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SVM138-A
June, 1998
LN-9 GMA Wire Feeder
For use with machines having Code Numbers: 9100 and Above
Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation. . . and
thoughtful operation on your
part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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ii
ii
SAFETY
ARC RAYS can burn.
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.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5.b. 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.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
LN-9 GMA Wire Feeder
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iv
iv
SAFETY
7. Quand on ne soude pas, poser la pince à une endroit isolé
PRÉCAUTIONS DE SÛRETÉ
de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
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 suiv-
antes:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de la faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le
risque de voir passer le courant de soudage par les chaines
de levage, câbles de grue, ou atres circuits. Cela peut
provoquer des risques d’incendie ou d’echauffement des
chaines et des câbles jusqu’à ce qu’ils se rompent.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter tou-
jours tout contact entre les parties sous tension et la
peau nue ou les vétements mouillés. Porter des gants
secs et sans trous pour isoler les mains.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumées toxiques.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement
dans les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opéerations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment roxique) ou autres produits irritants.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
PRÉCAUTIONS DE SÛRETÉ POUR LES
MACHINES À SOUDER À TRANSFOR-
MATEUR ET À REDRESSEUR
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous ten-
sion des porte-électrodes connectés à deux machines à
souder parce que la tension entre les deux pinces peut
être le total de la tension à vide des deux machines.
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enroule le câble-électrode autour de n’importe quelle partie du
corps.
2. Autant que possible, l’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
4. Garder tous les couvercles et dispostifis de sûreté à leur
place.
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnementde
l’arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
4. Des gouttes de laiter en fusion sont émises de l’arc de
soudage. Se protéger avec es vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir ttout risque d’incendie dû étincelles.
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v
v
MASTER TABLE OF CONTENTS
RETURN TO MAIN INDEX
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Installing the LN-9GMA 2-Roll and 4-Roll Models ......................................................................A-3
Installing the LN-9F GMA 2-Roll and 4-Roll Models...................................................................A-3
Electrical Connections - LN-9 GMA and LN-9F GMA.................................................................A-4
Machine Grounding...................................................................................................................A-12
Work Cable Connection ............................................................................................................A-12
Connecting the Gun Cable to the Wire Feeder ........................................................................A-13
Hooking Up GMA Shielding Gas...............................................................................................A-14
Operation...............................................................................................................................Section B
Operating Instructions.................................................................................................................B-2
Safety Precautions......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Processes and Equipment.................................................................................B-3
Controls and Settings..................................................................................................................B-5
Drive Roll Installation ................................................................................................................B-10
Wire Loading.............................................................................................................................B-14
Idle Roll Pressure Setting .........................................................................................................B-18
Making a Test Weld and Adjusting Response and Starting......................................................B-19
Procedure at End of Coil...........................................................................................................B-21
Security of Weld Procedure Settings ........................................................................................B-21
Accessories ..........................................................................................................................Section C
Auxiliary Equipment Contacts.....................................................................................................C-2
Optional Equipment and Accessories.........................................................................................C-2
Maintenance..........................................................................................................................Section D
Routine Maintenance..................................................................................................................D-2
Periodic Maintenance .................................................................................................................D-2
Gun and Cable Maintenance......................................................................................................D-3
Theory of Operation .............................................................................................................Section E
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vi
vi
MASTER TABLE OF CONTENTS (cont’d)
RETURN TO MAIN INDEX
Troubleshooting....................................................................................................................Section F
How to Use Troubleshooting Guide ............................................................................................F-2
PC Board Troubleshooting Procedures.......................................................................................F-3
Troubleshooting Guide ................................................................................................................F-4
Electrical Diagrams..............................................................................................................Section G
Parts...................................................................................................................................P289 Series
LN-9 GMA Wire Feeder
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vii
vii
NOTES
LN-9 GMA Wire Feeder
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Section A-1
Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications..............................................................................................................A-2
Installing the LN-9GMA 2-Roll and 4-Roll Models ......................................................................A-3
Attaching the Wire Reel stand..............................................................................................A-3
Mounting the Unit .................................................................................................................A-3
Installing the LN-9F GMA 2-Roll and 4-Roll Models...................................................................A-3
Mounting the Wire Feed Unit................................................................................................A-3
Mounting the Control Box.....................................................................................................A-3
Connecting the Wire Feed Unit to the Control Box..............................................................A-3
Routing the Electrode...........................................................................................................A-4
Electrical Connections - LN-9 GMA and LN-9F GMA.................................................................A-4
Power Input Cable Assembly ..............................................................................................A-4
Connecting the Power Input Cable Assembly to the LN-9 GMA Wire Feed Unit ................A-4
Connecting the Power Input Cable Assembly to the LN-9F GMA Wire Feed Unit .............A-5
Connecting the Power Input Cable Assembly to Power Sources ........................................A-5
Machine Grounding...................................................................................................................A-12
Work Cable Connection ............................................................................................................A-12
Direct Work Lead Connection.............................................................................................A-12
Connecting the Gun Cable to the Wire Feeder ........................................................................A-13
For GMA Gun Cables .........................................................................................................A-13
Hooking Up GMA Shielding Gas...............................................................................................A-14
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS
INPUT POWER
Supplied by power source: 115 VAC, 50/60 Hz., 350 VA
WIRE FEED SPEED
80 to 980 inches per minute (2.03 to 24.9 meters per minute)
VOLTAGE CONTROL RANGE
12.0 TO 60.0 VDC
TEMPERATURE RANGE
OPERATION:
- 20o C to +40o C (- 4o F to +104o F)
- 40o C to +40o C (- 40o F to +104o F)
Recommended
Maximum Rated
STORAGE:
- 40o C to +85o C (- 40o F to +185o F)
WIRE DIAMETERS
0.023 through 1/16
0.045 through 5/64
Solid Electrode
Cored Electrode
PHYSICAL DIMENSIONS
LENGTH
WIDTH
HEIGHT
TOTAL WEIGHT LESS
ELECTRODE
LN-9 GMA (2 ROLL)
LN-9 GMA (4 ROLL)
12.15 in.
(308.4 mm)
11.56 in.
(293.4 mm)
12.19 in.
(309.4 mm)
29.3 lbs
(13.3 kg)
12.15 in.
11.56 in.
12.19 in.
27.5 lbs
(308.4 mm)
(293.4 mm)
(309.4 mm)
(12.4 kg)
LN-9F GMA Control Box
10.4 in.
(264 mm)
6.17 in.
(156.6 mm)
11.26 in.
(293.4 mm)
16.3 lbs
(7.4 kg)
LN-9F GMA Wire Drive (2 ROLL)
LN-9F GMA Wire Drive (4 ROLL)
8.06 in.
(204.6 mm)
7.5 in.
(190.4 mm)
12.78 in.
(324.4 mm)
15.6 lbs
(7.1 kg)
8.06 in.
(204.6 mm)
7.5 in.
(190.4 mm)
12.78 in.
(324.4 mm)
20.5 lbs
(9.2 kg)
LN-9 GMA Wire Feeder
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A-3
A-3
INSTALLATION
INSTALLING THE LN-9 GMA
MOUNTING THE CONTROL BOX
2-ROLL AND 4-ROLL MODELS
The same control box is used for both the 2-Roll and 4-
Roll wire feed unit. It contains two keyhole slots and
one slot for mounting. Refer to the LN-9F GMA
al for the size and location of these slots. Mount the
box at some convenient location close to the wire feed
unit. This will enable the 16-foot control cable assem-
bly supplied with both the LN-9F GMA 2-Roll and 4-Roll
to reach between the control box and the wire feed
unit.
ATTACHING THE WIRE REEL STAND
Both the 2-Roll and 4-Roll LN-9 GMA are shipped with-
out the wire reel stand attached. The screws and wash-
ers for mounting the wire reel stand are included with
the LN-9 GMA (fastened in their respective mounting
holes). To attach the stand:
1. Remove the three 3/8" hex screws from the back of
the wire feed unit.
1. Drill the required holes in the mounting surface.
Partially install 1/4-20 screws.
2. Place the wire reel stand mounting bracket in posi-
tion against the back of the wire feed unit.
2. Open the control box door by removing the two door
screws.
3. Replace and tighten the screws. The long screw
and plain washer go into the top hole. For 4-Roll
feeders, one plain washer is used for mounting 60#
wire stands and 2 plain washers for mounting 30#
stands.
3. Mount the box.
4. Tighten the screws.
5. Close the control box door and replace the door
screws.
MOUNTING THE UNIT
LN-9 GMA wire feeders can be mounted directly on top
of their power source as long as it is secure and level.
When portability is required, the LN-9 GMA can be
CONNECTING THE WIRE FEED UNIT TO
THE CONTROL BOX
mounted on
Accessories section for details.
a
K163 undercarriage See the
Both the LN-9F GMA 2-Roll and 4-Roll include the
same 16 ft. control and electrode cable assembly.
Connect the wire feed unit to the control box as follows:
A K1557-1 swivel platform is available for mounting the
LN-9 GMA to the power source. See the Accessories
section for details.
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.
INSTALLING THE LN-9F GMA
2-ROLL AND 4-ROLL MODELS
2. Connect the cable connector to the receptacle on
the back of the wire feed unit connection box.
MOUNTING THE WIRE FEED UNIT
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.
Mount the wire feed unit by means of the insulated
mounting bracket attached to the bottom of the gear-
box. Refer to the LN-9F GMA Dimension Print in the
Diagrams section of this manual for the size and loca-
tion of the mounting holes. The gearbox assembly is
electrically "hot" when the gun trigger is pressed.
Therefore, make certain the gearbox does not come in
contact with the structure on which the unit is mounted.
The wire feed unit should be mounted so that the drive
rolls are in a vertical plane so dirt will not collect in the
drive roll area. Position the mechanism so it will point
down at about a 45o angle so the wire feed gun cable
will not be bent sharply as it comes from the unit.
4. At the control box end, connect the amphenol con-
nector of the control cable to the mating MS-type
receptacle on the bottom of the control box. (See
Figure A.3, later in this section, for the location of
this connection.)
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A-4
A-4
INSTALLATION
CONNECTING THE POWER INPUT
ROUTING THE ELECTRODE
CABLE ASSEMBLY TO THE LN-9 GMA
WIRE FEED UNIT
The electrode supply may be either from reels, Readi-
Reels, spools, or bulk packaged drums or reels.
Observe the following precautions:
The K196, K595, or K596 cable assembly consists of
an electrode cable and multiconductor control cable.
The control cable has a polarized plug on the wire
feeder end. To install:
• 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.
1. See Figure A.1. Connect the polarized plug of the
control cable to the mating connector on the back
of the wire feeder.
• The electrode is "hot" when the gun trigger is
pressed and must be insulated from the boom and
structure.
2. See Figure A.2. Remove the screws holding the
cable strain relief clamp located near the rear of
the wire reel stand base. Put the control cable and
the electrode cable under the clamp and install the
screws.
• 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.
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.
See the Accessories section for information about
mounting a K299 wire reel assembly.
3. See Figure A.1. Pass the single electrode cable
through the hole provided in the back corner of the
wire section and fasten it to the conductor block of
the copper strap along the side of the wire drive
unit.
ELECTRICAL CONNECTIONS -
LN-9 GMA AND LN-9F GMA
POWER INPUT CABLE ASSEMBLY
FIGURE A.1 – INPUT CONTROL CABLE AND
ELECTRODE CABLE CONNECTIONS
A special cable assembly is required to connect all LN-
9 GMA models to the power source. The assembly
includes control cable and electrode cable. Various
sizes are available, based on length and maximum
welding current. The following power source cable
assemblies are available:
K196 for Terminal Strip control connection and output
terminal.
K595 for 14-Pin receptacle and output terminal.
K596 for 14-Pin receptacle and Twist-Mate" connec-
tion.
NOTE: Use of an LN-9 GMA with a Pulse Power 500,
Invertec V300 or a DC650 PRO requires a K442-1
Pulse Power Filter Kit.
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A-5
A-5
INSTALLATION
FIGURE A.2 – STRAIN RELIEF CLAMP
FIGURE A.3 – LN-9F GMA CONTROL BOX
BOTTOM VIEW
CONNECTING THE POWER INPUT CABLE
ASSEMBLY TO POWER SOURCES
WARNING
Turn input supply power to the power source OFF
before connecting the LN-9 GMA or LN-9F GMA wire
feeder.
CONNECTING THE POWER INPUT CABLE
ASSEMBLY TO THE LN-9F CONTROL
BOX
Connect to an appropriate Lincoln power source as fol-
lows:
1. If using a multipurpose source (such as the DC-
250, DC-400 and DC-600), be sure it is properly
set for the welding process being used. See the
topic "Making a Test Weld," in the Operation sec-
tion of this manual.
1. See Figure A.3. Connect the polarized plug of the
K196, K595, or K596 control cable to the mating
MS-type connector on the bottom of the LN-9F
GMA control box.
2. Bolt the electrode lead from the power source to the
electrode lead to the wire feed unit using the nut
and bolt supplied. Insulate the connection with elec-
trical tape.
For terminal strip connections using the K196 power
input cable, connect the input cable to the power
source exactly as specified on the appropriate LN-9
GMA model connection diagram:
Figure A.4 for DC-250, DC-400 and CV-400, CV-500 l
Figure A.5 for DC-600
Figure A.6 for DC-1000
Figure A.7 for Pulse Power 500
Figure A.8 for V300
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A-6
A-6
INSTALLATION
Figure A.8 is a connection diagram for connecting the
LN-9 GMA to V300 power sources. The connection is
made with a K596 cable assembly, which has an
amphenol connection rather than a terminal strip con-
nection at the power source.
Depending on the power source and process you are
using, the jumpers on the LN-9 GMA voltage board
may have to be changed. As shipped, the LN-9 GMA is
connected for use with the DC-250 DC-400, CV-400,
CV-500-I and DC-600. For other power sources, refer
to the appropriate connection diagram.
NOTE: If you are using the Pulse Power 500, DC650
Pro, or V300 power source, the K442-1 Pulse Power
Filter Kit must be installed in the LN-9 GMA. See the
instructions included with the kit. If you are using the
Invertec V300, the K608-1 Adapter must also be
installed according to the connection diagram and
instructions provided in the Invertec Manual.
LN-9 GMA Wire Feeder
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A-7
A-7
INSTALLATION
FIGURE A.4 – CONNECTION OF LN-9 GMA 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
• Only qualified persons should install,
ELECTRIC SHOCK
use or service this machine.
can kill.
TO LN-9 GMA INPUT CABLE PLUG
Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and position the switch on power source to proper polarity.
* Does not apply to DC-400 below code 9200 with polarity switch.
N.A. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using #14 AWG or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage
sensing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the 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 #21 on the terminal strip. Note that this is not the preferred connection
because it adds error to the wire feeder voltmeter reading.)
N.C. Tape up bolted connection if lead #21 is extended.
N.D. Connect the control cable ground lead to the frame terminal marked
near the power source terminal strip. The power source
grounding terminal (marked and located near the power source input power connections) must be properly connected to elec-
trical ground per the power source operating manual.
N.F. The LN-9 GMA voltage control jumpers must be connected as follows:
White jumper on voltage board to pin “S”.
Blue jumper on voltage board (later units only), or on start board (earlier units), to pin “B”.
*N.G. If lead #21 is to be connected to the terminal strip, connect to the #21 terminal that matches work polarity. This connection must
be changed whenever the electrode polarity is changed.
LN-9 GMA Wire Feeder
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A-8
A-8
INSTALLATION
FIGURE A.5 – CONNECTION OF LN-9 GMA TO DC-600 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
• Only qualified persons should install,
ELECTRIC SHOCK
use or service this machine.
can kill.
TO LN-9 GMA INPUT CABLE PLUG
Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and position the switch on power source to proper polarity.
For optimum performance with the LN-9 GMA, DC-600’s with codes 8288 and above are preferred.
N.B. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.C. Extend lead #21 using #14 or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage sensing
work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding work
lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead. (This extended
#21 lead connection replaces the need to employ the remote work lead accessory on LN-9’s which have a direct work lead jack.)
N.D. Tape up bolted connection.
N.E. Connect the LN-9 GMA control cable ground lead to the frame terminal marked
power source must be properly grounded.
near the power source terminal strip. The
N.G. The LN-9 GMA voltage control jumpers must be connected as follows:
White jumper on voltage board to pin “S”.
Blue jumper on voltage board (Later units only) or on start board (Earlier units) to pin “B”.
N.H. For DC-600 Codes below 8200 connect a jumper from “N” to “P” on LN-9 GMA only. There is no NPS terminal strip on codes
above 8200.
LN-9 GMA Wire Feeder
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A-9
A-9
INSTALLATION
FIGURE A.6 – CONNECTION OF LN-9 GMA TO DC-1000 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
• Only qualified persons should install,
ELECTRIC SHOCK
use or service this machine.
can kill.
TO LN-9 GMA INPUT CABLE PLUG
Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source, position the positive - negative switch on power source to correspond to the polarity of the electrode cable connection.
N.A. Welding cables must be proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using #14 or larger insulated wire physically suitable for the installation. an S16586 remote voltage sensing work
lead is available for this purpose. Connect it directly to the work piece keeping it separate from the welding work cable connection
to work piece. For convenience, this extended #21 lead should be taped along the welding work cable. (This extended #21 lead
connection replaces the need to employ the remote work lead accessory on any LN-9 GMA which has a direct work lead jack).
N.C. Tape up bolted connection.
N.D. Connect the LN-9 GMA control cable ground lead to the frame terminal marked
power source must be properly grounded.
near the power source terminal strip. The
N.E. If using an older automatic control cable with leads #75, #76, #77; connect lead #75 to #75 on terminal strip, connect lead #76 to
#74 on terminal strip, connect lead #77 to #73 on terminal strip.
N.F. The LN-9 GMA voltage control jumpers must be connected as follows:
White jumper on voltage board to pin “S”.
Blue jumper on voltage board (Later units only) or on start board (earlier units) to pin “B”.
N.G. Set the DC-1000 controls as follows:
Set the control switch to “output control remote”. For submerged arc processes, set the mode switch to “C.V. submerged arc”.
For open arc processes, set the mode switch to “C.V. Innershield”.
N.H. Alternative 500 amp positive terminal connection provided on DC-1000 models above code 9500 only.
LN-9 GMA Wire Feeder
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A-10
A-10
INSTALLATION
FIGURE A.7 – CONNECTION OF LN-9 GMA 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 connect-
ing the wire feeder
• Only qualified persons should install,
ELECTRIC SHOCK
use or service this machine.
can kill.
TO LN-9 GMA INPUT CABLE PLUG
Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and properly set the feeder polarity switch.
N.A. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using 14 AWG or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage sens-
ing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding
work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead.
N.C. Tape up bolted connection.
N.D. Connect the control cable ground lead to the frame terminal marked
near the power source terminal strip. The power source
grounding terminal (marked and located near the power source input power connections) must be properly connected to elec-
trical ground per the power source Operating Manual.
N.E. Connect control leads t terminal strip as follows:
LN-9:
A to 75 B to 77 C to 78
N.F. The LN-9 GMA voltage control jumpers must be connected as follows:
White jumper on voltage board to pin “S”.
Blue jumper on voltage board is not connected to any pin. (Secure loose jumper clear of any possible interference.)
NOTE: For proper pulse welding operating with LN-9:
1. The LN-9 GMA must have an L6084-3 (or higher superseding part number) voltage board installed. (Standard above code
9100.)
2. The Pulse Power Filter board must be installed and connected in the LN-9 per instructions provided with the kit.
3. The pulse current sensor assembly (with looped copper energizer) must be installed. (Standard above code 9100.) Feeder
conversion kits are available for all LN-9 GMA model codes (below 9100 and above 9100).
LN-9 GMA Wire Feeder
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A-11
A-11
INSTALLATION
FIGURE A.8 – CONNECTION OF LN-9 GMA TO V300 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
• Only qualified persons should install,
ELECTRIC SHOCK
use or service this machine.
can kill.
K608-1
CONNECTION
DETAIL
LN-9 GMA WITH
K608-1 AND
K442-1 KITS
ELECTRODE CABLE
TO LN-9 GMA
P10,J10'
P10',J10
2
3
530A
521
500
500
524
C
2
3
TO WORK
14 PIN
AMPHENOL
4
4
5
5
6
6
K596 REMOTE
CONTROL CABLE
ASSEMBLY
7
11
INVERTEC
10
POWER SOURCE
WITH 110/115V AUX.
3.9K ohm
11
12
B
7
533
12
N.A. Welding cable must be sized for current and duty cycle of application.
N.B. Diagram shows electrode positive. To change polarity, turn power “OFF”, reverse electrode and work cable at power source. Set
meter polarity switch on rear of invertec to coincide with polarity used. Set LN-9 GMA polarity switch also.
N.C. Install K608-1 adapter in line with P10 to LN-9 GMA voltage board and secure to adjacent harness with wire tie provided. Turn
“start” trimmer on voltage board per instructions in V300 manual.
N.D. For GMAW welding, install Pulse Power Filter Kit K442-1 in LN-9 GMA.
LN-9 GMA Wire Feeder
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A-12
A-12
INSTALLATION
DIRECT WORK LEAD CONNECTION
MACHINE GROUNDING
Lincoln specified procedures give voltage readings
taken between the work and the gun cable brass con-
nection block of the LN-9 GMA. To match these voltage
readings, the connection diagrams show the #21 lead
being extended and connected directly to the work
instead of #21 on the power source terminal strip (or
Dual Process Kit terminal strip). This extended lead
must be connected directly to the work. When using a
Dual Process Kit, you must extend the lead individual-
ly for each LN-9 GMA.
LN-9 GMA wire feeders are grounded to the power
source through the input cable. The power source
grounding cable must be properly connected to electri-
cal ground. See your power source operating manual
for details.
WORK CABLE CONNECTION
Connect a work lead of sufficient size and length
between the proper output terminal on the power
source and the work. See Table A-1. Be sure the 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.
As an alternative, LN-9 GMA models are provided with
a quick-connect terminal splice connection in the #21
lead between the input Amphenol connector of the LN9
GMA and its polarity switch. See the LN-9 GMA wiring
diagram. This in-line connection consists of a red insu-
lated male and female .250 x .032 terminal pair locat-
ed in the lead harness. It runs along the right side of
the wire feed motor inside the control section of the LN-
9 GMA models and in the lead harness at the lower left
corner of the control box (near the input Amphenol) of
the LN-9F models. You may also open this #21 lead
and connect your own direct work lead equipped with a
.250 x .032 female quick-connect terminal to the male
side of the splice. This direct work lead connection
must be tape insulated, strain-relieved, and routed out-
side the LN-9 GMA control box to be connected direct-
ly to the work.
TABLE A.1 – WORK CABLE SIZES
Copper Work Cable Size, AWG
Current
60% Duty Cycle
Up to 50' length 50'-100' Iength
300 Amps
400 Amps
500 Amps
600 Amps
0
00
00
000
00
000
With either direct work lead connection method, the
LN-9 GMA regulates the power source to hold the arc
voltage constant, even with voltage drops in the elec-
trode lead, work lead, or work lead connection. If the
direct work lead becomes disconnected from the work,
the LN-9 GMA wire feeder will stop welding shortly
after the arc is struck. See the topic "Circuit
Protection and Automatic Shutdown" in the
Operation section of this manual.
000
0000
LN-9 GMA Wire Feeder
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A-13
A-13
INSTALLATION
FIGURE A.9 – GUN CABLE CONNECTIONS
CONNECTING THE GUN CABLE TO
THE WIRE FEEDER
A variety of gun and cable assemblies are available for
the LN-9 GMA 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 fully seated and tighten the plas-
tic thumbscrew. 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.
Thumb-
screw
FOR GMA GUN CABLES:
Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the LN-9 GMA
wire drive section. Connect the 3/16" I.D. gas hose
from the gun cable to the barbed fitting.
When you remove the gun, you can easily detach this
fitting by loosening the union nut.
LN-9 GMA Wire Feeder
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A-14
A-14
INSTALLATION
See American National Standard Z-49.1, "Safety in
Welding and Cutting," published by the American
Welding Society.
HOOKING UP GMA SHIELDING
GAS
The user must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve and a hose
from the flow valve to the gas inlet fitting of the LN-9
GMA. See Figure A.10 and install as follows:
WARNING
CYLINDER
damaged.
may
explode
if
1. Connect the supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on
the back panel of the LN-9 GMA wire drive section.
• Gas under pressure is explosive.
•· Always keep gas cylinders in an
upright position and always keep
them chained to the undercarriage
or a stationary support.
2. Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the LN-9
GMA. Connect the 3/16 inch (4.8 mm) I.D. gas
hose from the gun to the barbed fitting.
When you need to remove the gun, you can easily
detach this fitting by loosening the union nut.
FIGURE A.10 – SHIELDING GAS HOOKUP
LN-9 GMA Wire Feeder
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Section B-1
Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation
Operating Instructions.................................................................................................................B-2
Safety Precautions......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Processes and Equipment.................................................................................B-3
K424 LN-9 GMA 2-Roll and K568-1 LN-9 GMA 4-Roll.........................................................B-3
K436 LN-9F GMA 2-Roll and K538-1 LN-9 GMA 4-Roll ......................................................B-3
DC Constant Voltage Power Sources ..................................................................................B-4
Controls and Settings..................................................................................................................B-5
Circuit Protection and Automatic Shutdown .........................................................................B-8
Avoiding Grounding Lead Protector (GLP) Shutdown..........................................................B-8
Drive Roll Installation ................................................................................................................B-10
Changing Drive Rolls for 2-Roll Wire Feeders ...................................................................B-10
Changing Drive Rolls for 4-Roll Wire Feeders ...................................................................B-12
Wire Loading.............................................................................................................................B-14
Loading a 22 to 30 lb. Reddi-Reel Package.......................................................................B-14
Loading a 10 to 30 lb. Spool ..............................................................................................B-15
Loading 50 to 60 lb. Coils...................................................................................................B-16
Loading and Feeding 13-14 lbs. Innershield Coils.............................................................B-17
Idle Roll Pressure Setting .........................................................................................................B-18
2-Roll Wire Feeders............................................................................................................B-18
4-Roll Wire Feeders............................................................................................................B-18
Making a Test Weld and Adjusting Response and Starting......................................................B-19
Adjust the Power Source....................................................................................................B-19
Adjust the LN9 GMA Controls ............................................................................................B-19
Voltage Control Response..................................................................................................B-20
Starting Characteristics.......................................................................................................B-20
Making a Weld....................................................................................................................B-21
Procedure at End of Coil...........................................................................................................B-21
Security of Weld Procedure Settings ........................................................................................B-21
LN-9 GMA Wire Feeder
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B-2
B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions operating the machine.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
LN-9 GMA Wire Feeder
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B-3
B-3
OPERATION
K436 LN-9F GMA 2-ROLL AND K583-1
LN-9F GMA 4-ROLL
GENERAL DESCRIPTION
The LN-9 GMA 2-Roll and 4-Roll semiautomatic wire
feeder models feature the precise "set and forget" dig-
ital procedure control and the other welding and oper-
ator features pioneered by the original LN-9 models.
In addition, the LN-9 GMA models also have the fol-
lowing advantages for small wire gas metal arc weld-
ing with solid or flux cored Outershield® electrodes:
Separate wire feed unit and control box with 16 ft cable
assembly for boom or fixture mounting. See Figure
B.2.
FIGURE B.2 – BASIC LN-9F GMA HOOKUP
• High speed wire drive with a high torque permanent
magnet motor and tool-less "quickrelease" idle roll
pressure arms, guide tubes and gun cable fastening.
• Factory installed gas solenoid valve with gas inlet and
outlet fittings.
• Adjustable preflow, postflow and burnback timers.
Purge and cold inch switch functions are available.
• For 4-Roll models, a design which provides the addi-
tional feeding force. This is required when using gun
cables over 15 ft. long or when wire is being pulled
long distances (for example, bulk packages).
Because the 4-Roll feeder has twice the contact sur-
face, it can also help when feeding softer wires. It
delivers the same or more feeding force as the 2-Roll
with less overall wire deformation. Wire size range,
speed and features are the same as other LN-9 GMA
models.
When combined with the broad selection of quality
welding equipment and accessories, the LN-9 GMA
provides a versatile precision welding system to meet
the specific needs of gas metal arc and Innershield®or
submerged arc welding processes. The capabilities of
the LN-9 GMA 2-Roll and 4-Roll are:
RECOMMENDED PROCESSES AND
EQUIPMENT
Rated wire size range:
The LN-9 GMA is available in four models:
.023 through 1/16 solid wire electrode.
.045 through 5/64 Outershield® cored electrode.
.062 through 5/64 lnnershield® cored electrode.
Rated wire speed range:
K424 LN-9 GMA 2-ROLL AND K568-1 LN-9
GMA 4-ROLL
Wire feed unit and all controls completely enclosed in
a single portable enclosure. See Figure B-1.
80 through 980 inches per minute.
(2.03 through 24.9 meters per minute).
FIGURE B.1 – BASIC LN-9 GMA HOOKUP
K196-XXX,
LN-9 GMA Wire Feeder
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B-4
B-4
OPERATION
DC CONSTANT VOLTAGE POWER
SOURCES
The following welding system power sources are avail-
able for use with all LN-9 GMA models:
The Idealarc® DC-250, DC-400, CV-400, CV-500 and,
DC-600 are recommended for use with any LN-9 GMA
model, as well as the Pulse Power 500, Invertec V300,
and DC650 Pro, with the installation of the optional
K442-1 Pulse Power Filter Kit.
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B-5
B-5
OPERATION
HOT-COLD TRIGGER INTERLOCK SWITCH: This
CONTROLS AND SETTINGS
switch is located on the front rail on the LN-9 GMA
model and on the front panel of both the LN-9F GMA
2-Roll and 4-Roll control box. The three-position
switch serves a dual purpose:
Operator controls for LN-9 GMA models are shown in
Figure B.3. Controls for LN-9F models are shown in
Figure B.4. Refer to these figures and the following
descriptions of the controls.
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.
ELECTRODE POLARITY SWITCH: The polarity
switch is located inside the wire drive section on the
LN-9 GMA model and on the front panel of both the
LN-9F GMA 2-Roll and 4-Roll control box. Set the
switch to the same polarity as the electrode lead con-
nection to the power source. If the switch is not set
for the correct polarity, the wire feeder will stop weld-
ing shortly after the arc is struck. See the topic
"Automatic Shutdown" later in this section of the
manual.
2. Trigger Interlock Function - In the down position
the trigger interlock will be OFF, allowing the gun
trigger to function in the normal mode. This stops
wire feed and welding when the trigger is released.
In the up position the trigger interlock will be ON.
The trigger interlock feature functions as follows:
a) When you are not welding, the trigger will function
in the normal mode, which feeds only when the
trigger is closed.
WIRE FEED DIRECTION SWITCH: The direction
switch is located inside the wire drive section on the
LN-9 GMA model and on the front panel of both the
LN-9F GMA 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 K418 and K419 options. Be sure this
switch is set for forward feed when you are ready to
weld.
b) Once the welding arc has been struck, the gun trig-
ger may be released. Welding will continue until
one of the following occurs:
• The arc is extinguished by quickly pulling the gun
away from the work.
or
• The trigger is again depressed and released.
(This feature is not on earlier versions unless the
L7265-1 PM Power Board has been replaced
with a superceded version.)
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B-6
B-6
OPERATION
FIGURE B.3 – WIRE FEEDER CONTROLS FOR LN-9 GMA
LN-9 GMA Wire Feeder
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B-7
B-7
OPERATION
FIGURE B.4 – WIRE FEEDER CONTROLS FOR LN-9F GMA
LN-9 GMA Wire Feeder
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B-8
B-8
OPERATION
CIRCUIT BREAKER AND GROUNDING LEAD PRO-
TECTOR (GLP) RESET SWITCH: These protection
circuit devices are located on the front rail of the LN-9
GMA model and bottom panel of the LN-9F models.
See the topic "Circuit Protection and Automatic
Shutdown" later in this section of the manual.
SET-ACTUAL PUSHBUTTON: After the weld has
been started, the ACTUAL voltage or wire speed can
be read by pressing the pushbutton to the left of the
meter. The METER READING switch must be set in
the desired position. When the pushbutton is not being
operated, the meter continues to read the SET value.
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.
CIRCUIT PROTECTION AND AUTOMATIC
SHUTDOWN
CIRCUIT BREAKER
METER READING SWITCH, VOLTS AND WIRE
SPEED CONTROLS: This four-position rotary switch
is located to the right of the digital meter on LN-9 GMA
models 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 GMA
models is 12.0 to 60.0 volts.
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. If the breaker still trips, look for a defective elec-
trical component. When the circuit breaker is tripped,
the digital meter is off and the trigger circuit will not
operate.
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 GMA models are 80 to 980 inch-
es/minute (2.03 to 24.9 meters/minute).
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.
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.
VOLTAGE PC BOARD FUSE
The 1/8 amp fast-blow fuse protects the LN-9 GMA cir-
cuitry from damage that may result from a ground, or
case, faulted control lead. If this fuse blows, the LN-9
GMA arc voltage sensing lead circuit will be opened.
See the topic "Automatic Shutdown" below.
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 GMA will con-
tinuously monitor the volts and wire speed and correct
any deviation from the set value so there will be negli-
gible change.
AVOIDING GROUNDING LEAD PROTECTOR
(GLP) SHUTDOWN
The frames of all LN-9 GMA wire feed units and drive
motors are grounded to the frame of the power source
by a lead in the control cable. An overload protector
prevents welding current from damaging this lead if the
electrode circuit touches the wire feeder frame while
the gun trigger is pressed.
Should the range of the power source output voltage be
such that the unit circuit cannot keep the arc voltage as
set, the unit will stop welding shortly after the arc is struck.
See the topic "Circuit Protection and Automatic
Shutdown" later in this section of the manual.
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B-9
B-9
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.3 or B.4 for the
location of this button.
In the case of full range control power sources, such as
the DC-600, this protective shutdown circuit could pre-
vent welding under the conditions of (c), (d), and (e)
above by holding the power source output at minimum.
The power source output might even be too low to
establish an arc.
The following precautions are recommended to avoid
GLP shutdown:
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 GMA
controls are set for 29 volts and the input voltage to the
R3S goes up, it may not be possible for the LN-9 GMA
control circuit to hold the 29 volts. The welding will shut
down. By changing to the 27 volt triangle setting, the
range will be approximately 23-1/2 to 30-1/2 volts, and
at high input voltage there will be sufficient control to
hold the SET arc voltage.
• Do not allow the electrode to contact the case of the
wire feeder or uninsulated part of its wire reel stand
when the gun trigger is activated.
• Be sure that all work lead connections to the work
make tight metal-to-metal electrical contact.
• Do not allow excess input cable or work cable to be
placed closer than 3 feet to the wire feeder.
• Do not coil excess input cable assembly or use an
uncoiled assembly as shipped from the factory.
Instead, loop excess length back and forth in 3 to 6
foot straight lengths. Coiling the input cable results in
a transformer action between the electrode conductor
cable and ground lead in the multiconductor cable
and the ground lead in the multiconductor control
cable. This can cause current to flow in the ground
lead, which will falsely activate the GLP.
The same general procedure can be used on other
power sources. For example, if the LN-9 GMA keeps
shutting down and the other possible causes have
been checked, adjust the SET voltage higher and/or
lower than the desired voltage. Then you can deter-
mine what change in the range controls of the power
source is required to supply the desired voltage.
AUTOMATIC SHUTDOWN
If the LN-9 GMA voltage control is unable to supply the
SET value of arc voltage while welding, the automatic
shutdown circuit will activate. This protection circuit
immediately returns the LN-9 GMA control to idle state
within a few seconds after the arc voltage discrepancy
occurs.
In some cases, it is also possible to hold the ACTUAL
button pressed while starting the arc. Before the LN-9
GMA shuts down, the actual arc voltage can be read on
the digital meter. Comparing this reading to the SET
reading will tell what change in the range controls of
the power source is required to supply the desired volt-
age. Should the meter read zero, check the connec-
tions of LN-9 GMA sensing leads #21 and #67. Should
the meter read a minus (-) voltage, the polarity con-
nections or settings at the LN-9 GMA or power source
are wrong.
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 GMA or the power source.
e) Lost connection of LN-9 GMA voltage sensing
leads (#67 and #21) between the arc and voltage
control, or a blown 1/8 amp fuse on the Voltage PC
board.
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B-10
B-10
OPERATION
DRIVE ROLL INSTALLATION
CHANGING DRIVE ROLLS FOR 2-ROLL
WIRE FEEDERS
5. Back out the guide tube clamping screws. Remove
the old guide tubes, if installed.
To change drive rolls on a 2-roll wire feeder, refer to
Figure B.5 and perform the following steps.
6. Insert the outgoing guide tube (the one with the
plastic insert) into the front hole. If the guide tube
has a non-symmetrical chisel end, the larger radius
must face the drive roll. See Figure B.5. Push the
guide tube back as far as it will go and tighten the
clamping screw. Insert the incoming guide tube as
far back as it will go and tighten the clamping
screw. The clamping screws are dog points. When
the guide tubes are properly installed these dog
points will lock into the annular grooves in each of
the guide tubes.
NOTE: Although an LN-9 GMA model is shown in
Figure B.5, the following procedure also
applies to LN-9F GMA models.
1. Rotate the latch knob on the quick release arm.
2. Remove the hex head screw and clamping collar.
Remove the drive roll from the shaft.
3. The new roll to be installed is stamped for the size
to be fed. An "A" after the size indicates aluminum
wire. Remove the rolls from the kit and wipe them
clean. Wipe the output shaft and locating shoulder
clean.
7. Set the idle roll pressure as detailed in the Idle Roll
Pressure Setting procedure detailed later in this
section.
4. Use the drive key, clamping collar, and hex head
screw to install the roll on the output shaft. Certain
size drive rolls consist of two roll halves, and may
contain a spacer. If the drive roll you are installing
contains a spacer, the spacer fits between the two
halves of the drive roll. Tighten the hex head
screw.
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B-11
B-11
OPERATION
FIGURE B.5 – INSTALLING DRIVE ROLLS ON A 2-ROLL FEEDER
CLAMPING
COLLAR
SPACER
(IF REQ'D)
DRIVE
ROLL
HALVES
OUTPUT
SHAFT
KEY
GUIDE TUBE DETAIL
LARGE
RADIUS
OUTGOING
GUIDE TUBE
DRIVE
ROLL
OUTGOING
GUIDE TUBE
INSERT
INCOMING
GUIDE
IDLE
ROLL
TUBE
SMALL
RADIUS
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B-12
B-12
OPERATION
CHANGING DRIVE ROLLS FOR 4-ROLL
WIRE FEEDERS
To change drive rolls on a 4-roll wire feeder, refer to
Figure B.6 and perform the following steps.
7. Install the middle guide tube, but do not tighten at
this time. When installing a 0.035" middle guide
tube the larger radius should be aligned towards
the drive roll. Slide the guide tube up against the
drive roll.
NOTE: Although an LN-9 GMA model is shown in
Figure B.6, the following procedure also
applies to LN-9F GMA models.
8. Install the second drive roll on the remaining shaft
the same way as the first. Center the middle guide
tube between the rolls and tighten the thumb-
screws holding it in place.
1. Remove the gun and cable from the conductor
block on the feeder by loosening the hand screw
and pulling the gun straight out of the block.
2. Open both quick release levers by moving the
levers outward and pulling them toward you.
9. Close and latch both quick release levers.
10. Slide the incoming guide tube into the rear hole of
the gearbox until it almost touches the drive roll
and guide tube. Tighten the thumbscrew to hold it
in place.
3. Loosen the thumb screws holding the guide tubes
in place. Remove the incoming and outgoing
guide tubes, if installed.
4. Remove the hex head screws and clamping collars
from the output shafts. Remove the drive rolls and
middle guide tube, if installed.
11. Install the outgoing guide tube into the front hole of
the gearbox (through the conductor block) and
tighten the thumb screw. The 0.035 in. outgoing
guide tube should have the larger radius oriented
toward the drive roll. For proper installation of the
outgoing guide tube insert, refer to Figure B.6.
5. The new rolls to be installed are stenciled with the
wire size that will be fed. An "A" after the number
indicates aluminum wire. Remove the rolls from
the kit and wipe them clean. Wipe the output
shafts and locating shoulders clean.
12. Be certain that the guide tubes do not touch the
drive rolls or idle rolls. If they do touch, readjust
them and tighten in place.
6. Install one roll onto either output shaft using the
drive key, clamping collar, and hex head screw.
Certain size drive rolls consist of two roll halves,
and may contain a spacer. If the drive roll you are
installing contains a spacer, the spacer fits
between the two halves of the drive roll. Tighten
the hex head screw.
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B-13
B-13
OPERATION
FIGURE B.6 – INSTALLING DRIVE ROLLS ON A 4-ROLL FEEDER
CLAMPING
COLLAR
DRIVE
ROLL
HALVES
SPACER (IF
REQUIRED)
OUTPUT
SHAFT
KEY
LARGE
RADIUS
GUIDE TUBE DETAIL
OUTGOING
GUIDE TUBE
DRIVE
ROLL
OUTGOING
GUIDE TUBE
INSERT
MIDDLE
GUIDE
TUBE
IDLE
ROLL
SMALL
RADIUS
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B-14
B-14
OPERATION
FIGURE B.7a (Threaded Locking Collar)
WIRE LOADING
ADAPTER
2
IN. O.D. SPINDLE
Loading a 22 to 30 Lb. (10 to 14 kg) Readi-Reel
Package Using the Molded Plastic K363-P
Readi-Reel Adapter:
RETAINING SPRING
BRAKE
HOLDING
PIN
The Spindle should be located in the LOWER mounting hole.
1) Depress the Release Bar on the Retaining Collar and
remove it from the spindle. NOTE: Earlier spindles
used a threaded collar. See Figure B.7a or B.7b.
GROOVES
2) Place the Adapter on the spindle.
READI-REEL
3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.
THREADED
LOCKING
COLLAR
INSIDE CAGE WIRES
FIGURE B.7b (Retaining Collar)
4) Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.
5) Position the Readi-Reel so that it will rotate in a
direction when feeding so as to be de-reeled from
the bottom of the coil.
6) Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
7) Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with the
grooves in the molded adapter.
8) Slide the cage all the way onto the adapter until the
retaining spring "pops up" fully.
WARNING
Check to be sure the Retaining Spring has fully
returned to the locking position and has SECURELY
locked the Readi-Reel Cage in place. Retaining Spring
must rest on the cage, not the welding electrode.
___________________________________________
9) To remove Readi-Reel from Adapter, depress
retaining spring tab with thumb while pulling the
Readi-Reel cage from the molded adapter with both
hands. Do not remove adapter from spindle.
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B-15
B-15
OPERATION
FEEDING ELECTRODE AND BRAKE ADJUSTMENT
LOADING A 10 TO 30 LB. (4.5 TO 14 KG)
SPOOL (12" DIAMETER) OR 13 - 14 LB.
(6 KG) INNERSHIELD COIL:
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.")
The Spindle should be located in the LOWER mounting hole.
(For 8" (200 mm) spools, a K468 spindle adapter must
first be slipped onto spindle.)
(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil
Adapter must be used).
3. Insert the free end through the incoming guide
tube.
4. Press the gun trigger or "cold inch" (if used) and
push the electrode into the drive roll.
1) Depress the Release Bar on the Retaining Collar
and remove it from the spindle. NOTE: Eariler spin-
dles used a threaded collar.
WARNING
2) Place the spool on the spindle making certain the
spindle brake pin enters one of the holes in the back
side of the spool. Be certain the wire comes off the
reel in a direction so as to de-reel from the bottom
of the coil.
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.
3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.
5. Inch the electrode through the gun.
LOADING A 50-60 LB. (22.7-27.2 KG.) COIL
USING K1504-1 COIL REEL:
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.
(For 50-60 lb Readi-Reels a K438 Readi Reel Adapter
must be used.)
The Spindle must be located in the UPPER mounting
hole.
1. With the K1504-1 Coil Reel mounted on to the 2"
(51 mm) spindle (or with reel laying flat on the floor)
loosen the spinner nut and remove the reel cover.
2. Before cutting the tie wires, place the coil of elec-
trode on the reel so it unwinds from the bottom as
the reel rotates.
3. Tighten the spinner nut against the reel cover much
as possible by hand using the reel cover spokes for
leverage. DO NOT hammer on the spinner nut
arms.
4. Cut and remove only the tie wire holding the free
end of the coil. Hook the free end around the rim of
the reel cover and secure it by wrapping it around.
Cut and remove the remaining tie wires.
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B-16
B-16
OPERATION
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.8.
LOADING 50 AND 60 LB. COILS ON 1”
SPINDLE (K299 or K303 Wire Reel Stand)
ADJUSTABLE WIRE REEL BRAKE
The mount for standard 50 and 60 pound electrode
coils includes a two position brake assembly.
Generally the brake should be a 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.
c) Put the cover plate on the reel so that the four arms
of the cover straddle and are in line with the spring
loaded arm of the reel.
4. Tighten the cover as much as possible by hand.
DO NOT hammer on the spinner nut arms.
To adjust the brake position, remove the wire reel. Pull
the cotter pin that holds the brake shoe to the arm,
move the shoe and replace the cotter pin. Do not bend
the cotter pin - it is held in place by a friction fit.
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.
LOADING A 50 OR 60 LB. COIL
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.
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.
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 with the later removal of the
coil tie wires. See Figure B.8.
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.
FIGURE B.8 – LOADING A 50 OR 60 LB. COIL
SPINNER
NUT
7. The mount for standard 50 and 60 pound electrode
coils includes a two-position brake assembly.
Generally the brake should be at the inner position
(nearest to the wire reel shaft) for wire feed speeds
below 400 in/min. It should be at the outer position
for the faster wire speeds often used when feeding
small diameter electrode.
COVER
PLATE
SLOTS
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.
CARDBOARD
COIL
LINER
COIL
TIE WIRE
REEL
SPRING
LOADED
ARM
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B-17
B-17
OPERATION
FEEDING ELECTRODE AND BRAKE ADJUSTMENT
LOADING AND FEEDING 13-14 LB.
INNERSHIELD COILS (K378 REEL
MOUNTING STAND)
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.
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.
3. Cut off the first inch. Insert the free end through
the incoming guide tube.
To load a 14 pound coil:
4. Insert the free end through the incoming guide
tube.
1. Remove the snap-on lid from the plastic canister.
2. Remove the center clamping nut and the cover
plate from the wire reel.
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.")
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.
6. Inch the electrode through the gun.
WARNING
USE THE "COLD" TRIGGER SWITCH POSITION, OR
"COLD INCH" OPTION WHEN LOADING. WHEN
INCHING WITH A "HOT" GUN TRIGGER, THE 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.
5. Place the coil onto the disc support.
6. Replace the front reel cover and center clamping
nut, keep the reel from turning and tighten the
clamping nut securely.
7. Thread the exposed end of the electrode into the
wire feeder until it touches the drive rolls. Actuate
the gun trigger, and feed the electrode through the
system.
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B-18
B-18
OPERATION
FIGURE B.9 – IDLE ROLL PRESSURE SETTING
FOR TWO-ROLL FEEDERS
IDLE ROLL PRESSURE SETTING
The idle roll pressure is set at the factory backed out
two turns from full pressure for 2-roll feeders, three
turns from full pressure for 4-roll feeders. This is an
approximate setting. For small wire sizes and alu-
minum wire, the optimum idle roll pressure varies with
type of wire, surface condition, lubrication and hard-
ness. The optimum idle roll setting can be determined
as follows:
2-ROLL WIRE FEEDERS
1. Press the end of the gun against a solid object that
is electrically isolated from the welder output and
press the gun trigger for several seconds.
2. If the wire "birdnests," jams or breaks at the drive
roll, the idle roll pressure is too great. Back the
pressure setting out 1/2 turn, run new wire through
the gun, and repeat step 1. See Figure B.9.
3. If the only result is drive roll slippage, loosen the
gun cable clamping screw in the gearbox conduc-
tor block and pull the gun cable forward about six
inches. There should be a slight waviness in the
exposed wire. If there is no waviness, the pressure
is too low. Increase the pressure setting 1/4 turn,
lock the gun cable in place and repeat steps 1 and 2.
PRESSURE
ADJUSTMENT
KNOB
4-ROLL WIRE FEEDERS
1. Release the incoming idle roll and perform the
pressure setting procedure for two-roll wire feeders
to set outgoing idle roll pressure.
2. After the outgoing pressure is set, determine how
many turns away from full pressure the setting is.
3. Set both idle roll tensions to this setting. Engage
both idle rolls before welding. For most applica-
tions, best wire feeding will occur when both idle
roll pressures are set the same.
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B-19
B-19
OPERATION
PULSE POWER 500, DC650 PRO, V300
MAKING A TEST WELD AND
Refer to each machine Instruction Manual. The LN-9
GMA requires the K442-1 Pulse Power Filter Kit. (See
the Accessories section of this manual.)
ADJUSTING LN-9 GMA RESPONSE
AND STARTING CHARACTERISTICS
ADJUST THE POWER SOURCE
ADJUST THE LN-9 GMA CONTROLS
DC-250, DC-400, or DC-600
1. Set the "Electrode Polarity" switch to same polarity
as the electrode lead.
1. Connect electrode lead to terminal of desired
polarity.
2. Check that "Feed Direction" is set to forward.
3. Set the "Trigger Interlock" switch as desired.
2. Set toggle switch to same polarity as the electrode
cable connection.
4. Set the "Meter Reading" switch to "Wire Speed"
and adjust the "Wire Speed" rheostat so the meter
reads the desired wire feed speed.
3. Set toggle switch to "Output Control Remote."
4. Set mode switch to the desired position for the
process to be used.
5. 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.
CV-400, CV-500-I
1. Connect electrode lead to terminal of desired
polarity.
6. Load the LN-9 GMA with electrode.
2. Connect #21 control lead to the work polarity ter-
minal (+21 or -21), at the terminal strip, matching
the same polarity as the work cable connection.
3. Set toggle switch to "Output Control Remote."
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B-20
B-20
OPERATION
START VOLTAGE TRIM
VOLTAGE CONTROL RESPONSE
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 GMA SET level. This gen-
erally gives good starting for steel cored and MIG
The LN-9 GMA is provided with selectable voltage con-
trol 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 GMA
Voltage Board.
To change the voltage control response:
a) Turn OFF the control power to the LN-9 GMA at the
power source.
2
2
processes using CO 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 lowering the start voltage trim as fol-
lows:
b) Remove the screws holding the control section
cover in place and swing open.
c) Position the jumper plugs on the Voltage Board
according to the appropriate power source con-
nection diagram.
a) Turn off the control power to the LN-9 GMA at the
power source.
d) Reassemble.
b) Remove the screws holding the control section
cover in place and swing it open.
c) On the voltage board, locate trimmer R41 (below
R40 next to the 1/8 amp fuse) and labeled START.
STARTING CHARACTERISTICS
SELECT ACCELERATION
d) 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).
The LN-9 GMA models can provide optimum starting
for different processes. The wire feeder is designed
to start with two different speeds of controlled acceler-
ation. As shipped, it is connected for fast acceleration,
which is the best for most open arc procedures.
However, the slower acceleration may be more desir-
able for 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 GMA models as follows:
NOTE: If the start trim is set too low, stubbing may
occur at start, requiring increasing the START
trimmer by turning the slot CW (in the direc-
tion of the labeled arrow).
e) Re-assemble.
RUN-IN FEATURE
a) Turn OFF the control power to the LN-9 GMA at the
power source.
On new machines (above code 10350) a “Run-in” trim-
mer, labeled “RUN-IN,” is provided on the new L10068-
1 Control PC board.
b) Remove the screws holding the control section
cover in place and swing it open.
This trimmer can be used to set the run-in wire feed
speed as a percentage of the weld speed. When the
trimmer is turned fully counterclockwise, the run-in
speed is about 5% of the weld speed. When the trim-
mer is turned fully clockwise, the run-in speed is equal
to the weld speed. To increase the run-in speed, turn
the trimmer clockwise; and to decrease the run-in
speed, turn the trimmer counterclockwise.
c) On machines having an L7253 Control PC board,
move the jumper plug on the PM Control PC board
from pin "F" to pin "S."
On machines having an L10068 Control PC board,
set the DIP switch on the PM Control PC board to
the “S” position.
d) Reassemble.
The factory setting of the run-in trimmer is about 20%.
The trimmer should be set lower if arc starting tends to
stub or blast, and it should be set higher if the arc tends
to flare up. When the Actual button is pressed, the
actual speed setting can be viewed on the digital speed
meter for two seconds after closing the trigger or the
cold inch switch.
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B-21
B-21
OPERATION
MAKING A WELD
SECURITY OF WELD PROCEDURE
SETTINGS
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.
There are two ways to prevent or limit unauthorized
readjustment of the LN-9 GMA voltage and wire feed
speed controls.
1. Once the procedure is set, the security panel of the
LN-9 GMA can be locked to prevent access to the
control knobs.
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.
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:
3. Be sure the welding power source and the shield-
ing gas supply are turned on.
4. Position the electrode over the joint. The end of
the electrode should be slightly over the joint.
a) Turn off the input power to the LN-9 GMA unit.
5. 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.
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.
6. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
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).
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.
e) Remount the control potentiometer with the
fiber spacer under the locknut, then close and
secure the control panel.
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.
f) Replace the felt seal around the fiber spacer
so that the #4 screw protrudes between the
fiber spacer and the felt seal.
2. Uncouple the gun conductor cable from the wire
drive unit.
g) Turn on the input power to the LN-9 GMA unit
and set the desired procedure by rotating the
potentiometer shaft.
3. Lay the cable out straight.
4. Using pliers to grip the wire, pull it out of the cable
from the connector end. Do not pull it from the gun
end.
h) Carefully replace the control knob so that the
#4 screw inserts into the center of the shorter
length channel on the back of the knob for
about 3% of the total range of control, or the
center of the longer length channel for about
15% of the total range of control.
5. Put the conductor cable back on the wire drive unit
after the electrode has been removed.
6. Load a new reel of wire and feed it through the
cable as described earlier in this section.
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 GMA Wire Feeder
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B-22
B-22
NOTES
LN-9 GMA Wire Feeder
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Section C-1
Section C-1
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories
Auxiliary Equipment Contacts.....................................................................................................C-2
Optional Equipment and Accessories.........................................................................................C-2
Power Input Cable Assemblies (K196, K595, K596)............................................................C-2
Wire Reel Stands and Mountings.........................................................................................C-2
Gun and Cable Assemblies..................................................................................................C-5
Wire Feeder Accessories .....................................................................................................C-5
Drive Roll and Guide Tube Kits............................................................................................C-9
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C-2
C-2
ACCESSORIES
AUXILIARY EQUIPMENT CONTACTS
OPTIONAL EQUIPMENT AND
ACCESSORIES
The power for 115 volt AC auxiliary equipment can be
obtained from the terminals inside the LN-9 GMA con-
trol 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.
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.
WARNING
TURN THE INPUT POWER TO THE POWER
SOURCE OFF AT THE DISCONNECT SWITCH
BEFORE PERFORMING THE FOLLOWING WORK.
• K196 Input Cable Assemblies - For power sources
with terminal strip wire feeder connections and stud
output terminals.
LN-9 GMA MODEL:
• K595 Input Cable Assemblies - For power sources
with MS-type (Amphenol) wire feeder receptacle and
stud output terminals.
Install 1/4” quick connect terminals to the leads from
the auxiliary equipment. Route the leads to the termi-
nals marked #32A and #7 which come through the rec-
tangular hole in the control section sheet metal near
the wire feed motor.
• K596 Input Cable Assemblies - For power sources
with MS-type (Amphenol) wire feeder receptacle and
Twist-Mate™ output connectors.
LN-9F GMA 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.
WIRE REEL STANDS AND MOUNTINGS
50-60 LB. WIRE REEL MOUNTING STAND (K303)
NOTES:
The assembly includes a framework to which is
attached the 50-60 lb. wire reel, a mounting spindle, a
dust shield, a lift bail, and a cable clamp for fastening
the input cable assembly. It is easily mounted to the
basic wire feed unit by three bolts. The reel mounting
spindle is the pull knob type with a built-in brake.
1. The K418 and K419 burnback timer 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 accom-
plished 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 equip-
ment power requirements should not exceed 15
watts.
The brake pad is adjustable for proper braking at low
or high wire feed speeds.
50-60 LB. READI-REEL® MOUNTING STAND
(K445)
This alternate connection cannot be used with the
DC-250 or CV-400, 500-I Power Sources.
The assembly includes a framework to which is
attached a 2" O.D. spindle with adjustable brake and
50-60 lb. Readi-Reel Adapter. Includes a lift bail and
cable clamp for fastening the input cable assembly,
and easily mounts to the LN-9 GMA feeder. Does not
include dust shield.
2. If the LN-9 GMA gas solenoid valve is not required,
the gas solenoid terminals (#32A and #7A) may be
used in conjunction with the K418 GMATimer Kit to
obtain pre-weld and/or post-weld timing functions
for 115V AC auxiliary equipment. However, the
gas solenoid must be disconnected and the auxil-
iary equipment current draw must not exceed 1/4
ampere.
Can also be used for up to 60 lb. spools with 2" I.D.
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C-3
C-3
ACCESSORIES
ATTACHING THE WIRE REEL STANDS
READI-REEL ADAPTERS
The mounting hardware for mounting the stands is
included with the LN-9 GMA. Screws and washers are
inserted in their respective mounting holes. To con-
nect:
K363-P Adapts Lincoln Readi-Reel coils of electrode
(30 lb. and 22 lb.) 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.
1. Remove the three 3/8 in. hex head bolts from the
back of the wire feed unit.
K438 Adapts 50-60 lb. Lincoln Readi-Reel coils to a
K162-H spindle, or similar 2 inch spindle suitable for 60 lb.
spools. Two-piece construction made from a durable
flame retardant molded plastic. Designed for minimum
loading downtime, the coils easily load with inside adapter
half on spindle. Four twist latches lock adapter halves
together. Included with K445 50-60 lb. Readi-Reel stand.
2. Place the wire reel mounting stand mounting
bracket in position against the back of the wire feed
unit.
3. Replace and tighten the hex head bolts. The long
screw and plain washer go into the top hole.
WIRE REEL DOOR KIT
60 LB. (27.2 KG) COIL ADAPTER (K1504-1)
Mounts to K303 or to K445 equipped with an S14543
dust shield housing kit, to completely enclose wire
reels against extremely dusty and dirty environments.
Includes a hinged door and sliding bottom seal. Install
the door according to instructions included with the kit.
Permits 50-60 lb. (22.7-27.2 Kg) coils to be mounted to
a 2" (51mm) spindle.
SMALL MOUNTING STAND FOR READI-REEL
COILS OR 2" I.D. SPOOLS (K377)
(30 Lb. Maximum Capacity)
SPINDLE FOR READI-REELS AND 2" I.D. SPOOLS
(K162-H*)
(60 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 lb. spools with a 2 " I.D., a 12" max. O.D.,
and a 4 " width. For spools with an 8" O.D., a K468
Spindle Adapter is available.
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.
14 lb. lnnershield coils can be mounted to the spindle
using the K435 Adapter. The spindle has an easily
adjustable braking system.
When used with Readi-Reels, a Readi-Reel Adapter is
required.
When used with 8" O.D. spools, a K468 Spindle
Adapter is available.
SMALL MOUNTING STAND FOR 13-14 LB. INNER-
SHIELD COILS (K378)
14 Lb. lnnershield coils can be mounted to the spindle
using the K435 Adapter.
This assembly includes the same smaller frame as
used in the K377 and a fully enclosed canister system
for de-reeling of the 14 pound coil. This system has a
fixed brake for the 14 pound coil.
* 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 lb (27.2 kg) – M15241 Mounting instructions
50-60 LB. WIRE REEL ASSEMBLY FOR
CUSTOMER MOUNTING (K299)
This assembly is available only when ordering either
the LN-9F GMA 2-Roll or 4-Roll model. It includes a
50-60 lb. wire reel, spindle shaft, adjustable brake,
insulation and mounting hardware.
CAUTION
DO NOT USE COILS OR SPOOLS HEAVIER THAN
30 LBS. ON THE ORIGINAL K162 SPINDLE.
Install the assembly according to instructions included
with it.
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C-4
C-4
ACCESSORIES
UNIVERSAL WIRE REEL STAND (K1524-1)
Includes a 2" (51mm) O.D. Spindle with adjustable
brake and two locations for mounting the spindle to
allow for the mounting of 50 - 60lb, 10 - 30 lb, 13 - 14lb,
and 8" O.D. coils with proper spindle adapters. (See
OPERATION section) Capable of being mounted on
the top of a suitable power source or surface without
the need for any other mounting kit. Optional features
available for this stand include:
• K1555-1 insulated lift bale
• K1556-1 caster kit
• K1557-1 swivel platform.
K1551-1 Insulated Lift Bale: Provides a bolt on lift
bale with an electrically insulated lift hook.
K1556-1 Caster Kit: Comes with 4 light duty 2" O.D.
casters which mount in place of the rubber feet on the
wire stand. Use in light duty applications where porta-
bility is required. Can be used in combination with the
K1557-1 swivel platform.
K1557-1 Swivel Platform: Allows for the mounting of
the wire feeder reel stand assembly on top of a suitable
power source if the need for the wire feeder reel stand
assembly to swivel is desired. Also has mounting
holes in the base feet for mounting to any surface that
it can be fastened to. Comes with a rotating tool tray
to hold gun tips, guide tubes, drive rolls, etc. Will work
in combination with the K1556-1 caster kit.
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C-5
C-5
ACCESSORIES
GUN AND CABLE ASSEMBLIES
A variety of standard Lincoln and Magnum gun and
cable assemblies are available for the LN-9 GMA in
10 ft., 12 ft. and 15 ft. cable lengths. Choose the gun
and cable assembly to suit the LN-9 GMA welding
application and wire size. See Table C-1.
TABLE C.1 – LN-9 GMA GUN AND CABLE ASSEMBLIES
60% Duty
Rating
Process
Model
Electrode
Gas Metal Arc (GMA)
K426
.035-.052” (0.9-1.3 mm) solid
.045-5⁄64” (1.1-2.0 mm) cored
350 amps
350 amps
K427
.045-1⁄16” (1.1-1.6 mm) solid
⁄
500 amps
500 amps
1
16-5⁄64” (1.6-2.0 mm) cored
Magnum K470(1)
Magnum K471(1)
Magnum K478(2)
Magnum K479(2)
.035-1⁄16” (0.9-1.6 mm) solid
.035-5⁄64” (0.9-2.0 mm) cored
300 amps
300 amps
.035-1⁄16” (0.9-1.6 mm) solid
.035-5⁄64” (0.9-2.0 mm) cored
400 amps
400 amps
.035-1⁄16” (0.9-1.6 mm) solid
.035-5⁄64” (0.9-2.0 mm) cored
300 amps
300 amps
.035-1⁄16” (0.9-1.6 mm) solid
0.35-5⁄64” (0.9-2.0 mm) cored
400 amps
400 amps
Innershield®
K126
.068-5⁄64” (1.7-2.0 mm) Innershield
350 amps
450 amps
350 amps
500 amps
250 amps
500 amps
5
K115
⁄
64” (2.0 mm) lnnershield
K206(3)
K289(3)
K309(3)
K112
.068-5⁄64” (1.7-2.0 mm) Innershield
5
⁄
64” (2.0 mm) lnnershield
.068-5⁄64” (1.7-2.0 mm) lnnershield
1
Submerged Arc
⁄
16” (1.6 mm) Solid
(1)
(2)
(3)
K466-1 connector kit required.
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.
WIRE FEEDER ACCESSORIES
BURNBACK TIMER KIT (K419)
Install the kit according to the M15060 instructions
included with the kit.
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
(0.023-1/16") diameter wire at high wire feed speeds.
Also includes a cold inch switch. (Can be installed
only in GMA models.)
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C-6
C-6
ACCESSORIES
GMA TIMER KIT (K418)
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.
Provides the following functions:
1. Preflow Control - Provides flow of shielding gas to
the work before the arc is established. The sole-
noid valve is energized immediately when the gun
trigger is closed but the time delay before the wire
feeder is energized is adjustable from 0 to 1.5
seconds.
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.
2. Postflow Control - Provides flow of shielding gas
to the work after welding is stopped. Delay of the
shut off of the solenoid valve after the gun trigger
is released is adjustable from 0.5 to 4.5 seconds.
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 GMA may not be used with
an LN-7 or LN-8, although two LN-9 GMAs may be
used together.
3. Burnback Control - Provides a precise time delay
that allows the wire to be burned off at the end of
the weld. The delay is adjustable for optimum
burnback depending on wire size, processes, pro-
cedure, etc.
4. Purge - Cold Inch Switch - One momentary posi-
tion energizes the gas solenoid valve but not the
wire feeder or power source. The other momen-
tary position energizes the wire feeder but not the
power source or solenoid valve. For GMA models
only.
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 GMA 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 electrical 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.
Install the kit according to the M15059 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.
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)
Install the kit according to instructions included.
Required for any LN-9 GMA to be used with a Pulse
Power 500, DC650 Pro, or Invertec V300 power
source. Includes a Filter Board and connection har-
ness, easily installed in the control section and plugged
into the Voltage Board. The plug must be disconnect-
ed for use with other standard power sources.
DUAL PROCESS KIT (K318) - With Electrode
Polarity Change Capability
Functions essentially the same as the K317 except that
the kit includes two contactors to provide different
polarities on the two wire feeders. When connected in
this manner and one trigger is pressed, the other elec-
Install the kit according to instructions included.
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C-7
C-7
ACCESSORIES
SWIVEL PLATFORM (K178-1)
K320 FLUX TANK LOADING
For all LN-9 GMA 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.
Either turn off the incoming air line or remove the quick
disconnect if one has been installed. Slightly loosen
the tank cap and let the air in the tank escape through
the holes in the side of the cap. After pressure has
been released, remove the cap from the tank. Using
the funnel provided, put 100 pounds of flux into the
tank. It is very important that only new or properly
reclaimed flux be put in the tank. Coarse particles
and/or magnetic particles will stop the flux feeding
process. New Lincoln flux is properly screened at the
factory. All reclaimed flux must be separately screened
through a vibrated screen having 0.065 - 0.075 open-
ings and be put through a magnetic separator. The
K310 vibrated Flux Screen and a K58 Magnetic
Separator are available for this purpose. The screen in
the funnel supplied with the tank has much larger
openings, and its only purpose is to keep paper and
slag out of the tank. Screw the tank cap back on and
tighten it hand tight. Reconnect the incoming air line to
the tank.
Bolt the platform to the lift bail according to instructions
supplied with the platform (M16260).
UNDERCARRIAGE (K163)
For all LN-9 GMA 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 GMA to be tilted back and wheeled like
a two-wheel truck.
CONTINUOUS FLUX FEED TANK (K320)
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.
The K320 is available to permit the LN-9 GMA to be
used for submerged arc welding using the K112 sub-
merged arc gun and cable. Requires a supply of com-
pressed air at 60 to 120 psi with a flow of 1.5 cubic feet
per minute.
K310 FLUX SCREEN
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.
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.
Install the tank according to instructions included with
the K320 kit.
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.
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C-8
C-8
ACCESSORIES
K58 MAGNETIC SEPARATOR
The K58 is a permanent magnet type separator
designed to fit the top of the standard fill funnel of the
continuous flux feed system.
WARNING
WHEN USING COMPRESSED AIR BE CAREFUL TO
PROTECT YOURSELF AND OTHERS IN THE AREA
FROM FLYING PARTICLES.
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.
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.
Fit the magnetic separator into the funnel or hopper.
Pour the flux to be reclaimed into the top pan of the
separator. The separator is designed so that the flux
flows around three permanent magnets. The magnets
remove all magnetic particles. When the magnets
become covered with their full load, they automatically
stop the flux flow. When the flux flow stops, remove the
separator from the funnel or hopper. Turn it over and
open the panel that covers the magnets. Remove the
magnetic particles by brushing or by using an air blast.
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C-9
C-9
ACCESSORIES
TABLE C.2 – DRIVE ROLL AND GUIDE TUBE KITS
Kit
Wire Size
Solid Steel Electrode
2-Roll
4-Roll
0.023” - 0.025”
(0.6 mm)
KP653 - 025S
KP653 - 030S
KP653 - 035S
KP653 - 052S
KP653 - 1/16
___________
___________
___________
KP655 - 025S
KP655 - 030S
KP655 - 035S
KP655 - 052S
KP655 - 1/16
KP655 - 3/32
KP655 - 3/32
KP655 - 3/32
0.030”
0.035”
(0.8 mm)
(0.9 - 1.0 mm)
0.045” and 0.052” (1.2 - 1.4 mm)
0.062”
0.068”
5/64”
(1.4 - 1.6 mm)
(1.7 mm)
(2.0 mm)
3/32”
(2.4 mm)
Cored Electrode
(0.9 - 1.0 mm)
0.035”
KP653 - 035C
KP653 - 052C
KP653 - 1/16
KP653 - 3/32
KP653 - 3/32
KP653 - 3/32
KP655 - 035C
KP655 - 052C
KP655 - 1/16
KP655 - 3/32
KP655 - 3/32
KP655 - 3/32
0.045 and 0.052” (1.2 - 1.4 mm)
0.062
0.068
5/64”
3/32”
(1.4 - 1.6 mm)
(1.7 mm)
(2.0 mm)
(2.4 mm)
Aluminum Electrode
0.035”
3/64”
1/16”
(0.9 - 1.0 mm)
(1.2 mm)
KP654 - 035A
KP654 - 3/64A
KP654 - 1/16A
KP656 - 035A
KP656 - 3/64A
KP656 - 1/16A
(1.6 mm)
LN-9 GMA Wire Feeder
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C-10
C-10
NOTES
LN-9 GMA Wire Feeder
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Section D-1
Section D-1
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Maintenance
Routine Maintenance..................................................................................................................D-2
Drive Rolls and Guide Tubes ...............................................................................................D-2
Wire Reel Mounting - 50 and 60 lb. Coils ............................................................................D-2
Wire Reel Mounting Readi-Reels and Spools......................................................................D-2
Periodic Maintenance .................................................................................................................D-2
Control Box...........................................................................................................................D-2
Wire Drive Motor and Gear Box...........................................................................................D-2
Gun and Cable Maintenance......................................................................................................D-3
Proper Speed Sensor Module Mounting..............................................................................D-3
Gun Cable Connector Requirements ...................................................................................D-4
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D-2
D-2
MAINTENANCE
WIRE REEL MOUNTING - 50 AND 60 LB.
COILS WITH 1” SPINDLE
SAFETY PRECAUTIONS
WARNING
To prolong the life of the reel shaft, periodically coat it
with a thin layer of grease. No maintenance of the two-
position adjustable brake is needed. If the brake shoe
wears through to metal, replace the brake assembly.
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this maintenance.
WIRE REEL MOUNTING - READI-REELS
AND 10 THROUGH 44 LB. SPOOLS AND
50 AND 60 LB. COILS WITH K1504-1
ADAPTER
• Turn the input supply power
OFF at the disconnect switch or
fuse box before working on this
equipment.
• Do not touch electrically hot parts.
No routine maintenance required. Do not lubricate the
2" spindle.
ROUTINE MAINTENANCE
PERIODIC MAINTENANCE
DRIVE ROLLS AND GUIDE TUBES
CONTROL BOX
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.
Every six months open and inspect the control section.
The accumulated dirt should be gently blown off all of
the electrical components. 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.
The drive rolls for 0.035 and 0.052 cored electrode and
1/16 through 7/64 electrode have a double set of teeth
so they can be reversed for additional life. Drive rolls
for 0.023 through 0.052 solid electrodes and aluminum
sizes have no teeth, but use two grooves so they also
can be reversed for additional life.
WIRE DRIVE MOTOR AND GEAR BOX
See the Operation Section for drive roll installation
instructions.
Every year examine the gearbox. Paint the gear teeth
with molydisulfide-filled grease (Lincoln specification
E2322). Do not use a graphite grease.
See Table C.2 in the Accessories section for drive roll
and guide tube kits.
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.
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D-3
D-3
MAINTENANCE
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.
FIGURE D.1 – SPEED SENSOR MODULE LOCATION
PROPER SPEED SENSOR MODULE
MOUNTING
The LN-9 GMA Speed Sensor Module is a three lead
Hall-Effect switch device encased in an externally
threaded housing. It is screwed into a mounting plate
on the motor side of the wire drive gearbox. See
Figure D.1.
Proper positioning of this module is critical to operation
of the LN-9 GMA wire feed speed control. If the device
is not screwed in far enough, the LN-9 GMA motor
speed could be unstable or run at full speed with no
control. If screwed in too far it will rub a moving part
inside the gearbox.
The module is properly mounted to the gearbox as
shipped from the factory. If the device is ever removed
or replaced, proper mounting technique is as follows:
1. Be sure all power to the LN-9 GMA is shut off at the
power source.
2. Check that the module mounting plate is screwed
securely to the side of the gearbox and seated
flush against the top surface after being tightened.
3. Gently screw the module into the mounting plate
until it just touches and stops against the rotating
part inside the gearbox.
4. Back the module out 1/2 turn, then snug the mod-
ule locknut without rotating the module position.
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D-4
D-4
MAINTENANCE
GUN CABLE CONNECTOR REQUIRE-
MENTS TO PERMIT PROPER CONNEC-
TION TO LINCOLN LN-9 GMA AND LN-9F
GMA WIRE FEEDER
“A” Diameter Hole
to be Concentric to
.749/.747 (19.0/18.9)
Wire Size
in. (mm)
Diameter Within .008 (.20) F.I.M.
.125 [1/8” (3.2 mm) Drill]
.078 [5/64” (2.0 mm) Drill]
.062 [1/16” (1.6 mm) Drill]
.055 [(1.4 mm) #54 Drill]
0.68-5/64 (1.7-2.0)
1/16-0.062 (1.6)
The following Figures D.2 and D.3 should serve as a
guide to determine if a particular gun or switch can be
connected to the LN-9 GMA and LN-9F GMA.
.045 & .052 (1.1 & 1.3)
.023-.035 (0.6-0.9)
FIGURE D.2 – LN-9 GMA CONNECTORS
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
LN-9 CONNECTOR FOR 1/16-5/64” (1.6-2.0 MM) WIRE)
LN-9 CABLE CONNECTOR FOR .023-.052” (0.6-1.3 mm)
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.
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Section E-1
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation .............................................................................................................Section E
General Description...............................................................................................................E-2
Power Input Circuits...............................................................................................................E-2
Trigger and Shutdown Circuit ................................................................................................E-3
Arc Voltage, Wire Speed Control and Metering.....................................................................E-4
Printed Circuit Board Functions.............................................................................................E-5
VOLTAGE CONTROL
WORK VOLTAGE SENSING
ELECTRODE VOLTAGE SENSING
GEAR
BOX
POLARITY
SWITCH
WIRE
SPEED
CONTROL
WIRE
FEED
MOTOR
HALL EFFECT
DEVICE
POWER SOURCE OUTPUT TRIGGER (#2 )
WIRE SPEED CONTROL
+ 15VDC
TRIGGER
BOARD
T2
TRIGGER
CONNECTOR
GAS
SOLENOID
CIRCUIT
BREAKER
C
O
N
T
24VAC
B
O
A
R
D
TRIGGER SIGNAL
F
INPUT
U
S
E
CONNECTOR
R
+ 15VDC
R1
P
O
B
O
A
R
D
O
L
W
E
S
H
U
T
R
D
O
W
N
TO
CONTROL
BOARD
R
E
F
E
R
E
N
C
E
V
O
L
T1
TO
VOLTAGE
BOARD
T
A
G
E
METER
10VAC
28VAC
BOARD
VOLTAGE
CONTROL
VOLTS
SPEED
SWITCH
VOLTAGE
BOARD
TRIGGER SIGNAL
GROUND
LEAD
PROTECTOR
FIGURE E.1 – LN-9 GMA BLOCK LOGIC DIAGRAM
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E-2
E-2
THEORY OF OPERATION
GENERAL DESCRIPTION
The LN-9 GMA 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
regulated to the preset condition. When the LN-9 GMA is
coupled to an appropriate Lincoln constant voltage
power source, the actual arc voltage is also regulated to
match the preset voltage. The LN-9 GMA models also
incorporate a factory installed gas solenoid valve, high
speed wire drive, adjustable run-in and acceleration
speeds, and a two-step/four-step trigger interlock system.
FIGURE E.2 – POWER INPUT CIRCUITS
VOLTAGE CONTROL
WORK VOLTAGE SENSING
ELECTRODE VOLTAGE SENSING
GEAR
BOX
POLARITY
SWITCH
WIRE
SPEED
CONTROL
WIRE
FEED
MOTOR
HALL EFFECT
DEVICE
POWER SOURCE OUTPUT TRIGGER (#2 )
WIRE SPEED CONTROL
+ 15VDC
TRIGGER
BOARD
T2
TRIGGER
CONNECTOR
GAS
SOLENOID
CIRCUIT
BREAKER
C
O
N
T
24VAC
B
O
A
R
D
TRIGGER SIGNAL
F
INPUT
U
S
E
CONNECTOR
R
+ 15VDC
R1
P
O
B
O
A
R
D
O
L
W
E
S
H
U
T
R
D
O
W
N
TO
CONTROL
BOARD
R
E
F
E
R
E
N
C
E
V
O
L
T1
TO
VOLTAGE
BOARD
T
A
G
E
METER
10VAC
28VAC
BOARD
VOLTAGE
CONTROL
VOLTS
SPEED
SWITCH
VOLTAGE
BOARD
TRIGGER SIGNAL
GROUND
LEAD
PROTECTOR
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.
The 28VAC produced by the T1 transformer secondary
is applied to the power board. There it is rectified and
regulated to 15VDC. This 15VDC powers the electron-
ics on the power, control, and voltage boards. The
10VAC secondary voltage is rectified, regulated, and
utilized by the meter board.
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.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – TRIGGER AND SHUTDOWN CIRCUIT
VOLTAGE CONTROL
WORK VOLTAGE SENSING
ELECTRODE VOLTAGE SENSING
GEAR
BOX
POLARITY
SWITCH
WIRE
SPEED
CONTROL
WIRE
FEED
MOTOR
HALL EFFECT
DEVICE
POWER SOURCE OUTPUT TRIGGER (#2 )
WIRE SPEED CONTROL
+ 15VDC
TRIGGER
BOARD
T2
TRIGGER
CONNECTOR
GAS
SOLENOID
CIRCUIT
BREAKER
C
O
N
T
24VAC
B
O
A
R
D
TRIGGER SIGNAL
F
INPUT
U
S
E
CONNECTOR
R
+ 15VDC
R1
P
O
B
O
A
R
D
O
L
W
E
S
H
U
T
R
D
O
W
N
TO
CONTROL
BOARD
R
E
F
E
R
E
N
C
E
V
O
L
T1
TO
VOLTAGE
BOARD
T
A
G
E
METER
10VAC
28VAC
BOARD
VOLTAGE
CONTROL
VOLTS
SPEED
SWITCH
VOLTAGE
BOARD
TRIGGER SIGNAL
GROUND
LEAD
PROTECTOR
TRIGGER AND SHUTDOWN
CIRCUIT
When the gun trigger switch is activated (closed), the
trigger board completes the trigger signal path. This
energizes the CR1 relay located on the power board.
The CR1 relay activates the wire drive motor and the
#2 and #4 circuit, which then activates the Lincoln
welding power source. The CR1 relay is also used to
energize the gas solenoid.
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 con-
tacts would "open," and the trigger signal path would
be interrupted. This would cause the wire feeder to
"shut down" until the gun trigger is released or the
ground fault protector is reset.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 – ARC VOLTAGE, WIRE SPEED CONTROL AND METERING
VOLTAGE CONTROL
WORK VOLTAGE SENSING
ELECTRODE VOLTAGE SENSING
GEAR
POLARITY
SWITCH
BOX
WIRE
SPEED
WIRE
FEED
CONTROL
MOTOR
HALL EFFECT
DEVICE
POWER SOURCE OUTPUT TRIGGER (#2 )
WIRE SPEED CONTROL
+ 15VDC
TRIGGER
T2
BOARD
TRIGGER
CONNECTOR
GAS
SOLENOID
CIRCUIT
BREAKER
C
O
N
T
24VAC
B
O
A
TRIGGER SIGNAL
F
U
S
E
INPUT
CONNECTOR
R
D
R
+ 15VDC
R1
P
O
B
O
A
R
D
O
L
W
E
S
H
U
T
R
D
O
W
N
TO
CONTROL
BOARD
R
E
F
E
R
E
N
C
E
V
O
L
T1
TO
VOLTAGE
BOARD
T
A
G
E
METER
10VAC
28VAC
BOARD
VOLTAGE
CONTROL
VOLTS
SPEED
SWITCH
VOLTAGE
BOARD
TRIGGER SIGNAL
GROUND
LEAD
PROTECTOR
ARC VOLTAGE, WIRE SPEED
CONTROL AND METERING
The hall effect device sends motor speed information
to the control board. This feedback voltage is com-
pared to the reference command preset by the wire
speed control. The control board determines what cor-
rection is needed and sends the appropriate signal to
the power board. The power board then adjusts the
motor armature voltage to comply with the command
from the control board.
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
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.
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.
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E-5
E-5
THEORY OF OPERATION
VOLTAGE BOARD
PRINTED CIRCUIT BOARD
FUNCTIONS
The voltage board compares the SET voltage values to
the actual voltage values and makes any necessary
correction by sending the appropriate signal to the
Lincoln CV power source. If for any reason the arc
voltage cannot be controlled to the SET voltage, the
voltage board interrupts the LN-9 GMA trigger path,
and the unit shuts down. The response (Fast or Slow)
to changes in arc voltage is also controlled by the volt-
age board, as well as the SET and actual arc voltage
signals for the digital meter circuitry.
POWER BOARD
The input power (115VAC) is applied to the power
board, and from that the power board develops the
variable DC armature voltage for the permanent mag-
net wire drive motor. The SCR circuitry, used to con-
trol the motor armature voltage, is also contained on
the power board.
The relay used to activate motor armature voltage, the
gas solenoid, and power source output (#2 and #4) is
housed on the power board.
TRIGGER 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 GMA control circuitry, are
included in the power board design.
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.
CONTROL BOARD
HALL EFFECT DEVICE
The control board provides a reference voltage to the
wire speed control and voltage control potentiometers,
allowing SET (pre-set) signals to be produced.
A square wave frequency signal, proportional to motor
speed, is generated by the hall effect device and sent
to the control board.
The control board also powers and processes the feed-
back signals from the hall effect device. 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.
METER BOARD
The meter board contains signal scaling and power
supply circuitry for the digital meter.
Acceleration and run-in rates for wire feed speed are
controlled by the control board as well as the SET speed
and actual speed signals for the digital meter circuitry
.
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E-6
E-6
NOTES
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Section F-1
Section F-1
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section ................................................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
PC Board Troubleshooting Procedures .................................................................................F-3
Troubleshooting Guide................................................................................................F-4 - F-23
Test Procedures
T1 Transformer Test ......................................................................................................F-24
T2 Transformer Test ......................................................................................................F-27
Wire Drive Motor Test....................................................................................................F-31
Hall Effect Test and Alignment.......................................................................................F-34
Voltmeter Accuracy Test................................................................................................F-38
Meter Circuit Accuracy Test...........................................................................................F-41
Wire Speed Accuracy Test ............................................................................................F-46
Out of Voltage Range Shut Down Test .........................................................................F-48
General Power Supply Tests.........................................................................................F-51
Replacement Procedures
Digital Meter and Meter PC Board Removal and Replacement ...................................F-54
Reed Switch (CR2) Removal and Replacement...........................................................F-57
T1 Transformer Removal and Replacement .................................................................F-59
Drive Motor Removal and Replacement .......................................................................F-64
Retest After Repair...............................................................................................................F-69
NOTE
This Troubleshooting section is specific to the
LN-9 GMA. However, much of this information
may apply to the LN-9 F GMA model with slight
adaptation. Refer to LN-9F GMA Wiring Diagram.
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc-
tions. Simply follow the three-step procedure list-
ed below.
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.
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, Welding Problems, Meter Problems,
and Starting Problems.
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.
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.
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 for electrical troubleshooting assistance before
you proceed. Call 216-383-2531 or 1-800-833-9353.
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
• 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.
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.
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
er failure analysis.
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:
4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
1. Determine to the best of your technical ability that
the PC board is the most likely component causing
the failure symptom.
NOTE: Allow the machine to heat up so that all electri-
cal components can reach their operating tem-
perature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and substitute
it with the original PC board to recreate the original
problem.
3. If the problem persists, replace the suspect PC
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:
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.
PC Board can be damaged by
static electricity.
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.
• Remove your body’s static charge
before opening the static-shielding
bag. Wear an anti-static wrist
strap. For safety, use a 1 Meg
ohm resistive cord connected to a
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
grounded part of the equipment
frame.
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
• 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.
NOTE: Following this procedure and writing on the
Workstations
warranty
report,
“INSTALLED
AND
SWITCHED PC BOARDS TO VERIFY PROB-
LEM,” will help avoid denial of legitimate PC
board warranty claims.
Reusable
Container
Do Not Destroy
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
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F-4
F-4
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS
No wire feed when gun trigger is 1. Make sure 115VAC is being 1. Check for loose or faulty lead
activated. The digital meter does
NOT light. The drive rolls do not
turn.
applied to the LN-9 GMA at the
input connector. Pin "C" is lead
#31 and pin "D" is lead #32.
connections between the input
connector, the T1 transformer,
and the power PC board.
2. Check the 3 amp circuit breaker. 2. The T1 transformer may be
Reset if tripped.
faulty. Perform the T1 Trans-
former Test.
3. The F101 4/10 amp slow blow
fuse, located on the power PC
board, may be blown.
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.
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F-5
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
No wire feed when gun trigger is 1. The Ground Lead Protector 1. The 1CR relay on the power PC
activated. The drive rolls do not
turn. The digital meter does light
but reads only SET voltage and
wire speed values.
may have tripped. Reset and
clear possible fault between
electrode circuit and feeder
frame.
board may be faulty. Check or
replace.
2. Check resistor R1. Normal
resistance is 2 ohms.
2. The gun trigger may be faulty.
3. Perform
the
Trigger
Transformer T2 Test.
4. Perform the Wire Drive Motor
Test.
5. The Trigger Board may be faulty.
6. If the wire drive motor is OK, the
power PC board or the control
board may be faulty.
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-6
F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS
The wire feed “coasts” when the 1. Make sure the gun trigger is not 1. The relay 1CR may be faulty.
gun trigger is released. “sticking.” Replace.
The gas solenoid does not activate 1. If a K418 GMA Timer Kit or a 1. With the gun trigger closed,
when the gun trigger is closed. The
wire feeds and arc voltage is pre-
sent.
K419 Burnback Timer Kit is
installed, disconnect it and
replace it with the jumper plug.
If the problem is resolved, the
K418 or K419 is faulty.
check for 115VAC at the power
PC board terminals #7A to
#32A.
a. If the 115VAC is present,
the solenoid may be faulty.
Replace.
b. If the 115VAC is NOT pre-
sent at terminals #7 and
#32, the relay CR1 on the
power PC board may be
faulty. Replace.
The gas solenoid stays open after 1. The gas solenoid may be stuck 1. With the gun trigger NOT
the gun trigger switch is released.
in the open position.
closed, check for 115VAC at the
power PC board terminals #7 to
#32A.
a. If the 115VAC is present,
the relay CR1 may be
defective.
b. If the 115VAC is NOT pre-
sent, the gas solenoid may
be defective.
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-7
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The wire feeds when the gun trig- 1. Make sure the interlock switch 1. The 1CR relay, located on the
ger is activated, but there is no arc
voltage.
is in a "Wire Hot" position.
power PC board, may be faulty.
Check or replace.
2. Check the welding cables for
loose or faulty connections.
2. If a burnback kit is installed,
remove and install the jumper
plug. If the problem is solved,
the burnback kit is faulty.
3. Put a jumper wire from #2 to #4
on the power source terminal
strip. (Machines with 14 pin
amphenols: pin C to pin D.) If 3. Check the #2 and #4 leads in
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.
the LN-9 GMA wiring harness
for loose or faulty connections.
See the Wiring Diagram.
4. Check the continuity of leads #2
and #4 through the control
cable. Replace if "open."
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-8
F-8
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS
The SET speed is adjustable and 1. Contact your local Lincoln 1. While the motor is running,
steady. The actual speed is uncon-
trollable. The meter displays the
actual speed correctly or reads
"EEE."
Authorized
Facility.
Field
Service
carefully unplug the 15 pin
molex plug from the control PC
board.
If the motor continues to run,
the power PC board may be
faulty. Replace.
If the motor stops, the control
PC board may be faulty.
Replace.
2. Perform the Wire Drive Motor
Test.
The SET speed is adjustable and 1. Check for loose or faulty con- 1. Perform the Hall Effect Module
steady. The actual speed reading
is incorrect and/or erratic.
nections on leads #510, #525,
and #555 between the hall
effect module and the control
PC board.
Alignment Procedure.
2. Perform the Hall Effect Feed-
back Test.
3. If the Hall Effect Feedback
Test is OK, the control 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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-9
F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The SET speed is erratic or not 1. Check for loose or faulty con- 1. Remove power to the LN-9
adjustable over entire range of con-
trol. The actual speed is also errat-
ic like the SET speed.
nections on leads #631, #632,
and #633 between the speed
control potentiometer (R2) and
the control PC board.
GMA and disconnect the plug to
the control PC board. Check
the resistance of the speed con-
trol potentiometer (R2). When
measured 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.
2. The control PC board may be
faulty. Replace.
The wire continues to feed with the 1. Disconnect the gun trigger cable. 1. Disconnect lead #530 from the
gun trigger open, and the wire is
electrically "hot." The interlock
switch is in the "OFF" position.
If the problem is resolved, the
gun trigger or cable is faulty.
Repair or replace.
trigger PC board. See the
Wiring Diagram. If the problem
is resolved, the trigger board is
faulty. Replace.
2. Relay 1CR may be stuck
closed. Check or replace.
3. 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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-10
F-10
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
TRIGGER INTERLOCK FUNCTION PROBLEMS
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
welding or gun trigger activation.
2CR is stuck closed.
sticking and associated leads
(#529 and #628) for shorts.
2. The power PC board may be
faulty. Replace.
With the interlock switch in the 1. Check leads #529 and #628 for 1. The 2CR reed switch may be
"ON" position, the wire feed stops
when the gun trigger is released.
loose or faulty connections
between the 2CR reed switch
and the power PC board.
faulty. Check to see if it closes
when welding.
2. Check the continuity (zero
ohms) of leads #529 and #628
from the 2CR reed switch to the
power PC board. Also check
continuity of leads #530 and
#522 from the power PC board
to the interlock switch. See the
Wiring Diagram.
3. Check the interlock switch for
proper operation.
4. 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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-11
F-11
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The SET voltage is erratic or not 1. Check for loose or faulty con- 1. Remove power to the LN-9
adjustable over the entire range of
control. The actual voltage is also
erratic like the SET voltage.
nections on leads #634, #635,
and #636 between the voltage
control potentiometer (R3) and
the voltage PC board.
GMA and disconnect Plug J9
from the voltage PC board.
Check the resistance of the volt-
age control potentiometer (R3).
When measured from the wiper
(lead #635) to lead #634, the
resistance should vary smoothly
from 0 to 10,000 ohms when the
shaft is rotated.
2. The voltage PC board may be
faulty. Replace.
The field fuse (F101), located on 1. Make sure the replacement fuse 1. Perform the T1 Transformer
the power PC board, repeatedly
fails.
is a 4/10 amp slow blow type
fuse.
Test.
2. Disconnect the meter PC board.
If the problem is resolved, the
meter PC board may be faulty.
3. 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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-12
F-12
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Circuit breaker (3 amp) repeatedly 1. Check or replace gun trigger 1. Disconnect lead #500 from the
trips when the gun trigger is acti-
vated.
and leads. Make sure the trig-
ger leads are not shorted to the
electrode or work cables.
trigger PC board. If the breaker
still trips when the gun trigger is
activated, the trigger PC board
may be faulty. Replace
2. Disconnect any accessory that
may be connected to terminals
#7 and #32A. See the Wiring
Diagram. If the problem is
resolved, the accessory may be
faulty. Replace.
3. Perform the Wire Drive Motor
Test.
4. The power PC board may be
faulty. Replace.
Circuit breaker (3 amp) trips when 1. Disconnect any kits that may be 1. Disconnect lead #620 from the
power is applied to the LN-9 GMA.
Gun trigger is NOT activated.
incorporated in the LN-9 GMA
(K418, K419, etc.). Be sure to
install any necessary jumper
plugs. If the problem is re-
solved, the fault may be in the
disconnected kit.
trigger PC board. See the
Wiring Diagram. If the problem
is resolved, the trigger PC
board may be faulty. Replace.
2. Perform the T2 Transformer
Test.
3. Check the harness leads #32A,
#31, and #531 for shorts or
grounds.
Diagram.
See the Wiring
4. 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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-13
F-13
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The 1/8 amp fuse on the voltage 1. Check to make sure the PC 1. Remove input power to the LN-
PC board repeatedly fails.
boards are NOT grounded to
the case of the LN-9 GMA.
This can happen due to metal-
lic wire shavings build-up.
9 GMA. Replace the 1/8 amp
fuse and switch the LN-9 GMA
polarity switch to the "NEG"
position.
Make a resistance check from
the following leads to the LN-9
GMA case grounding screw:
Leads # 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.
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-14
F-14
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The LN-9 GMA shuts down while 1. Make sure the power source 1. Perform the Out of Voltage
welding. Upon retriggering the
gun, the unit will weld again for a
period of time.
and wire feeder polarity switch-
es are set correctly for the
process being used.
Range Shutdown Test.
2. The control cable may be faulty.
Check or replace.
2. Make certain the voltage control
switch on the Lincoln CV power
source is set in the "Remote"
position.
3. The voltage PC board may be
faulty. Replace.
3. Make sure the #21 lead in the
control cable has continuity to
the work piece.
4. Check the 1/8 amp fuse on the
LN-9 GMA voltage PC board.
Replace if faulty.
5. Be sure the welding power
source is compatible with the
LN-9 GMA.
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-15
F-15
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
When the gun trigger is activated 1. Check or replace the gun cable. 1. If conditions are extremely dirty,
the drive rolls turn, but the wire will
not feed or wire feeding is rough.
It may be kinked, clogged, or
twisted.
install a wiper on the wire before
it enters the guide tube. Use a
piece of cloth saturated with
"Pyroil B."
2. Make certain the drive rolls and
guide tubes are correct for the
wire being used.
3. Check or replace the gun con-
tact tip.
4. The electrode wire may be rusty
or dirty. Replace if necessary.
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-16
F-16
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The welding arc is variable or 1. Make sure the welding parame- 1. Put the power source in
"hunting."
ters are correct for the welding
procedure being used.
"Machine Control" for voltage,
and check whether welding per-
formance improves. If the prob-
lem is resolved, check or
replace the control cable. Or,
the LN-9 GMA voltage PC board
may be faulty.
2. Check the welding cables for
loose or faulty connections.
3. The gun cable may be faulty.
Check or replace.
4. The gun contact tip may be 2. Perform the Wire Drive Motor
worn. Check or replace.
Test.
6. The welding power supply may
be faulty. Check or 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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-17
F-17
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Poor arc striking with sticking or 1. Make sure the welding parame- 1. Put the power source in
"blast offs." The weld bead may
also be ropey and display weld
porosity.
ters and techniques are correct
for the welding procedure being
used.
"Machine Control" and check
whether welding performance
improves. If the problem is
resolved, check or replace the
control cable. Or, the LN-9
GMA voltage PC board may be
faulty.
2. Check the welding cables for
loose or faulty connections.
3. The gun cable may be faulty.
Check or replace.
4. The gun contact tip may be
worn. Check or replace.
5. The welding power source may
be faulty. Check or replace.
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-18
F-18
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
METER FUNCTION PROBLEMS
The arc is unstable or oscillating.
1. Check the welding cables for 1. The LN-9 GMA voltage PC
loose or faulty connections.
board may be faulty. Replace.
2. Make sure the electrode and
gas (if used) are correct for the
process being used.
3. Put the Lincoln power source in
the “Machine Control” mode.
Jumper the “BYPASS” pins on
the LN-9 GMA voltage PC
board. Adjust the weld voltage
from the power source for the
process being used. If the prob-
lem is NOT resolved, the power
source may be faulty.
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-19
F-19
INSTALLATION
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
METER FUNCTION PROBLEMS
The SET and actual speed meter 1. Contact your local Lincoln 1. Perform the Hall Effect
readings match within a few IPM,
but both are in error.
Authorized
Facility.
Field
Service
Alignment Procedure.
2. Perform the Meter Circuit
Accuracy Test.
3. The control PC board may be
faulty. Replace.
SET speed and actual speed meter 1. Contact your local Lincoln 1. Check the Volts-Speed meter
readings do NOT match within a
few IPM. One or both readings
may be erratic.
Authorized
Facility.
Field
Service
selector switch and the associ-
ated wiring. See the Wiring
Diagram.
2. Check the SET-ACTUAL switch
and the associated wiring. See
the Wiring Diagram.
3. Perform the Hall Effect
Alignment Procedure.
4. Perform the Meter Circuit
Accuracy Test.
LN-9 GMA Wire Feeder
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F-20
F-20
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
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
while welding. However, both read-
ings are inaccurate.
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.
leads for continuity (zero ohms).
Lead #21 should have continu-
ity to the work piece, and #67
should have continuity to the
brass conductor block. See the
Wiring Diagram.
2. The control cable may be faulty. 2. Perform the Meter Circuit
Check or replace.
Accuracy Test.
3. The voltage PC board may be
faulty. Replace.
The actual volts reading does NOT 1. Make sure the shutdown 1. If the actual reading is the prob-
match the SET volts reading within
a few tenths of a volt while welding.
One reading may be erratic. The
LN-9 GMA does NOT shut off.
"BYPASS" pins are NOT
jumpered together on the LN-9
GMA voltage PC board.
lem, check the actual volts
switch and associated leads.
2. If the SET reading is the prob-
lem, check the set volts switch
and the associated leads.
2. Check the voltage sensing
leads for continuity (zero ohms).
Lead #21 should have continu-
ity to the work piece, and #67
should have continuity to the
NOTE: The Pulse Power Filter kit
may slow down the shutdown fea-
ture.
3. Check the Volts-Speed selector
switch and associated leads.
brass conductor block. See the 4. The voltage PC board may be
Wiring Diagram.
faulty. Replace.
3. Put the Lincoln power source in
the "Machine Control" mode.
Check to see if the power sup-
ply can be set for the arc volt-
age required for the process. If
not, the power supply may be
faulty.
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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-21
F-21
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
STARTING PROBLEMS
The output voltage is too low to 1. Check the welding cables for 1. Check the voltage control
start the weld.
loose or faulty connections.
potentiometer (R3) and the
associated leads.
Wiring Diagram.
See the
2. Put the Lincoln power source in
the "Machine Control" mode.
Jumper the "BYPASS" pins on 2. The voltage PC board may be
the LN-9 GMA voltage PC
board. Adjust the weld voltage
from the power source for the
process being used. If the cor-
rect voltage cannot be set, the
power source may be faulty.
faulty. Replace.
3. Check for correct control cable
connections to the power supply.
4. The control cable may be faulty.
Check or 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 GMA Wire Feeder
Download from Www.Somanuals.com. All Manuals Search And Download.
F-22
F-22
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
STARTING PROBLEMS
Voltage seems to be too high or the 1. Adjust the "start" trimmer on the 1. The LN-9 GMA voltage PC
arc flares at the start of weld.
Welding is good.
voltage PC board. It should be
only slightly higher than the weld
voltage. See Starting Charac-
teristics in the Operation section
of this manual.
board may be faulty. Replace.
2. Put the Lincoln power source in
the "Machine Control" mode.
Jumper the "BYPASS" pins on
the LN-9 GMA voltage PC
board. Adjust the weld voltage
from the power source for the
process being used. If the cor-
rect voltage cannot be set, the
power source may be faulty.
3. Check for correct control cable
connections to the power supply.
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 GMA Wire Feeder
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F-23
F-23
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
STARTING PROBLEMS
The arc voltage appears to rise too 1. Adjust the "start" trimmer on the 1. The voltage PC board may be
slowly or stubs or blasts at the start
of a weld. Once started the weld-
ing is good.
voltage PC board. It should be
slightly higher than the weld
voltage. See Starting Charac-
teristics in the Operation section
of this manual.
faulty. Replace.
NOTE: Pulse Power 500 operation
with a filter kit may exhibit these
symptoms.
3. Put the Lincoln power source in
the "Machine Control" mode.
Jumper the "BYPASS" pins on
the LN-9 GMA voltage PC
board. Adjust the weld voltage
from the power source for the
process being used. If the cor-
rect voltage cannot be set, the
power source may be faulty.
4. Check for correct control cable
connections to the power supply.
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.
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F-24
F-24
TROUBLESHOOTING & REPAIR
T1 TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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 functioning.
MATERIALS NEEDED
115VAC power supply
Phillips head screwdriver
Volt/ohmmeter (multimeter)
This procedure takes approximately 20 minutes to perform.
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F-25
F-25
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
1. Remove input power to the LN-9 GMA wire
feeder.
4. Apply power (115VAC) to the T1 transformer
primary leads #31 and #532. See Figure F.1
and the Wiring Diagram.
2. Using the phillips head screwdriver, remove
the screws holding the left side cover
assembly.
5. Using the volt-ohmmeter, check for 28VAC
at secondary leads #526 and #527. See
Figure F.1. Place the meter probes where
the leads attach to the power PC board ter-
minals.
3. Disconnect lead #532 from the power PC
board terminal. See Figure F.1.
WARNING
Electric Shock can kill.
• With power applied,
there are high voltages
inside the wire feeder.
Do not reach into the
wire feeder or touch any
internal part of the wire
feeder while power is
applied.
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F-26
F-26
TROUBLESHOOTING & REPAIR
T1 TRANSFORMER TEST (continued)
FIGURE F.2 – SECONDARY LEADS #601 AND #602 AT LEAD SPLICES
LEAD 601
LEAD 602
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.
7. With 115VAC applied to the primary leads
#532 and #31, if either or both of the sec-
ondary voltages are missing or low the T1
transformer may be faulty. Replace the
transformer.
8. After the test is completed, disconnect the
115VAC from the T1 transformer primary
leads. Reconnect lead #532 to the power
PC board terminal. Close the left side cover
assembly and re-assemble the screws.
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F-27
F-27
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 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
This test will aid the technician in determining if the T2 transformer is functioning.
MATERIALS NEEDED
115VAC power supply
Phillips head screwdriver
Volt/ohmmeter (multimeter)
This procedure takes approximately 20 minutes to perform.
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F-28
F-28
TROUBLESHOOTING & REPAIR
T2 TRANSFORMER TEST (continued)
FIGURE F.3 – “PROTECTION CIRCUIT TROUBLESHOOTING” NAMEPLATE
PROTECTION CIRCUIT
TROUBLESHOOTING NAMEPLATE
TEST PROCEDURE
1. Remove input power to the LN-9 GMA wire
feeder.
3. Lift the right side cover assembly.
4. Using the phillips head screwdriver, remove
the two screws from the Protection Circuit
Troubleshooting nameplate. Remove the
nameplate as far as the lead length will
allow. See Figure F.3.
2. Using the phillips head screwdriver, remove
the screws holding the left side cover
assembly.
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F-29
F-29
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
LEAD 531
R1 RESISTOR
4. Locate the T2 transformer primary lead
#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.
5. Lift the left side cover assembly.
6. Locate T2 transformer primary lead #531
connected to the R1 2-ohm resistor. See the
Wiring Diagram. See Figure F.4.
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F-30
F-30
TROUBLESHOOTING & REPAIR
T2 TRANSFORMER TEST (continued)
FIGURE F.5 – T2 SECONDARY LEADS #621 AND #620 ON TRIGGER PC BOARD
LEAD LEAD
620
621
TRIGGER
PC BOARD
8. Using the volt/ohmmeter, check for approx-
imately 24VAC at the T2 transformer sec-
ondary leads #621 and #620. Place the
probes where the leads connect on the trig-
ger PC board. See Figure F.5.
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.
9. With 115VAC applied to the primary leads
#531 and #32A, if the secondary voltage is
missing or low the T2 transformer may be
faulty. Replace the T2 transformer.
10. After the test is completed, disconnect the
115VAC from the T2 transformer primary
leads #531 and #32A. Reconnect lead #32
to the circuit breaker. Re-attach the
Protection Circuit Troubleshooting name-
plate. Close the right and left side cover
assemblies and replace all previously
removed screws.
7. Insulate the T2 transformer primary leads
#531 and #32A and apply 115 VAC power.
See the Wiring Diagram and Figure F.4.
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F-31
F-31
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR 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.
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 drive motor is functioning properly.
MATERIALS NEEDED
Phillips head screwdriver
Analog volt/ohmmeter (multimeter)
This procedure takes approximately 12 minutes to perform.
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F-32
F-32
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR TEST (continued)
FIGURE F.6 – LEAD #539 AND #541 AT POWER PC BOARD TERMINAL STRIP
LEAD 539
LEAD 541
TEST PROCEDURE
1. Remove input power to the LN-9 GMA wire
feeder.
4. Lift the left side cover assembly.
5. Locate leads #539 and #541 at the power
PC board terminal strip. See Figure F.6.
2. Remove any electrode wire or disengage
the drive rolls.
3. Using the phillips head screwdriver, remove
the screws from the left side cover assem-
bly.
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F-33
F-33
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR TEST (continued)
8. If the above voltages are present and the
motor does not operate, the motor, motor
brushes or gear box may be faulty.
WARNING
ELECTRIC SHOCK can kill.
If the armature voltage is missing or not cor-
rect, the power board or 1CR relay may be
faulty.
• 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.
If the motor is running at high speed and the
armature voltage is high and uncontrollable,
proceed with the Hall Effect Module Test.
6. Apply 115 VAC power.
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 is 5 to
95VDC depending on the wire feed speed
setting. As the armature voltage is increased
the wire feed speed should increase.
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F-34
F-34
TROUBLESHOOTING & REPAIR
HALL EFFECT MODULE TEST AND ALIGNMENT
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-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the Hall Effect Module is correctly aligned and functioning prop-
erly.
MATERIALS NEEDED
9/16” Wrench
Analog volt/ohmmeter (multimeter)
Phillips head screwdriver
The Hall Effect Module Test takes approximately
10 minutes to perform.
The Hall Effect Alignment Procedure takes approximately
10 minutes to perform.
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F-35
F-35
TROUBLESHOOTING & REPAIR
HALL EFFECT MODULE TEST AND ALIGNMENT (continued)
FIGURE F.7 – LEADS #525, #510, #555 ON CONTROL PC BOARD
LEAD LEAD LEAD
525
510
555
HALL EFFECT MODULE FEEDBACK
TEST PROCEDURE
1. Remove the input power to the LN-9 GMA
wire feeder.
4. Lift the left side cover.
5. Locate the hall effect leads #510, #525 and
#555 on the control PC board. See Figure
F.7.
2. Remove any electrode wire or disengage
the drive rolls.
3. Using the phillips head screwdriver, remove
the screws from the left side cover assembly.
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F-36
TROUBLESHOOTING & REPAIR
HALL EFFECT MODULE TEST AND ALIGNMENT (continued)
7. With the gun trigger activated or the gun ter-
minals 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 hall effect module
to the control PC board. This voltage is
dependent upon motor speed. If the feed-
back voltage is missing or does not vary with
motor speed, the hall effect module may be
faulty.
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.
6. Apply input power to the LN-9 GMA and test
for 15VDC at leads #525(+) to #510(-). This
is the supply voltage from the control PC
board to the hall effect module. If the correct
voltage is present, proceed to the next step.
If the voltage is missing, check the wiring
and perform the General Power Supply
Test.
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F-37
F-37
INSTALLATION
HALL EFFECT MODULE TEST AND ALIGNMENT (continued)
FIGURE F.8 – HALL EFFECT MODULE LOCATION
HALL-EFFECT
MODULE
HALL EFFECT MODULE
ALIGNMENT TEST PROCEDURE
The LN-9 GMA wire speed sensor is a three
lead hall-effect device encased in an externally
threaded housing. It is screwed into a mounting
plate on the motor side of the wire drive gear-
box. See Figure F.8.
4. Back the module out 1/2 turn. Then, using
the 9/16” wrench, carefully snug the module
locknut without rotating the module position.
5. After the hall effect module tests are com-
pleted, remove the jumper from the gun ter-
minals (if used). Close the left side case
cover assembly and reattach the screws.
1. Remove the input power to the LN-9 GMA.
2. Check that the module mounting plate is
screwed securely to the side of the gearbox
and seated flush against the top surface.
3. Gently screw the hall effect module into the
mounting plate until it just touches and stops
against the rotating part inside the gearbox.
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F-38
F-38
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 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
This test will help determine if the LN-9 GMA voltmeter is providing accurate readings.
MATERIALS NEEDED
Phillips head screwdriver
Digital volt/ohmmeter (multimeter) with at least 3-1/2 digits and ± 0.5% accuracy
This procedure takes approximately 8 minutes to perform.
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F-39
F-39
TROUBLESHOOTING & REPAIR
VOLTMETER ACCURACY TEST (continued)
FIGURE F.9 – VOLTMETER CONNECTION POINT
BRASS
CONDUCTOR
BLOCK
TEST PROCEDURE
1. Lift the right side cover assembly.
Perform the following checks with the LN-9 GMA
wire feeder connected to a Lincoln CV welding
power source according to the proper connection
diagram. (See the Installation section of this
manual.)
2. Connect the test meter (see Materials
Needed) between the brass conductor block
on the wire feeder and the work piece.
See Figure F.9 for this test.
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F-40
F-40
TROUBLESHOOTING & REPAIR
VOLTMETER ACCURACY TEST (continued)
3. With the LN-9 GMA gun trigger closed or the
gun terminals jumpered together (see the
Wiring Diagram), the test meter reading
should match the LN-9 GMA ACTUAL volts
reading within ± 0.5 volts. If it does not, check
the integrity and placement of the voltage
sensing leads #21 and #67. Perform the
Meter Circuit Accuracy Test.
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.
4. Remove the test voltmeter and, while weld-
ing, compare the SET volts and ACTUAL volts
meter readings. Depending upon 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. If no further tests are required, remove the
jumper from the gun terminals (if used) and
close the left case side cover assembly.
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F-41
F-41
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 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
This test will help determine if the LN-9 GMA meter circuit is functioning properly.
MATERIALS NEEDED
Phillips head screwdriver
Digital volt/ohmmeter (multimeter) with at least 3-1/2 digits and ± 0.5% accuracy
Slot head screwdriver
3/8" Nut driver
This procedure takes approximately 17 minutes to perform.
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F-42
F-42
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (continued)
FIGURE F.10 – METER PC BOARD LOCATIONS AND COVER
MOUNTING SCREWS
TEST PROCEDURE
1. Remove input power to the LN-9 GMA 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.10.
3. Locate and gain access to the meter PC
board. See Figure F.10.
4. Apply input power to the wire feeder.
WARNING
ELECTRIC SHOCK can kill.
• With power applied, there
are high voltages inside
the wire feeder. Do not
reach into the wire feeder
or touch any internal part
of the wire feeder while
power is applied.
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F-43
F-43
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (continued)
FIGURE F.11 – METER PC BOARD TEST POINTS
TP5
602
601
TP4
510C
561
519
560
517
5. Test for AC supply to the meter PC board.
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.
Check for 8 to 11 VAC from lead #601 to
#602. See Figure F.11.
If AC voltage IS present at leads #601 to #602
and the DC voltage is missing, the meter PC
board may be faulty.
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.11.
NOTE: The coating will have to be removed
from the test points.
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F-44
F-44
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (continued)
Test Digital Meter Accuracy. (For LN-9 GMA
models above code 7980 with separable digital
meter and meter boards only).
If the test meter does not match the readings, the
meter PC board may be faulty. Replace the
meter PC board.
1. Use a test meter with at least 3-1/2 digits and
± 0.5% accuracy.
LN-9 GMA SET
VOLTS READING
TEST VOLTMETER
READING
2. Connect the + probe to TP4 and the - probe to
lead #510C.
15.0 V
30.0 V
60.0 V
1.50 ± .05 VDC
3.00 ± .05 VDC
6.00 ± .07 VDC
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.
Test Meter PC Board Wire Feed Speed
Accuracy. (For LN-9 GMA, LN-9F GMA Models
Only)
If the LN-9 GMA digital meter does not match
the readings, the LN-9 GMA digital meter may
be faulty. Replace the digital meter.
1. Use a test meter with at least 3-1/2 digits and
± 0.5% accuracy.
2. Connect the + probe to lead #519 and the -
probe to lead #510C.
LN-9 GMA SET
VOLTS READING
TEST VOLTMETER
READING
15.0 V
30.0 V
60.0 V
.150 ± .004 VDC
.300 ± .004 VDC
.600 ± .006 VDC
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 GMA 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.
Test Meter PC Board Voltage Accuracy.
(All Models)
LN-9 GMA SET
VOLTS READING
TEST VOLTMETER
READING
1. Use a test meter with at least 3-1/2 digits and
± 0.5% accuracy.
082 IPM
489 IPM
978 IPM
0.50
±
.05 VDC
2. Connect the + probe to leads #517 and the -
probe to lead #510C.
3.00 ± .05 VDC
6.00 ± .07 VDC
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 GMA meter matches the
settings in the table below.
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F-45
F-45
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (continued)
Test Meter PC Board Wire Feed Speed Accuracy.
(Metric Models Only)
1. Use a test meter with at least 3-1/2 digits and
± 0.5% accuracy.
2. Connect the + probe to lead called for in the table
below and the - probe to lead #510C.
NOTE: The coating will have to be removed from the
test points.
3. With the meter in SET M/MIN, adjust the speed
control until the LN-9 GMA meter matches the set-
tings in the table below. If the test meter does not
match the readings, the meter PC board may be
faulty. Replace the meter PC board.
METRIC MODEL
METRIC RANGE
SET M/MIN READING
TEST VOLTMETER
READING
LN-9 GMA or LN-9F GMA
LO
HI
8.28
24.8
LEAD #560
2.00 ± .05VDC
LEAD #561
6.00 ± .07VDC
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F-46
F-46
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 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
This test will help determine if the LN-9 GMA is providing the proper wire feed inches per rev-
olution of the drive roll.
MATERIALS NEEDED
Phillips head screwdriver
Ruler or other linear measuring device
This procedure takes approximately 12 minutes to perform.
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F-47
F-47
TROUBLESHOOTING & REPAIR
WIRE SPEED ACCURACY TEST (continued)
B. Check for the proper drive roll revolutions
per minute.
TEST PROCEDURE
Perform the following checks with the LN-9 GMA
wire feeder connected to a Lincoln CV welding
power source according to the proper connection
diagram. (See the Installation section of this
manual.)
1. Adjust the LN-9 GMA wire speed control
for the LN-9 GMA ACTUAL speed meter
readings given in the table below.
2. Compare the corresponding LN-9 GMA
drive roll RPM (counted revolutions in 60
seconds) and LN-9 GMA SET speed
meter readings with the table below. The
numbers should match. If not, perform
the Meter Circuit Accuracy Test.
A. Check for the proper wire feed inches per
revolution of the drive roll.
1. Set the LN-9 GMA wire speed control for
between 50 and 120 IPM (1.27 to 3.17
M/MIN).
2. Measure the precise length of wire fed by
exactly 10 revolutions of the drive rolls.
This measured length should be 53.0 ± .8
inches (1.35 ± .02 meters). If not, there
may be a problem with the wire or the wire
feed path. See the Troubleshooting
Guide (Feeding Problems) in this sec-
tion of the manual. Also check for correct
drive roll tension adjustment.
MODEL
ACTUAL SPEED METER
READING
MEASURED
DRIVE ROLL
SPEED
SET SPEED METER
READING
MODEL
IN/MIN
M/MIN
RPM
IN/MIN
M/MIN
LN-9 GMA
or
161
322
4.1
8.2
30 ± 1/2
60 ± 1
161 ± 3
322 ± 3
04.1 ± .1
08.2 ± .1
LN-9F GMA
LN-9 GMA Wire Feeder
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F-48
F-48
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 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
This test will help determine if the out-of-voltage range shut down circuitry is functioning prop-
erly.
MATERIALS NEEDED
Phillips head screwdriver
Volt/ohmmeter (multimeter)
Jumper wire
This procedure takes approximately 18 minutes to perform.
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F-49
F-49
TROUBLESHOOTING & REPAIR
OUT OF VOLTAGE RANGE SHUT DOWN TEST (continued)
FIGURE F.12 – VOLTAGE PC BOARD WITH JUMPERS
1/8 AMP
FUSE
BYPASS
PINS
5. Connect to a Lincoln Electric CV power
source per connection diagram. See the
Installation section of this manual.
TEST PROCEDURE
1. Remove input power to the LN-9 GMA wire
feeder.
6. Start welding and observe the ACTUAL volt-
age reading on the LN-9 GMA digital meter.
The actual voltage must match the SET volt-
age within ± 0.5V. If it does NOT, the LN-9
GMA is designed to shut down.
2. Using the phillips head screwdriver, remove
the screws from the left side cover assembly.
3. Lift the left side cover assembly.
4. Locate the voltage PC board. Jumper together
the "BYPASS" pins on the LN-9 GMA voltage
PC board. See Figure F.12. (On older voltage
boards these pins may be labeled "B".) This
should disable the shut down circuit.
7. If the LN-9 GMA continues to shut down with
the "BYPASS" pins jumpered together, the
voltage PC board may be faulty.
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 GMA Wire Feeder
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F-50
F-50
TROUBLESHOOTING & 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.
10. If the ACTUAL voltage reading is different
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 GMA
voltage PC board may be faulty.
11. After all tests are complete, remove 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.
9. Check the polarity switches in the LN-9
GMA and the Lincoln power source and their
associated leads. Set the switches to the
same polarity as the electrode. See the
Wiring Diagram.
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F-51
F-51
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 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
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.
MATERIALS NEEDED
Phillips head screwdriver
Volt/ohmmeter (multimeter)
This procedure takes approximately 18 minutes to perform.
LN-9 GMA Wire Feeder
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F-52
F-52
TROUBLESHOOTING & REPAIR
GENERAL POWER SUPPLY TESTS (continued)
5. Apply power (115VAC) to the wire feeder at
the correct pins. See the Wiring Diagram.
TEST PROCEDURE
1. Remove input power to the LN-9 GMA wire
feeder.
6. Perform the power supply checks as
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.
2. Using the phillips head screwdriver, remove
the screws from the left side cover assembly.
3. Lift the left side cover assembly.
NOTE: Do NOT unplug the Molex connector.
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.
7. Also perform the T1 Transformer Test.
WARNING
ELECTRIC SHOCK can kill.
• With power applied, there
are high voltages inside
the wire feeder. Do not
reach into the wire feeder
or touch any internal part
of the wire feeder while
power is applied.
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F-53
F-53
TROUBLESHOOTING & REPAIR
GENERAL POWER SUPPLY TESTS (continued)
GENERAL POWER SUPPLY CHECKS
CHECKPOINT
LOCATION
TEST
DESCRIPTION
CONNECTOR
PLUG PIN NO.
LEAD NO.
NORMAL
ACCEPTABLE
VOLTAGE
READING
525
CONTROL P.C.
BOARD
CHECK
+15VDC
CONNECTOR
PLUG
SUPPLY FROM
POWER
BOARD TO
CONTROL
BOARD
525(+)
510(-)
13.5 - 15.5 VDC
510
10(+)
9(-)
CONTROL P.C. CHECK - 10 VDC
500
BOARD
CONNECTOR
PLUG
SUPPLY FROM
POWER
BOARD TO
CONTROL
BOARD
500(-)
510(+)
9.2 - 10.8 VDC
510
14(-)
9(+)
525
VOLTAGE P.C.
BOARD UPPER
CONNECTOR
PLUG NEXT TO
"F" AND “S”
CHECK
+ 15 VDC
SUPPLY FROM
POWER
BOARD TO
VOLTAGE
BOARD
525(+)
510(-)
13.5 - 15.5 VDC
510
PINS
4(+)
6(-)
VOLTAGE P.C.
BOARD UPPER
CONNECTOR
PLUG NEXT TO
"F" AND "S"
510(+)
65(1+0)
CHECK - 10 VDC
SUPPLY FROM
POWER
PINS
500
9.2 - 10.8 VDC
BOARD TO
VOLTAGE
BOARD
VOLTAGE P.C.
BOARD LOWER
CONNECTOR
PLUG NEXT TO
PLASTIC
500(-)
4(-)
COVERED
RELAY
LN-9 GMA Wire Feeder
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F-54
F-54
TROUBLESHOOTING & REPAIR
DIGITAL METER AND METER 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 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.
MATERIALS NEEDED
Slot head screwdriver
5/16" Nut driver
Phillips head screwdriver
This procedure takes approximately 20 minutes to perform.
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F-55
F-55
TROUBLESHOOTING & REPAIR
DIGITAL METER AND METER PC BOARD REMOVAL AND
REPLACEMENT (continued)
2. Locate and remove the two screws on the top
left and right side of the meter panel assem-
bly. See Figure F.13.
METER PC BOARD REMOVAL
PROCEDURE
1. Remove input power to the LN-9 GMA Wire
Feeder.
FIGURE F.13 – METER PANEL ASSEMBLY SCREWS
MOUNTING SCREWS
METER
3. Lift the right side cover assembly.
4. Carefully remove the meter enclosure panel.
Note the limited lead length. See Figure F.14.
FIGURE F.14 – METER REMOVAL (WITH SHORT LEADS)
LN-9 GMA Wire Feeder
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F-56
F-56
TROUBLESHOOTING & REPAIR
DIGITAL METER AND METER PC BOARD REMOVAL AND
REPLACEMENT (continued)
FIGURE F.15 – METER PC BOARD REMOVAL
4 MOUNTING NUTS
5. Using the 5/16" nut driver, remove the four
REPLACEMENT PROCEDURE
nuts mounting the meter PC board to the
meter assembly. See Figure F.15.
1. With the 5/16" nut driver, fasten the digital
meter to the cover assembly with two screws,
lockwashers and nuts.
6. Unplug the meter PC board from the wiring
harness.
2. Using the phillips head screwdriver, reattach
the meter shield frame and bezel assembly.
7. Remove the meter PC board. Note insulation
placement for reassembly. Also be sure that
the plug on the back of the board plugs into
the prongs on the meter when you reassem-
ble.
3. Position the insulation removed in step 7,
above. Plug the digital meter into the meter
PC board and into the wiring harness.
4. Mount the meter PC board onto the meter
assembly with four nuts.
DIGITAL METER REMOVAL
PROCEDURE
5. Install the meter enclosure panel using two
screws at the top left and right of the meter
panel assembly.
1. Using the phillips head screwdriver, remove
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.
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F-57
F-57
TROUBLESHOOTING & REPAIR
REED SWITCH (CR2) 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 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 reed switch for repair or replace-
ment.
MATERIALS NEEDED
3/4" Wrench
Slot head screwdriver
11/32" Wrench
This procedure takes approximately 12 minutes to perform.
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F-58
F-58
TROUBLESHOOTING & REPAIR
REED SWITCH (CR2) REMOVAL AND REPLACEMENT (continued)
FIGURE F.16 – CR2 REED SWITCH LOCATION AND COMPONENTS
LEAD 628
LEAD 529
SELF-TAPPING
SCREW
COPPER
ENERGIZER
3/4" BOLT
PROCEDURE
REPLACEMENT
1. Remove input power to the LN-9 GMA wire
feeder.
9. Slide the reed switch into the energizer.
Position it according to step 7.
2. Lift the right side cover assembly.
10. With the slot head screwdriver and the
11/32" wrench, connect the #529 and #628
lead splices with the screws and nuts. Tape
the connections.
3. Locate the CR2 reed switch. See Figure
F.16.
4. 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.
11. With the slot head screwdriver, tighten the
self-tapping screw that holds the reed switch
to the copper energizer.
12. With the 3/4" wrench, mount the copper
energizer to the conductor block.
5. Using the slot head screwdriver, remove the
self-tapping screw holding the reed switch
into the copper energizer.
6. Locate and untape the splices from leads
#529 and #628 to the reed switch leads.
7. Using the slot head screwdriver and 11/32"
wrench, remove the screws and nuts from the
lead splices. Note the position of the reed
switch in the energizer for reassembly.
8. Carefully slide the reed switch assembly from
the copper energizer.
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F-59
F-59
TROUBLESHOOTING & REPAIR
T1 TRANSFORMER 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 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 T1 Transformer for repair or
replacement.
MATERIALS NEEDED
Soldering iron
Phillips head screwdriver
Slot head screwdriver
Needle nose pliers
5/16" Wrench
11/32" Wrench
This procedure takes approximately 25 minutes to perform.
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F-60
F-60
TROUBLESHOOTING & REPAIR
T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued)
FIGURE F.17 – PRIMARY LEAD #31 AT R1 RESISTOR
LEAD 532
R1 RESISTOR
LEAD 31
4. Disconnect primary lead #532 from the power
PC board terminal.
PROCEDURE
1. Remove input power to the LN-9 GMA.
5. Disconnect the primary lead #31 from the R1
(2 ohm) resistor. See Figure F.17. Upon
reassembly this lead will have to be soldered
onto the R1 resistor.
2. Using the phillips head screwdriver remove the
screws holding the left side cover assembly.
3. Lift the cover.
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F-61
F-61
TROUBLESHOOTING & REPAIR
T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued)
6. Disconnect leads #526 and #527 from the
power PC board terminals. See Figure F.18.
FIGURE F.18 – LEADS #526 AND #527 AT POWER PC BOARD
LEAD 527
LEAD 526
7. Disconnect yellow leads #601 and #602 from
the lead splices. See Figure F-19.
FIGURE F.19 – LEADS #601 AND #602 AT LEAD SPLICES
LEAD 601
LEAD 602
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F-62
F-62
TROUBLESHOOTING & REPAIR
T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued)
8. Remove the two phillips head screws from the
control PC board mounting panel.
10. Remove the clip holding the 1CR relay, then
unplug the relay from the power PC board.
See Figure F.20.
9. Using the 11/32" wrench, remove the nut and
screw from the top of the PC board mounting
panel.
FIGURE F.20 – 1CR RELAY REMOVAL
NUT AND SCREW
CONTROL
PC BOARD
1CR
RELAY
PHILLIPS
SCREWS
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F-63
F-63
TROUBLESHOOTING & REPAIR
T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued)
FIGURE F.21 – TERMINAL STRIP MOUNTING
T1
TRANSFORMER
MOUNTING
TERMINAL
SCREWS
STRIP
11. Using the 5/16" wrench, remove the nuts
and lockwashers mounting the terminal strip
to the mounting panel. See Figure F.21.
17. Plug the 1CR relay into the power PC board
and attach the clip. See Figure F.20.
18. Mount the power PC board mounting panel
with the two phillips head screws and 11/32
nut.
12. Remove the terminal strip and set it aside.
13. Using the 5/16" wrench, remove the two
nuts and washers from the T1 transformer
mounting screws.
19. Connect leads #601 and #602 at the lead
splices. See Figure F.19.
14. 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.
20. Connect leads #526 AND #527 at their ter-
minals on the power PC board. See Figure
F.18.
21. Solder lead #31 to the R1 (2 ohm) resistor.
See Figure F.17.
22. Connect primary lead #532 to its power PC
board terminal.
REPLACEMENT
15. Position the T1 transformer and use the
5/16" wrench to attach it with the two nuts
and washers.
23. Close the left cover and reattach the screws.
16. With the 5/16" wrench, mount the terminal
strip.
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F-64
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. 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 screwdriver
3/8" Wrench
7/16” Wrench
9/16” Wrench
Phillips head screwdriver
This procedure takes approximately 40 minutes to perform.
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F-65
F-65
TROUBLESHOOTING & REPAIR
DRIVE MOTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.22 – TOP MOTOR PLATE SCREWS
MOTOR
GROUND
LEAD
LEAD 539
LEAD 541
6. 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.
PROCEDURE
1. Remove input power to the LN-9 GMA wire
feeder.
2. Using the phillips head screwdriver, remove the
screws holding the left side cover assembly.
7. Remove the hall effect module. (See the
Hall Effect Module Alignment procedure).
3. Lift the cover assembly.
8. Locate and remove motor leads #539 and
#541 at their quick-connectors. Note lead
placement for reassembly. See Figure F.22.
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.
9. Remove the green motor ground lead. Cut
or untape any necessary cable ties. See
Figure F.22.
5. Using the phillips head screwdriver, remove
the 9 pin amphenol connector.
10. Using the slot head screwdriver, remove the
gas hose and clamp from the brass inlet
connector.
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F-66
F-66
TROUBLESHOOTING & REPAIR
DRIVE MOTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.23 – GLASTIC MOUNTING SCREWS
NUTS AND
WASHERS
(4-ROLL
FEEDERS)
11. Remove the three screws and lock washers
that hold the glastic mounting to the LN-9
GMA floor assembly. It may be necessary to
remove the copper reed switch energizer to
access one of the mounting screws. See
Figure F.23.
NOTE: Four- roll drive units have nuts and wash-
ers also. Screw heads are located under the
Mylar insulator.
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F-67
F-67
TROUBLESHOOTING & REPAIR
DRIVE MOTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.24 – MOTOR AND WIRE DRIVE REMOVAL
MYLAR
INSULATOR
GLASTIC
MOUNTING
BOARD
MOUNTING
BOLTS
12. Lift the right side cover assembly and care-
fully lift and slide the motor and wire drive
assembly partially out of the LN-9 GMA box
assembly. See Figure F.24.
13. Using the 7/16" wrench, remove the bolts
and associated washers holding the glastic
mounting board and mylar insulator to the
gear box assembly. Remove the copper
reed switch energizer.
14. Using the 7/16" wrench, remove the two
bolts from the gear box inspection plate
located below the drive motor. Remove the
inspection plate. This will give access to one
of the slot head screws mounting the motor
to the gear box assembly. See Figure F.25.
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F-68
F-68
TROUBLESHOOTING & REPAIR
DRIVE MOTOR REMOVAL AND REPLACEMENT (continued)
15. With the slot head screwdriver, remove the
three screws, lock washers, flatwashers,
and insulators holding the drive motor to the
gear box assembly. See Figure F.25. Note
their positions for reassembly.
19. From the right side, slide the motor and gear
box assembly into the LN-9 GMA. Attach
the glastic mounting to the floor with the
screws. Four-roll units have nuts and wash-
ers. Attach the gas hose and clamp to the
brass inlet connector.
16. Carefully remove the motor and plate. Note
which side of the insulator motor faces the
wire drive rollers for reassembly.
20. Connect motor leads #539 and #541 to their
quick-connectors. Attach the green motor
ground lead. Install any cable ties cut earli-
er or tape the harness as needed.
REASSEMBLY
21. Install the hall effect module. See the Hall
Effect Module Alignment procedure.
17. Attach the drive motor and insulator plate to
the gear box assembly. Use the insulators
and mounting hardware from step 16,
above. Replace gear box inspection plate
removed in step 14.
22. Install the 9-pin amphenol and the R1 resis-
tor. Be sure to position the resistor insula-
tors properly.
23. Close and fasten the left cover assembly
with screws.
18. Attach the glastic mounting board and mylar
insulator to the gear box assembly with the
bolts and washers. Install the copper reed
switch energizer previously removed.
FIGURE F.25 – DRIVE MOTOR REMOVAL FROM GEAR BOX
GEAR BOX
(INSPECTION
PLATE REMOVED)
MOTOR
MOUNTING
SCREWS (3)
DRIVE MOTOR
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F-69
F-69
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Retest the LN-9 GMA 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 GMA ...........................................................................................80 - 980 IPM
Voltmeter.....................................................................................Refer to Voltmeter Accuracy Check
Wire Speed Meter.....................................................................Refer to Meter Circuit Accuracy Test
Gas Solenoid.....................................................................Must function when gun trigger is activated
Voltage control and shutdown..................................Refer to Out of Voltage Range Shut Down Test
LN-9 GMA Wire Feeder
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F-70
F-70
NOTES
LN-9 GMA Wire Feeder
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
Theory of Operation ................................................................................................................Section G
Wiring Diagram-LN-9 GMA ...................................................................................................G-3
Wiring Diagram-LN-9F GMA .................................................................................................G-4
Voltage Board Schematic......................................................................................................G-5
Power PC Board Schematic..................................................................................................G-6
Trigger PC Board Schematic.................................................................................................G-7
PM Control Schematic...........................................................................................................G-8
Meter Board Schematic.........................................................................................................G-9
Operating Schematic...........................................................................................................G-10
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G-2
G-2
NOTES
LN-9 GMA Wire Feeder
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G-3
G-3
ELECTRICAL DIAGRAMS
Wiring Diagram-LN-9 GMA
SET-ACTUAL
SWITCH
DIGITAL METER
METER BOARD
WIRE SPEED CONTROL
RHEOSTAT
1/8 AMP FAST
BLOW FUSE
VOLTS
-
SPEED
N.O. N.C. N.O. N.C.
SELECTOR SWITCH
S5
(J11)
631
(P11)
631
(P9)
5
3
517
633
10K
VOLTAGE P.C. BOARD
WHITE
3
10
9
12
7
1
4
2
6
8
11
5
634
635
636
510B
514
515
525
520
510
721
667
500
S6
C1
R2
632
C2
4
7
9
6
632
633
634
635
510
518
562
518
JUMPER
3
S
4
8
2
516
513
5
1
(J8)
(P8)
12
11
6
N.A.
635
R3
7
F
10
9
*
634
(J9)
B
8
10K
636
620
621
636
C3
A
B
Y
P
A
S
S
2
1
VOLTS CONTROL
RHEOSTAT
METER
BOARD
PLUG
519
560
BLUE
CONTROL
561
(J10)
JUMPER
*
RHEOSTAT
PLUG
1
2
3
4
5
2
6
3
9
12 4
8
7
11 10
1
525
521A
500
521
BURNBACK
TIMER
P.C. BOARD
(OPTIONAL)
*
(J7)
B1
B
B
P
P
C
C
T2 T1
T2 T1
METER
PANEL
PLUG
JUMPER PLUG IS REMOVED
AND THE HARNESS RECEPTACLE
IS CONNECTED TO THE
OPTIONAL GMA OR BURNBACK
TIMER P.C. BOARD PLUG.
REPLACE JUMPER PLUG IF
TIMER IS DISCONNECTED.
8
7
6
5
9
3
4
1
2
(P12)(J12)
GMA TIMER
P.C. BOARD
(OPTIONAL)
S
B1
S1
32
N.C.
(P7)
3
AMP
(P10)
CIRCUIT BREAKER
(P6)
32A
32A
*
(J6)
534
9
4
3
5
6
2
10 12 11 7
8
SWITCH
BOX
ASSEMBLY
GROUND
G.L.P.
RESET
S4
POLARITY
667
721
N.D.
SWITCH
S3
DIRECTION
SWITCH
539B
539
541
S2
S7
HOT-COLD
INTERLOCK
SWITCH
500
METER PANEL
ASSEMBLY
GROUND
METER BOX
GND.
GLP, REED
SWITCH (CR4)
2A
530B
522
21
67
541B
533
2
67
CASE
GND.
N.D.
500
510
500
ELECTRICAL SYMBOLS PER E1537
RED BLK BLUE
CONNECTOR CAVITY NUMBER
RED
BLUE
BLK
*
(P4)
CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT
(P2)
631
632
633
5
6
4
11
14
8
3
2
1
15
9
(J5)
HALL EFFECT
MODULE
X1
NOTES:
555
510
525
A
622
623
B
C
D
E
N.A. VOLTAGE P.C. BOARD WHITE JUMPER TO BE SHIPPED
CONNECTED TO PIN "S" AND VOLTAGE P.C. BOARD BLUE
JUMPER TO BE SHIPPED CONNECTED TO PIN "B".
TRIGGER
539
CONNECTOR
500
510A
511
512
520
524A
510
628
525
540
WHITE
N.B.
541
S
F
(P3)
N.B. CONTROL P.C. BOARD JUMPER TO BE SHIPPED CONNECTED
TO PIN "F".
BLACK
(J2)
*
3
6
2
5
9
8
4
7
1
2A
504
*
539B
541B
(J4)
PM POWER
P.C. BOARD
JUMPER
N.C. JUMPER PLUG IS REMOVED WHEN THE OPTIONAL PULSED
POWER FILTER P.C. BOARD HARNESS PLUG IS CONNECTED
TO THE VOLTAGE P.C. BOARD. REPLACE JUMPER PLUG IF
THE OPTION IS DISCONNECTED.
522
(J3)
32A
7A
PM CONTROL
P.C. BOARD
524A
525
13
*
10
12
7
32A
7
N.D. NOT PRESENT ON EARLER CODES.
529
628
522
WIRE FEED
MOTOR
CONNECTION FOR D.C. TYPE POWER SOURCES. FOR OTHER
TYPE POWER SOURCES (R3S, SAM, AND SAF OR SA WITH
K224) SEE OPERATING MANUAL.
532
527
526
(R4)
22K
ONE MAGNETICALLY
TIGHTLY COUPLED TURN
534
533
500
(J1)
C
B
32
A
2
4
31
21
GND
4/10 AMP
SLOW BLOW
FUSE
602
601
H
G
D
F
A
B
C
E
I
YELLOW
RED
15/64 ø
RED
TRIGGER
P.C. BOARD
530
500
J12
PIN
32A
621
INPUT
CONNECTOR
4
531
T2
BLACK
31
RED
T1
31
(R1)
620
621
622
623
7A
32A
2
620
531
BLACK
BLACK
GAS SOLENOID
GROUNDING STUD
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF BOARD)
67
WELD CURRENT
REED SWITCH (CR2)
GUN CABLE
INPUT CABLE
529
628
1-10-97G
L10247
CLEVELAND, OHIO U.S.A.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. It is provided for reference only.
LN-9 GMA
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G-4
G-4
ELECTRICAL DIAGRAMS
Wiring Diagram-LN-9F GMA
(P9)
531
531
31
R1
2
3
2
1
11
14
12
15
13
5
7
6
10
9
8
METER
BOARD
PLUG
VOLTS
-
SPEED SELECTOR SWITCH
517
PM POWER
P.C. BOARD
7
7A
DIGITAL
METER
METER
BOARD
530B
521
510
510
500
1/8 AMP FAST
BLOW FUSE
12
10
1
4
3
S6
C1
C2
S5
510
(P11)
601
602
510C
3
(P10)
601
602
4
8
2
N.C.
N.O.
N.C.
N.O.
518
562
518
11
1
10
12
9
13
8
3
2
15
7
14
5
6
511
VOLTAGE P.C. BOARD
WHITE
5
1
*
3
10
9
12
7
1
4
2
6
8
11
5
N.B.
F
634
635
636
510B
514
515
525
520
510
721
667
500
12
11
512
514
515
6
520
525
540
510
628
510A
511
512
524A
522
500
631
632
633
513
516
(J9)
510A
518
7
510B
518
10
9
JUMPER
S
539B
541B
32A
7A
32A
7
518
510
517
519
560
561
562
540
6
2
5
11
7
C3
510
N.A.
560
561
628
500
530A
530
32A
(P8)
2A
SET-ACTUAL SWITCH
S
519
F
517
519
560
561
562
*
(J11)
B
*
A
B
Y
P
A
S
S
(J10)
4
8
9
JUMPER PLUG IS REMOVED AND THE HARNESS
RECEPTACLE IS CONNECTED TO THE OPTIONAL
GMA OR BURNBACK TIMER P.C. BOARD PLUG. REPLACE
JUMPER PLUG IF TIMER IS DISCONNECTED.
4/10 AMP
SLOW BLOW
FUSE
BLUE
3
6
2
5
9
8
4
7
1
(J12)
*
JUMPER
(J6)
(P6)
504
1
2
3
4
5
3
6
2
4
12 7 11 10
8
9
1
522
525
521A
500
521
VOLTS CONTROL
RHEOSTAT
BURNBACK TIMER
*
B1
B
P
C
T2 T1
4
524A
525
(J8)
P.C. BOARD
(OPTIONAL)
PM CONTROL
P.C. BOARD
636
(J5) (P5)
(J13)
GMA TIMER
P.C. BOARD
(OPTIONAL)
(P12)
529
628
S
B1
S1
B
P
C
T2 T1
(P13)
532 527
526
555 510 525
620
2
1
8
6
9
7
4
3
5
N.C.
621
636
635
634
633
632
631
(P7)
RED
*
635
634
633
632
BLACK
524
BLACK
32A
620
9
4
3
5
6
1
2
10 12 11 7
8
531
T2
(J7)
621
RED
TERMINAL
601
STRIP
531
7
31
CONTROL
RHEOSTAT
PLUG
TRIGGER
P.C. BOARD
530
500
BLACK
631
7
32A
7
602
620
621
622
623
RED
WIRE SPEED
CONTROL
RED
RHEOSTAT
539B
541B
539
T1
21
S3
S7
S2
2A
667
67
721
21
533
541
539B
541
541B
539
530B
522
GLP
REED
2
SWITCH
CR4
500
POLARITY
SWITCH
HOT-COLD
INTERLOCK
SWITCH
DIRECTION
SWITCH
OUTPUT
CONNECTOR
N.D.
& N.E.
500
32A
534
32
534
S4
(J2)
(P2)
CASE
GROUNDING
STUD
TACH CABLE
N
N
F
F
E
E
K
K
B
J
A
P
L
G
H
C
C
D
D
M
M
MAGNETICALLY
COUPLED
D
E
B
A
C
H
G
F
I
ELECTRICAL SYMBOLS PER E1537
CONNECTOR CAVITY NUMBER
INPUT RECEPTACLE
(J1)
CONTROL CABLE
GLP
RESET
*
3
AMP
(P3)
(J3)
CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT
NOTES:
N.A. VOLTAGE P.C. BOARD WHITE JUMPER TO BE SHIPPED CONNECTED TO PIN "S"
CURCUIT BREAKER
B
J
A
P
L
G
H
WIRE FEED UNIT
CASE GROUNDING STUD
AND
VOLTAGE P.C. BOARD BLUE JUMPER TO BE SHIPPED CONNECTED TO PIN "B"
.
N.B. CONTROL P.C. BOARD JUMPER TO BE SHIPPED CONNECTED TO PIN "F"
A
B
C
D
E
622
623
N.C. JUMPER PLUG IS REMOVED WHEN THE OPTIONAL PULSED POWER FILTER P.C. BOARD
HARNESS PLUG IS CONNECTED TO THE VOLTAGE P.C. BOARD. REPLACE JUMPER PLUG
IF THE OPTION IS DISCONNECTED.
(J4)
541
539
67
BLACK
WHITE
WIRE FEED
MOTOR
TRIGGER
CONNECTOR
510
525
555
529
628
7A
BLACK
RED
BLUE
32A
N.D. NOT PRESENT ON ALL CODES.
WELD CURRENT REED SWITCH
N.E. CONNECTED TO THE BUSHING OF THE COMPONENT.
CONNECTION FOR D.C. TYPE POWER SOURCES. FOR OTHER TYPE POWER SOURCES
529
628
CR2
(R3S, SAM, AND SAF OR SA WITH K224) SEE OPERATING MANUAL.
Ô
=
7A
32A
J6, J7,
J13
PIN
J5, J8
PIN
J9, J10
15 PIN
BLACK
RED
BLUE
HALL EFFECT
MODULE
X1
J11, J12
4
9
67
GAS SOLENOID
12 PIN
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF BOARD)
GUN CABLE
INPUT CABLE
1-10-97G
R
L10250
CLEVELAND, OHIO U.S.A.
DEC 97
LN-9 GMA
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. It is provided for reference only.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
Voltage Board Schematic
67
(+15V)
525
667
11
667
J1
44.2K
4
4
C11
C20
C21
C3
515
NEG
POS
X1
X2
4.7
35V
TP1
150V
45J
13
12
LM224
LM224
510
14
6
S3
R4
X1
510B
CW
11
11
POLARITY
A
7
C22
510B
8
1
100K
X1
B
R36
267
C2
.0047
1400V
SWITCH
J1
J1
5
500
515
C19
510
TO METER
PANEL PLUG
C1
C4
4
0.125A
250V
.1
D2
100V
50V
4.75K
21
(-10V)
500
A
510B
510B
A
B
R33
R47
10
5.11K
5.11K
J2
510B
15.0K
R6
B
C7
PIN
S
F
R34
47.5
R48
47.5
11
J2
(+15V)
525
WHITE
R10
4.75K
R45
667
PIN
681K
1
5
4
13.7K
13.7K
13.7K
1.00M
1.00M
C9
C
C
OCI1
4N26
DZ1
C8
39
20V
1W
(+15V)
33.2K
525
20V
2
6
13.7K
510B
C18
39
20V
7
C6
J2
1.00K
R35
10K
R7
681K
Q1
200mA
30V
2
3
D16
2
3
1
12
13
X2
R11
A
1
14
100K
D
X1
X2
D
D5
D6
D17
56.2K
1.00M
1.00M
D3
PIN
PIN
A
B
D1
DZ3
C5
26.7K
D4
5.1V
.47
BLUE
500mW
50V
510
3
5K
CW
525
521
500
521A
GAIN
2
1
2K
1
START
J3
J3
J3
J3
510
2
CW
(+15V)
525
3
1
4
3
2
4.7
35V
C12
TO POWER BOARD
525
4
5.62K
1.00K
J1
(+15V)
(+10V)
5.62K
510
520
525
2.21K
4
5
CR1
520
2
D14
24Vdc
J1
TO CONTROL
BOARD
22.1K
22.1K
332K
15.0K
VOLTAGE P.C. BOARD RECEPTACLE
FOR OPTIONAL PULSED POWER
FILTER P.C. BOARD PLUG
510
(SHOWN WITH JUMPER PLUG
INSTALLED). EARLIER VOLTAGE
P.C. BOARDS DO NOT HAVE THE
C15
Q2
2N4857
R25
4.75K
5
6
1.0
35V
J1
3
3
2
7
514
4
PIN RECEPTACLE AND 521A IS 521.
D10
D11
X2
B
R30
26.7K
10
9
100K
C
X2
R24
8
9
634
635
525
1
4.75K
8
7
D13
X1
R18
267
56.2K
22.1K
C
"VOLTS"
CONTROL
J1
J1
10
R3
514
10
2.21K
TO METER
100K
D18
PANEL PLUG
D7
636
C16
510
524
CR1
C10
1.8
DZ2
22.1K
D12
J2
B7
Q3
500mA
300V
510
20V
524
TO R107
9
2
12
CR1
6
C17
.47
50V
J2
1.00K
15V
1W
J1
SHUTDOWN
BYPASS TABS
533
1
C13
27
35V
D15
3
100K
1.82K
J1
5
522
3
B8
TO 5J2
500
2
D8
CR4
534
S4
J2
530
J1
530
510
510B
6
12
C14
J1
G.L.P. RESET
TO METER
PANEL PLUG
530
S2b
1
HOT COLD
INTERLOCK
SWITCH
510B
(-10V)
500
521A
510
500
J2
J2
4
500
LN-9 ABOVE CODE
9131 AND LN-9F
D9
(-10V)
500
GND
J2
J2
USED ON LN-9
BELOW CODE 9131
3
5
521
TO POWER BOARD
TO 5J1
500
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 are 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
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
LN-9 GMA
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
Power PC Board Schematic
31
7
3
9
7A
4
HOT-COLD
INTERLOCK
SWITCH
11
524A
524
S2A
7
HOT
J2
2A
COLD
3
2
TWO CONNECTOR PINS AND THE RELAY
4
7
CR1
CONTACT ARE LOCATED ON THE P.C. BOARD.
HOT
2
J2
6
6
504
4
5
628
10
12
500
J2
32A
7
529
WELD
J1
CURRENT
REED
SWITCH
4
CR2
32
0.4A
125V
32A
J2
F1
628
1
532
541B
B532
6
9
32A
B32A1
7A
B32A2
J1
B541B
628
CR1
2
1
4
3
6
C2
.047
100V
C3
.047
100V
525
628
541
(B)
7
GAS
SOLENOID
525
0.2mH
PT1
0.2mH
PT1
S7
DIRECTION
SWITCH
C1
+15V
B7A
B7
510
.0047
1400V
8
D16
1N4936
C9
D10
J2
D4
REV
FWD
D8
12
13
10
11
X2
R14
D3
3
4
M
D5
J1
1.00K
2N6397
SCR2
16A
CR1
526
Q3
500mA
300V
24Vdc
400V
T1
C18
500
1
Q5
1A
8
J1
B526
2N6397
TP1
150V
45J
2N5655
Q1
C6
D11
SCR1
100V
14
13
Q2
/Q1
X1
VDD
Q1
.15
CR1
2
1
200V
530
9
3
26 VAC
R13
100
C5
.0047
1400V
3
4
5
6
12
11
10
9
C4
.0047
1400V
/Q2
CLOCK
RESET
D1
1
TRIGGER
BOARD
C8
C17
.15
CLOCK
RESET
2
1
2
4
D9
1N4936
1
532
(W)
C15
527
500
D12
1N4936
200V
2
D2
R1
D2
2
4
SET
VSS
1
B527
D6
D1
DZ3
16V
1W
16A
400V
J1
D7
J1
332
7
8
16A
SET
9
13
400V
B539B
MC14013B
J1
C14
DZ1
15V
5W
530A
D19
J1
J2
2
539B
J2
5
9
S2B
8
5
HOT COLD
INTERLOCK
SWITCH
CR1
J1
11
510
J1
601
540
7
ON
DZ4
27V
1W
C7
524
J1
524A
150
J1
12
D20
1N4936
530B
9.6 VAC
50V
531
15
3
TRIGGER
INTERLOCK
14
C11
4.7
35V
DZ2
10V
5W
OFF
521
J1
602
5
510
C12
.01
200V
32A
T2
Q2
2N5655
115 VAC
531
500
PT1
0.2mH
C10
6
24 VAC
621
31
TO CONTROL
RHEOSTAT PLUG
J1
620
1
2
X2
500
10
3
4
510
X2
621
620
530
14
14
622
623
X1
5
6
C20
622
X2
X2
COMPONENTS IN THE DASHED AREAS ARE NOT ON THE P.C. BOARD UNLESS
OTHERWISE NOTED.
MC14013B
7
9
8
623
500
7
X2
TRIGGER SWITCH
11
10
X2
500
500
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 are 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
LN-9 GMA
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
Trigger PC Board Schematic
M
1 7 9 5 0
+20V
R1
332
623
D5
1A
600V
D1
D2
1A
600V
R7
1A
56.2K
622
600V
530
OCI1
TRIGGER
SWITCH
1
4
3
620
DZ2
75V
1W
5
4
2
500
2
X1
X1
C1
50
R4
25V
24 VAC
10.0K
DZ1
20V
1W
7
6
1
621
D4
D3
1A
1A
11
600V
600V
13
9
8
X1
C2
R9
10
14
2.7
2.80K
X1
50V
C3
1.0
35V
+20V
3
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R- 15
X-
1
C-
D-
4
5
OCI-
DZ-
1
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
2
LABELS
=
Ohms
(
NOTES :
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
C4
SUPPLY
VOLTAGE NET
X1
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
COMPLETE BOARD, THIS DIAGRAM MAY
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
WITHOUT AFFECTING THE INTERCHANGEABILITY OF
A
LM2901
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
12
FRAME CONNECTION
EARTH GROUND CONNECTION
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
THE LINCOLN ELECTRIC CO.
FILENAME: M17950_1AA
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ChÕge.Sht.No.
EQUIP.
TYPE
LN-9 GMA & LN-9F GMA
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
10-6-95B
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
TRIGGER PCB SCHEMATIC
SUBJECT
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
NONE
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
SHT.
LM
5/15/95
CHK.
SUPÕSÕDÕG.
M
17950
DR.
DATE
NO.
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 are 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
LN-9 GMA
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
PM Control Schematic
525
+15V
525
+15V
525
+15V
520
+10V
9
8
J10
X4
525
+15V
10
10
525
4
4
12
9
C17
C18
C19
Q7
600mA
40V
520
+10V
11
6
10
Vc
Vo
X3
X4
C21
X1
520
+10V
X1
X2
500
-10V
2
Vref
NC
NC
NC
+Vin
Vee
ILIMIT
Vcc
10.0
LM224
LM224
LM723
LM2907
12
1
C20
R43
J10
TO
VOLTAGE
PCB
C4
4.7
35V
8
3
11
11
ISENSE
1.00K
7
12
520
1
14
4
-Vin
1.00K
5
7
9
Vz
COMP
C2
13
C1
LM723
510A
510A
510A
500
-10V
500
-10V
500
C3
18
15V
FROM
POWER
BOARD
CW
J10
J10
J10
512
2
3
8
2.94K
TO
METER
CIRCUIT
511
J10
J10
9
510
C14
4.7
35V
510A
510A
14
500
-10V
500
510A
J
525
+15V
525
+15V
C9
.047
100V
15.0K
R21
520
+10V
512
C8
4
50V
33.2K
15.0K
2
3
11
6
8
5
1
6
5
TACH INPUT
ISINK
ISOURCE
GND
1.00M
X3
R44
267
R17
7
NC
NC
NC
NC
1.00K
X3
X2
12
15.0K
22.1K
7
C12
13
14
1
10
IBIAS
K
5.62K
4
9
IBIAS
510A
V+
TACH INPUT
R7
510A
2
3
/
Ic
10K
525
+15V
CW
LM2907
D6
J10
5
10K
10K
6.81K
511
631
CW
2
3
C24
525
RED
1
X4
6
CW
J10
10K
13
12
WIRE
SPEED
CONTROL
632
10K
14
Q4
600mA
40V
X3
R2
R18
1.00K
10K
C10
2.7
50V
68.1K
13.7K
267
633
HALL
EFFECT
MODULE
C16
100p
100V
C5
.0033
200V
C6
C13
M
4
555
BLUE
.33
CW
J10
50V
Q3
600mA
40V
C15
18
15V
R31
15.0
100K
562
C28
510
BLK
C23
D4
DZ3
510A
3V
6
5
511
500mW
R12
R14
7
X4
15.0K
1.00K
C11
.15
100V
QU1
2N6027
D5
9
525
CW
8
X3
16
RUN-IN
10
20K
1.00K
D8
S1
1
33.2K
L
OPEN
-
SLOW
FAST
47.5K
CLOSED
-
525
+15V
C25
1.00K
DZ4
30V
1W
CW
525
+15V
POWER
BOARD
13
12
50K
47.5K
J10
Q8
2N4401
14
540
X4
R47
R48
12
PUT
RESET
10.0K
10.0K
J10
FROM
Q1
628
POWER
13
600mA
40V
33.2K
DZ5
10V
1W
C30
PCB
Q5
15.0K
2.7
1A
50V
100V
DZ1
D10
D11
D2
D7
6.8V
1W
15.0K
C7
Q2
600mA
40V
3.9
Q6
600mA
40V
35V
500
C26
10K
-10V
6.81K
DZ2
16V
1W
C22
D9
47.5K
D1
100K
D3
1.00K
100K
C29
.47
50V
100
C27
2.67K
10K
MOTOR DISABLE
J10
11
524A
500
J10
J10
15
7
524A
522
-10V
CURRENT FLOWING
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 are 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
LN-9 GMA
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
Meter Board Schematic
2 1 1 4 6
S
511 512
514 515
SET
ACTUAL
510A
510B
513
C2
5
516
C3
9
C1
8
12
1
4
HI
IN/MIN
10
TO DIGITAL METER
10 VAC
M/MIN
2
3
6
LO
7
VOLTS
11
518
562
TP4
4
510C
E
510
8
+5V
2
+5V
A
3
4
C
2
1
B
D
5
561
B8
560
B7
519
B11
517
B5
518
B6
562
B9
510
B2
510C
B3
602
B4
601
B1
6
3
10
1
7
9
5
J14
J14
J14
J14
J14
J14
J14
J14
J14
J14
D1
61.9K
3.74K
13.7K
24.3K
D5
X1
C7
C6
C5
TP5
C4
CW
CW
CW
CW
D2
5K
500
2K
2K
OUT
IN
C1
C2
500
50V
4.7
35V
GND
D3
C3
27
10V
2.8K
TP4
D4
NOTES :
FILE: S21146_1CB
LABELS
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
N.A.
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD MAY CHANGE
A PRINTED
FRAME CONNECTION
WITHOUT AFFECTING
SUPPLY
VOLTAGE NET
MFD
(
CAPACITORS =
RESISTORS Ohms
DIODES
(
.022/50V
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
THE INTERCHANGEABILITY
OF A COMPLETE
SHOW THE EXACT COMPONENTS
CONTROLS HAVING A COMMON CODE NUMBER.
BOARD.
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
=
THIS DIAGRAM MAY NOT
EARTH GROUND CONNECTION
OR CIRCUITRY OF
=
1A, 400V
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
EQUIP.
TYPE
ChÕge.Sht.No.
LN-9H & LN-9FH (METRIC)
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
3-25-94
METER BOARD SCHEMATIC
SUBJECT
NONE
SCALE
SHT.
9-24-93
FM
DR.
DATE
CHK.
SUPÕSÕDÕG.
NO.
S
21146
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 are 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
LN-9 GMA
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
Operating Schematic
1 7 6 G 3
C
MOTOR CONTROL CIRCUIT
A
INPUT AND MOTOR POWER CIRCUIT
B
CONTROL POWER SUPPLY AND RELAY CIRCUIT
525
B
628
B
32
3A CIRCUIT BREAKER
628
529
S7
DIRCTION
SWITCH
32A
628
CR101
C109
CR2
525
525
520
Q207
R203
Q103
C204
32A
B
B
D110
+10.00 V.
11
12 10
X201
F101
532
D108
C113
CR101
CR101
541B
2
3
525
C221
B
D104
D105
C209
J
541
(B)
32A
7A
6
5
C217
R244
C219
Q101
D116
C102
C103
R221
530
REV.
FWD
7
D111
R111
C115
525
D112
C116
C117
4
GAS
SOLENOID
+15V
8
C208
-
D
9
P.M.
ARM
-
Q104
X203
526
526
D117
Q105
512
CW
D206
LO
2
REF
4
10
5
4
D103
14
PT
101
C106
527
A
R217
PT
101
-
X204
C108
D109
500
1
6
5
2
3
1
D113
11
CW
C202
26 VAC
+
A
C218
11
X202
2
3
5
C
D
S
Q
Q
R
R113
A
631
C212
7
3
1
+
R101
+
+
CW
524A
B 500
K
2
WIRE SPEED
CONTROL
SCR102
SCR101
C105
-
CW
H1
X203
D114
13
522
527
TP
X101
1
539
(W)
C224
DZ101
6
4
C203
C101
101
3
12
4
+
7
X203
B
524
632
633
-
C216
511
C210
+
ON
C201
9
11
13
7
8
10
R202
R218
C107
C220
CR501
D101
C104
D102
12
500
+
14
+
CW
Q204
R231
601
9.6 VAC
602
510
530A
D119
B
C213
OFF
CAL
+
539B
530B
TRIGGER
ZERO
VOLT
INTERLOCK
C215
CR101
Q203
M
C228
T1
+
521
512
531
C114
REFERENCE
D120
+
R212
525
R214
D
D
D106 D107
530
C111
C
C223
D205
Q102
525
-
-
DZ102
C214
500
D204
S2b
9
9
C110
8
8
31
C
B
QU201
DZ203
Q205
HOT COLD
INTERLOCK
SWITCH
B
510A
10
10
31
+
+
500
-10V
531
PIN
F
PIN
S
115 VAC
X203
X204
32A
(R)
(B)
C225
C211
T2
RING
MAGNET
7A
B
4
24 VAC
CW
511
L
620
621
TO CONTROL
9
7
(Y)
X1
C
540
S2A
ACC
RHEOSTAT PLUG
D208
555
3
31
Q201
C226
HOT-COLD
INTERLOCK SWITCH
D202
11
7
524A
524
HALL EFFECT
MODULE
R533
R534
A
+
B
HOT
621
620
Q206
C112
C207
TRIGGER
BOARD
B
COLD
2
2A
DZ201
530
500
622
B
TRIGGER
SWITCH
HOT
2
B
525
622
623
530
500
CR101
Q202
PT
101
+
C229
6
5
504
D201
C227
1
5
4
623
B
4
D203
C222
OCI
501
B
B
10
12
628
500
D
TRIGGER CIRCUIT
500
6
2
12
C507
C508
GMA TIMER AND BURNBACK TIMER
RECEPTACLE (SHOWN WITH JUMPER
PLUG INSTALLED)
525
+
-
B
14
C509
B
PIN
WHITE
F
D
R510
13
524A
X502
+
Q501
C503
A
667
C520
67
D517
DZ
501
500
PIN
S
B
510B
TP
501
525
C
E
E
511
C
514
512
515
ACTUAL
GAIN
S3
START
CW
B
4
SET
POLARITY
-
R535
R507
C518
1
-
C
14
2
3
S5
13
12
A
SWITCH
721
R511
A
CW
CW
S6
X501
C521
CR
501
+
+
D514
11
X502
C3
C2
8
CAL
513
12
POS
NEG
525
C1
516
4
PIN
A
B
510
D502
500
R525
X502
+
IN./MIN.
VOLTS
9
1
2
5
C501
C502
10
667
HI
M/MIN
518
6
7
525
BLUE
561
11
560
D506
3
+
-
C515
519
LO
517
E
10
B
F501
510B
C511
R524
C
518
B
PIN
B
C506
1
B
9
+
C407
C406
CW
C405
C404
X501
510B
562
515
C512
-
D510
D511
7
-
6
5
D513
5
6
2
3
R536
4
B
+
CR501
D
D518
D516
7
+
D503
B
+
CW
R530
C519
CW
CW
A
TP5
+5V
D505
3
C504
DZ502
533
534
S
X501
D
X502
C505
+
-
11
1
2
Q503
Q502
CR4
OUT
4
C
522
DZ503
IN
D501
G
D512
C513
D402
B
C514
TP4
+
C522
X401
DM401
510B
D515
B
525
21
D504
GND
S4
+
D401
C403
R508
C
E
530A
+
601
602
G.L.P. RESET
500
B
B
D507
C402
510
521A
D509
C401
SHUTDOWN
B
525 521 500
B
BYPASS TABS
520
D403 D404
VOLTAGE P.C. BOARD RECEPTACLE
FOR OPTIONAL PULSED POWER
FILTER P.C. BOARD PLUG
(SHOWN WITH JUMPER PLUG
INSTALLED)
B
510C
500
B
+
C517
510B
510A
1
4
3
2
634
X501
-
9
C
+
CW
635
R518
D508
"VOLTS"
CONTROL
10
8
514
GND
+
636
500
521A
C510
C516
B
E
510B
E
VOLTAGE CONTROL CIRCUIT
G
F
METER CIRCUIT
SHUTDOWN CIRCUIT
COMPONENTS NOT ON P.C. BOARD
COMPONENTS
CONTROL CIRCUIT
METER CIRCUIT
VOLTAGE CIRCUIT
KEY TO SYMBOLS
INPUT CABLE CONNECTION
POWER CIRCUIT
FOR POWER BOARDS
NOTES
FOR P.M. CONTROL BOARDS
L10068-1 OR HIGHER USE
SCHEMATIC L10069.
CIRCUIT
L7265-3 OR HIGHER USE
SCHEMATIC L8871.
C101
C102
C103
C104
C105
C106
C107
C108
C109
C110
C111
C112
C113
C114
C115
C116
C117
D101
D102
D103
D104
THRU
D108
D109
D110
D111
D112
D113
D114
D116
.005/1400
.047/100
.047/100
.005/1400
.005/1400
.15/200
150/50
.022/25
.022/25
.022/25
2.7/50
D117
D119
D120
1A
C201
.022/25
.022/25
18/15
R208
R209
R210
R211
R212
R213
R214
R215
R216
R217
R218
R219
R220
R221
R222
R223
R224
R225
R226
R227
R228
R229
R230
R231
R232
R233
R234
R235
R236
R237
R238
100K OHM TRIMMER
33K OHM
C401
C402
C403
C404
THRU
C407
D401
THRU
D404
X401
DM401
R401
R402
R403
R404
R405
R406
R407
R408
R409
500 MFD
4.7 MFD
27 MFD
C501
.1/100
Q501
Q502
Q503
X501
X502
TP501
2N4123
R525
R526
R527
R528
R529
R530
R531
R532
R533
R534
R535
R536
R537
R538
R539
R540
R541
R542
4.7K OHM
22K OHM
ELECTRICAL SYMBOLS PER E1537
CAPACITORS MFD/VOLTS
RESISTORS OHMS/WATTS
A
C
E
F
1A
C202
C203
C204
C205
C206
C207
C208
C209
C210
C211
C212
C213
C214
C215
C216
C217
THRU
C228
C229
D201
THRU
D206
D208
R201
R202
R203
R204
R205
R206
R207
C502
C503
C504
C505
C506
C507
C508
C509
C510
C511
C512
C513
C514
C515
C516
C517
C518
C519
THRU
C522
CR501
D501
THRU
D518
DZ501
DZ502
DZ503
F501
.005/1400
4.7/35
4.0/50
.47/50
.022/25
.022/25
39/20
2N4857
R1
2
OHM 50W
=
=
.15A
10K OHM
MPSA42
22K OHM
R2
10K OHM 2W POT.
10K OHM 2W POT.
22K OHM
22K OHM
R3
4.7/35
5.6K OHM
15K OHM
I.C. QUAD OP-AMP
I.C. QUAD OP-AMP
TRANSIENT
PROTECTOR
44.2K OHM 1/4W 1%
500 OHM TRIMMER
4.75K OHM 1/4W 1%
100K OHM
POWER OR SIGNAL SOURCE POINT
REMOVABLE CONNECTION
*
F101
R101
R102
R103
R104
R105
R106
R107
R108
R109
R110
R111
R112
R113
CR101
4/10 SLOW BLOW FUSE
330 OHM
.0033/200
.33/50
.022 MFD
2.2K OHM
27K OHM
R4
CR2
B
47K OHM
WELD CURRENT-
REED SWITCH
*
1
/2 WATT UNLESS OTHERWISE
SPECIFIED.
100K OHM
27K OHM
10 OHM
18/15
15K OHM
F
D
2.2K OHM
15K OHM
4/50
100K OHM
1K OHM
R501
R502
R503
R504
R505
R506
R507
R508
R509
R510
R511
R512
R513
R514
R515
R516
R517
R518
R519
R520
R521
R522
R523
R524
CR4
S1
G.L.P. REED SWITCH
SPST TRIGGER SWITCH
1A
COMMON CONNECTION
OP
-
AMP
=
LM 224
LM 723
F/V CONVERTER LM 2907
DUAL "D" FLIP FLOP MC14013B
10K OHM
.04/100
2.7/50
.022/25
1.8/20
.022/25
4.7/35
27/35
.022/50
1/35
.022/25
.47/50
39/20
R239
15K OHM
5.6K OHM
15K OHM
560 OHM
100 OHM
DPDT
CENT. OFF
HOT-COLD
1K OHM
1K OHM
R240
R241
R242
R243
R244
R245
R246
X201
X202
X203
X204
Q201
Q202
Q203
Q204
Q205
Q206
Q207
QU201
DZ201
DZ202
DZ203
VOLTAGE REGULATOR
DIGITAL METER
REGULATOR
=
B & D
S2
1K OHM
INTERLOCK SWITCH
10K OHM
.15/200
.022/25
.022/25
4.7/35
1K OHM
A
=
THRU
THRU
SOURCE POINT CIRCUIT LOCATION
TEST POINTS
G
E
F
270 OHM
.01/100
.022/25
.022/25
.022/25
.022/25
.15/200
16A
100K OHM
22K OHM
33K OHM
27K OHM
S3
S4
S5
S6
S7
T1
T2
X1
DPDT POLARITY SWITCH
24.3K OHM 1/4W 1%
2K OHM TRIMMER
2.80K OHM 1/4W 1%
13.7K OHM 1/4W 1%
2K OHM TRIMMER
3.74K OHM 1/4W 1%
*
33K OHM
=
50K OHM TRIMMER
15K OHM
15K OHM
SPST G.L.P. RESET SWITCH
DPDT SET-ACTUAL SWITCH
10 OHM
G
G
A
B
D
B
56K OHM
47K OHM
10K OHM
270 OHM
M
J
27K OHM
22K OHM
18/15
100pf/100
10K OHM TRIMMER
33K OHM
2.2K OHM
3
POLE VOLTS-SPEED SELECTOR SWITCH
10K OHM
68.1K OHM
I.C. REGULATOR
5K OHM TRIMMER
2K OHM TRIMMER
5.6K OHM
15K OHM
2.7MEG OHM
4.7K OHM
DPDT DIRECTION SWITCH
15K OHM
100K OHM
1K OHM
13.7K OHM
6.8K OHM
10K OHM
POWER SUPPLY TRANSFORMER
TRIGGER SUPPLY TRANSFORMER
HALL EFFECT MODULE
LEAD COLOR CODING
SINCE COMPONENTS OR CIRCUITRY ON
BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY
OF COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
A
PRINTED CIRCUIT
100 OHM
.022/25
.47/50
1A.
100K OHM
I.C. F/V CONVERTER
I.C. QUAD OP-AMP
I.C. QUAD OP-AMP
500 OHM TRIMMER
61.9K OHM 1/4W 1%
5K OHM TRIMMER
16A
16A
3PDT 24 VDC
1K OHM
B
R
-
-
BLACK
RED
D509 NOT USED FOR
GMA MODELS
SCR101 12A, 400V
SCR102 12A, 400V
.022/25
2.7MEG OHM
5.6K OHM
A
COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
CODE NUMBER.
A
COMMON
1A
Q101
Q102
Q103
Q104
Q105
PT101
TP101
X101
2N5655
2N5655
10K OHM TRIMMER
22K OHM
S.P.D.T. 24VDC
AMP
1.8K OHM
2N4123
U
-
BLUE
WHITE
100K OHM
CR501 N.C. CONTACT ARE
W
-
.15A
1A
MPS A92
1A.
1K OHM
270 OHM
15 OHM
100 OHM
1
1K OHM
2N4125
BS170
2N4123
2N5816
2N6027
6.8V.
SHOWN IN SECTION
B
FOR VOLTMETER P.C. BOARDS
L6688-1 OR HIGHER USE S21146
SCHEMATIC FOR COMPONENT
VALUES AND CIRCUIT CONNECTIONS.
2N4125
BS170
270 OHM
1A
6.8K OHM
2.7K OHM
10K OHM
20V, 1W
15V, 1W
100K OHM
.15A
1A
1:1:1 PULSE TRANS.
TRANSIENT PROTECTOR
I.C. DUAL "D" FLIP FLOP
15V, 5W
500 OHM TRIMMER
1.00K OHM 1/4W 1%
2.94K OHM 1/4W 1%
15K OHM
15K OHM
*
5.1V
56K OHM
FOR VOLTAGE P.C. BOARDS
L6084-4 OR HIGHER USE L8388
SCHEMATIC FOR COMPONENT
VALUES AND CIRCUIT
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E2056
THIS SHEET CONTAINS PROPRIETARY INFORMATION
6-7-96A
EQUIP.
TYPE
1 /8 AMP FAST
BLOW FUSE
15K OHM
330K OHM
22K OHM
4.7K OHM
1A
.15A
LN-9 GMA AND LN-9F GMA
OPERATING SCHEMATIC
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
OWNED BY
AND IS
12-21-89C
11-9-90D
11-1-91A
8-2-96B
THE LINCOLN ELECTRIC CO.
ON
ON
2
3
PLACE DECIMALS IS .02
PLACE DECIMALS IS .002
DZ101
DZ102
10K OHM
16.0V.
3.0V.
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
10K OHM
1M OHM
OCI501 OPTO-ISOLATOR
SUBJECT
10V, 5W
ON ALL ANGLES IS .5 OF
A
DEGREE
SCALE
6-25-92
DATE
NONE
*
t
SHT.
NO.
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
1-21-94H
3-25-94A
C112 AND PT101 PRIMARY ARE SHOWN IN SECTION
C
THE LINCOLN ELECTRIC CO.
6-26-86
CONNECTIONS.
DAD
REF.
1763
DR
CHK
SUPÕSÕDÕG
G
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 are 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
LN-9 GMA
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
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