the voltage PC board repeatedly fails.
Return to Master TOC Return to Section TOC F-14 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The LN-9 shuts down while welding. Upon retriggering, the gun the unit will weld again for a period of time.
Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check or replace the gun cable. It may be kinked, clogged, or twisted. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC 2. Make certain the drive rolls and guide tubes are correct for the wire being used.
Return to Master TOC Return to Section TOC F-16 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure the welding parameters are correct for the welding procedure being used. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC 2. Check the welding cables for loose or faulty connections.
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure the welding parameters and techniques are correct for the welding procedure being used. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC 2. Check the welding cables for loose or faulty connections.
Return to Master TOC Return to Section TOC F-18 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-18 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION METER FUNCTION PROBLEMS The SET and actual speed meter readings match within a few IPM, but both are in error. 1. Contact your local Lincoln Authorized Field Service Facility. 1.
Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 1. Put the Lincoln power source in the "Machine Control" mode. Check to see if the power source can be set for the arc voltage required for the process. If not, the power source may be faulty. 1.
Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION STARTING PROBLEMS The output voltage is too low to start the weld. Return to Section TOC F-20 1. Check the welding cables for loose or faulty connections. 2. Put the Lincoln power source in the "Machine Control" mode.
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION STARTING PROBLEMS Voltage seems to be too high or the arc flares at the start of weld. Welding is good. Return to Section TOC F-21 1.
Return to Master TOC Return to Section TOC F-22 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) NOTE: Pulse Power 500 operation with a filter kit may exhibit these symptoms. Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION STARTING PROBLEMS The arc voltage appears to rise too slowly or stubs or blasts at the start of a weld. Once started the welding is good.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR T1 TRANSFORMER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-24 F-24 TROUBLESHOOTING & REPAIR T1 TRANSFORMER TEST (continued) FIGURE F.1 – LEAD #532 AT POWER PC BOARD LEAD 526 LEAD 527 T1 TRANSFORMER LEAD 532 LEAD 31 115 VAC TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove input power to the LN-9 wire feeder. 2. Using the phillips head screw driver, remove the screws holding the left side cover assembly. 3.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-25 TROUBLESHOOTING & REPAIR T1 TRANSFORMER TEST (continued) FIGURE F.2 – SECONDARY LEADS #601 AND #602 AT LEAD SPLICES LEAD 601 LEAD 602 Return to Section TOC Return to Master TOC Return to Master TOC 6. Using the volt/ohmmeter, check for 10VAC at secondary leads #601 and #602. Typically, these leads are yellow. Place the probes at the lead splices. See Figure F.2. Return to Section TOC F-25 7.
Return to Master TOC Return to Section TOC F-26 TROUBLESHOOTING & REPAIR T2 TRANSFORMER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-27 TROUBLESHOOTING & REPAIR F-27 T2 TRANSFORMER TEST (continued) FIGURE F.3 – “PROTECTION CIRCUIT TROUBLESHOOTING” NAMEPLATE PROTECTION CIRCUIT TROUBLESHOOTING NAMEPLATE TEST PROCEDURE 3. Lift the right side cover assembly. 1. Remove input power to the LN-9 wire feeder. 4.
Return to Master TOC F-28 TROUBLESHOOTING & REPAIR T2 TRANSFORMER TEST (continued) FIGURE F.4 – T2 PRIMARY LEADS #32A AT 5 AMP CIRCUIT BREAKER AND #531 AT R1 RESISTOR CIRCUIT BREAKER LEAD 32A Return to Master TOC Return to Section TOC Return to Section TOC F-28 LEAD 531 R1 RESISTOR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4. Locate the T2 transformer primary lead #32A connected to the 5 amp circuit breaker.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-29 TROUBLESHOOTING & REPAIR T2 TRANSFORMER TEST (continued) FIGURE F.5 – T2 SECONDARY LEADS #621 AND #620 ON TRIGGER PC BOARD LEAD 620 LEAD 621 TRIGGER PC BOARD 8. Using the volt/ohmmeter, check for approximately 24VAC at the T2 transformer secondary leads #621 and #620. Place the probes where the leads connect on the trigger PC board. See Figure F.5.
Return to Master TOC Return to Section TOC F-30 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACH FEEDBACK TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-31 TROUBLESHOOTING & REPAIR F-31 WIRE DRIVE MOTOR AND TACH FEEDBACK TEST (continued) FIGURE F.6 – LEAD #539, #541, #626B AND #627B AT POWER PC BOARD TERMINAL STRIP Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC LEAD 539 LEAD 541 LEAD 626B LEAD 627B TEST PROCEDURE 1. Remove input power to the LN-9 wire feeder. 2. Remove any electrode wire or disengage the drive rolls. 4.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-32 INSTALLATION F-32 WIRE DRIVE MOTOR AND TACH FEEDBACK TEST (continued) 6. Apply 115 VAC power. WARNING ELECTRIC SHOCK can kill. • With power applied, there are high voltages inside the wire feeder. Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied. 8.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-33 TROUBLESHOOTING & REPAIR F-33 WIRE DRIVE MOTOR AND TACH FEEDBACK TEST (continued) FIGURE F.7 – LEADS #525, #510, #555 ON CONTROL PC BOARD LEAD LEAD LEAD 525 510 555 If the feedback voltage is missing or does not vary with motor speed, the tach PC board may be faulty. TACH FEEDBACK TEST PROCEDURE 1.
Return to Master TOC Return to Section TOC F-34 TROUBLESHOOTING & REPAIR VOLTMETER ACCURACY TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR VOLTMETER ACCURACY TEST (continued) FIGURE F.8 – VOLTMETER CONNECTION POINT BRASS CONDUCTOR BLOCK TEST PROCEDURE Perform the following checks with the LN-9 wire feeder connected to a Lincoln CV welding power source according to the proper connection diagram. (See the Installation section of this manual.) 1. Lift the right side cover assembly.
Return to Master TOC Return to Section TOC F-36 TROUBLESHOOTING & REPAIR VOLTMETER ACCURACY TEST (continued) WARNING Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC ELECTRIC SHOCK can kill. Return to Section TOC F-36 • 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. 3.
Return to Master TOC Return to Section TOC F-37 TROUBLESHOOTING & REPAIR METER CIRCUIT ACCURACY TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-38 TROUBLESHOOTING & REPAIR METER CIRCUIT ACCURACY TEST (continued) FIGURE F.9 – METER PC BOARD LOCATIONS AND COVER MOUNTING SCREWS TEST PROCEDURE Return to Master TOC Return to Section TOC 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-39 TROUBLESHOOTING & REPAIR F-39 METER CIRCUIT ACCURACY TEST (continued) FIGURE F.10 – METER PC BOARD TEST POINTS TP5 Return to Master TOC Return to Section TOC 602 TP4 601 510C 560 561 517 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.
Return to Master TOC Return to Section TOC F-40 TROUBLESHOOTING & REPAIR METER CIRCUIT ACCURACY TEST (continued) Test Digital Meter Accuracy. (For LN-9 models above code 7980 with separable digital meter and meter boards only). 1. Use a test meter with at least 3-1/2 digits and +/- .5% accuracy. 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 2.
Return to Master TOC Return to Section TOC F-41 F-41 TROUBLESHOOTING & 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 Master TOC Return to Section TOC NOTE: The coating will have to be removed from the test points. 3.
Return to Master TOC Return to Section TOC F-42 TROUBLESHOOTING & REPAIR WIRE SPEED ACCURACY TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR WIRE SPEED ACCURACY TEST (continued) TEST PROCEDURE Perform the following checks with the LN-9 wire feeder connected to a Lincoln CV welding power source according to the proper connection diagram. (See the Installation section of this manual.) B. Check for the proper drive roll revolutions per minute. 1. Adjust the LN-9 wire speed control for the LN-9 actual speed meter readings given in the table below. 2.
Return to Master TOC Return to Section TOC F-44 TROUBLESHOOTING & 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-45 TROUBLESHOOTING & REPAIR OUT OF VOLTAGE RANGE SHUT DOWN TEST (continued) FIGURE F.11 – VOLTAGE PC BOARD WITH JUMPERS 1/8 AMP FUSE BYPASS PINS Return to Master TOC Return to Section TOC TEST PROCEDURE 1. Remove input power to the LN-9 wire feeder. 2. Using the phillips head screw driver, remove the screws from the left side cover assembly. 3. Lift the left side cover assembly. 4. Locate the voltage PC board.
Return to Master TOC TROUBLESHOOTING & REPAIR 8. If the ACTUAL voltage reading is zero, the sensing leads may be faulty. Check the continuity (zero ohms) of leads #21 and #67. Lead #21 must have continuity to the workpiece, and #67 must have continuity to the electrode. Also check the 1/8 amp fuse on the voltage PC board. 10.
Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING & REPAIR GENERAL POWER SUPPLY TESTS 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.
Return to Master TOC Return to Section TOC F-48 TROUBLESHOOTING & REPAIR GENERAL POWER SUPPLY TESTS (continued) TEST PROCEDURE 1. Remove input power to the LN-9 wire feeder. 2. Using the phillips head screw driver, remove the screws from the left side cover assembly. 3. Lift the left side cover assembly. 4. Locate the power PC board and the control PC board in the wire feeder main assembly; locate the voltage PC board in the left side cover. 5.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-49 TROUBLESHOOTING & REPAIR F-49 GENERAL POWER SUPPLY TESTS (continued) GENERAL POWER SUPPLY CHECKS CHECKPOINT LOCATION TEST DESCRIPTION CONTROL P.C. BOARD CONNECTOR PLUG CHECK +15VDC SUPPLY FROM POWER BOARD TO CONTROL BOARD CONTROL P.C. BOARD CONNECTOR PLUG VOLTAGE P.C.
Return to Master TOC Return to Section TOC F-50 TROUBLESHOOTING & REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT WARNING Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR F-51 DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT (continued) METER PC BOARD REMOVAL PROCEDURE 2. Locate and remove the two screws on the top left and right side of the meter panel assembly. See Figure F.12. 1. Remove input power to the LN-9 wire feeder. FIGURE F.12 – METER PANEL ASSEMBLY SCREWS Return to Master TOC METER Return to Section TOC Return to Master TOC Return to Master TOC 3.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-52 TROUBLESHOOTING & REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.14 – METER PC BOARD REMOVAL 4 MOUNTING NUTS 5. Using the 5/16" nut driver, remove the four nuts mounting the meter PC board to the meter assembly. See Figure F.14. Return to Master TOC Return to Section TOC 6. Unplug the meter PC board from the wiring harness. 7. Remove the meter PC board.
Return to Master TOC Return to Section TOC F-53 TROUBLESHOOTING & REPAIR REED SWITCH (CR2) REMOVAL AND REPLACEMENT WARNING Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-54 TROUBLESHOOTING & REPAIR F-54 REED SWITCH (CR2) REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – CR2 REED SWITCH LOCATION AND COMPONENTS LEAD 628 Return to Master TOC Return to Section TOC LEAD 529 SELF-TAPPING COPPER 3/4" BOLT SCREW ENERGIZER Return to Master TOC Return to Section TOC PROCEDURE REPLACEMENT 1. Remove input power to the LN-9 wire feeder. 2. Lift the right side cover assembly. 3. Locate the CR2 reed switch. F-15. See Figure 4.
Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT WARNING Return to Master TOC Return to Section TOC 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-56 TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – PRIMARY LEAD #31 AT R1 RESISTOR R1 RESISTOR LEAD 31 PROCEDURE Return to Section TOC Return to Master TOC Return to Master TOC 1. Remove input power to the LN-9. Return to Section TOC F-56 2. Using the phillips head screw driver remove the screws holding the left side cover assembly. LEAD 532 4.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-57 TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued) 6. Disconnect leads #526 and #527 from the power PC board terminals. See Figure F.17. FIGURE F.17 – LEADS #526 AND #527 AT POWER PC BOARD LEAD 527 LEAD 526 Return to Master TOC FIGURE F.18 – LEADS #601 AND #602 AT LEAD SPLICES Return to Master TOC Return to Section TOC Return to Section TOC 7.
Return to Master TOC Return to Section TOC F-58 TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued) 8. Remove the two phillips head screws from the control PC board mounting panel. 9. Using the 11/32" wrench, remove the nut and screw from the top of the PC board mounting panel. 10. Remove the clip holding the 1CR relay, then unplug the relay from the power PC board. See Figure F.19. FIGURE F.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-59 TROUBLESHOOTING & REPAIR F-59 T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.20 – TERMINAL STRIP MOUNTING TERMINAL STRIP T1 TRANSFORMER MOUNTING SCREWS 11. Using the 5/16" wrench, remove the nuts and lockwashers mounting the terminal strip to the mounting panel. See Figure F.20. 12.
Return to Master TOC Return to Section TOC F-60 TROUBLESHOOTING & REPAIR TACH PC BOARD 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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-61 TROUBLESHOOTING & REPAIR F-61 TACH PC BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – TACH ASSEMBLY COVER SCREWS SCREWS TACH ASSEMBLY COVER 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-62 TROUBLESHOOTING & 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 Master TOC Return to Master TOC Return to Section TOC 6. Hold the nut in place with the 3/8" wrench. With the phillips head screw driver, remove the locking screw from the rotating disc.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-63 TROUBLESHOOTING & 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 Return to Section TOC Return to Master TOC Return to Master TOC REASSEMBLY Return to Section TOC F-63 8.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-64 TROUBLESHOOTING & 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-65 TROUBLESHOOTING & REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.25 – TOP MOTOR PLATE SCREWS MOTOR GROUND LEAD SCREWS REMOVE FROM OPPOSITE SIDE TOP PLATE PROCEDURE 1. Remove input power to the LN-9 wire feeder. Return to Section TOC Return to Master TOC Return to Master TOC 2. Using the phillips head screw driver, remove the screws holding the left side cover assembly.
Return to Master TOC TROUBLESHOOTING & REPAIR F-66 DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.26 – GLASTIC MOUNTING SCREWS NUTS AND WASHERS (4-ROLL FEEDERS) Return to Master TOC Return to Section TOC Return to Section TOC F-66 11. Remove the three screws that hold the glastic mounting to the LN-9 floor assembly. See Figure F.26. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC NOTE: Four- roll drive units have nuts and washers also.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-67 TROUBLESHOOTING & REPAIR F-67 DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.27 – MOTOR AND WIRE DRIVE REMOVAL MYLAR INSULATOR Return to Master TOC Return to Section TOC GLASTIC MOUNTING BOARD MOUNTING BOLTS (4) 13. Lift the right side cover assembly and carefully lift and slide the motor and wire drive assembly partially out of the LN-9 box assembly. See Figure F.27. 14.
Return to Master TOC Return to Section TOC F-68 TROUBLESHOOTING & REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) 15. With the slot head screw driver, remove the three screws, lock washers, flatwashers, and insulators holding the drive motor to the gear box assembly. See Figure F.28. 19. From the right side, slide the motor and gear box assembly into the LN-9. Attach the glastic mounting to the floor with the screws. Four-roll units have nuts and washers. 16.
Return to Master TOC Return to Section TOC F-69 TROUBLESHOOTING & 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 component.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-70 NOTES LN-9 Wire Feeder F-70
Return to Master TOC G-1 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAM SECTION Electrical Diagram Section ............................................................................................Section G Wiring Diagram......................................................................................................................G-2 Operating Schematic.............................................................................................................
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC NOTES LN-9 Wire Feeder
Wiring Diagram LN-9 SET-ACTUAL VOLTS-SPEED 513 516 SELECTOR SWITCH SWITCH DIGITAL METER 517 CONTROL RHEOSTAT PLUG N.O. N.C. N.O. N.C. C2 WIRE SPEED CONTROL C1 3 635 10 636 9 510B 3 4 1 2 11 500 5 525 1 521A 2 500 METER PANEL METER ASSEMBLY GROUND BOX 531 504 4 2A 502 667 POLARITY SWITCH 510B 9 635 6 636 8 620 2 635 636 634 10K VOLTS CONTROL 1 RHEOSTAT 1/8 AMP FAST N.D. 32 32A 626B DIRECTION 5 AMP 32A CIRCUIT BREAKER 32A 534 SWITCH G.L.P.
5 AMP CIRCUIT BREAKER 525 R236 R235 R233 R230 R239 R229 R226 R238 R211 Q202 Q206 PT 101 C227 C222 R237 R209 R204 R2 R222 C105 DZ201 D505 X501 521A 8 - C515 10 D513 4 + + 7 - 11 R530 CR501 D518 DZ502 X502 1 4 3 P.C. BOARDS DO NOT HAVE THE 2 R540 R541 500 C514 D515 "VOLTS" 4 PIN RECEPTACLE AND 521A IS 521. CONTROL CW 517 3 9 10 X501 C + C406 CW C404 CW 517 R518 S4 G.L.P. RESET C510 510 IN./MIN.
Return to Master TOC METER BOARD (L6687) SCHEMATIC 511 512 514 515 SET ACTUAL 510A 513 C3 516 C1 9 12 1 4 10 2 11 C2 8 5 HI M/MIN 3 510B IN/MIN 6 LO 7 TO DIGITAL METER 518 B8 B7 562 517 518 B5 B6 562 510 510C B2 B3 B9 TP4 3 6 510C 4 3 4 510 E 10 +5V C +5V 2 8 2 B 1 D 7 5 9 7.68K R1 R6 102K J14 J14 J14 J14 J14 J14 J14 24.3K J14 601 B1 J14 D5 TP5 C4 CW CW D2 10K R2 R7 R9 CW 1K X1 2K OUT C2 IN Return to Master TOC C1 500 4.
Return to Master TOC G-5 ELECTRICAL DIAGRAMS TRIGGER BOARD (M13861) SCHEMATIC 530 S 20031 Return to Section TOC G-5 4 DZ2 75V OCI1 1W R3 3 332 500 620 Return to Master TOC Return to Section TOC OCI1 1 R1 622 2 332 D1 D2 1A 1A 600V 600V D4 600V 600V 562 562 DZ1 50 D5 1A SWITCH 1A 1W 600V 1A Return to Master TOC Return to Section TOC 621 623 R5 R6 562 562 FILE: S20031_3EB NOTES : GENERAL INFORMATION N.A.
Return to Master TOC G-6 ELECTRICAL DIAGRAMS TACHOMETER SCHEMATIC S 19852 Return to Section TOC G-6 15.0K 1.3K R4 R2 1.00K 555 1 FRANCE Return to Master TOC Return to Section TOC R1 525 3 Q1 600mA OCI1 40V 4 510 AUSTRALIA Return to Master TOC Return to Section TOC CANADA 2 NOTES : LABELS GENERAL INFORMATION N.A.