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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
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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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 8. S’assurer que la masse est connectée le plus prés possible manuel aussi bien que les précautions de sûreté générales suiv- de la zone de travail qu’il est pratique de l
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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 Inst
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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 .....................
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vii vii NOTES LN-9 GMA Wire Feeder Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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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 ..............
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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 o o o o OPERATION: - 20 C to +40 C (- 4 F to +104 F) Recommended o o o o - 40 C to +40 C (- 40 F to +104 F) Maximum Rated o o o o STORAGE: - 40 C to +85 C (- 40 F to +185 F) WIRE DIAMETERS 0.023 through 1/16 Solid Electrode 0.045 through 5/64 Cored Electr
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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 ATTACHING THE WIRE REEL STAND one slot for mounting. Refer to the LN-9F GMA Dimension Print in the Diagrams section of this manu- Both the 2-Roll and 4-Roll LN-9 GMA are shipped with- al for the size and location of these slots. Mount the out the wire reel stand attached. The screws and wa
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A-4 A-4 INSTALLATION CONNECTING THE POWER INPUT ROUTING THE ELECTRODE CABLE ASSEMBLY TO THE LN-9 GMA The electrode supply may be either from reels, Readi- WIRE FEED UNIT 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 electrode must be routed to the wire feed unit so The control cable has a polarized plug on the wire that the bends in the wire are
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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 Connect to an appropriate Lincoln power source as fol- ASSEMBLY TO THE LN-9F CONTROL lows: BOX 1. If using a multipurpose source (such as the DC- 1. See Figure A.3. Connect the polarize
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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 sourc
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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
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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
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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 t
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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 a
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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 ELECTRODE CABLE P10,J10' P10',J10 K442-1 KITS TO LN-9 GMA 2 530A 2 TO WORK 14 PIN AMPHENOL 3 521 3 4 500 4 5 500 5 6 524 6 K596 REMOTE
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A-12 A-12 INSTALLATION DIRECT WORK LEAD CONNECTION MACHINE GROUNDING Lincoln specified procedures give voltage readings LN-9 GMA wire feeders are grounded to the power taken between the work and the gun cable brass con- source through the input cable. The power source nection block of the LN-9 GMA. To match these voltage grounding cable must be properly connected to electri- readings, the connection diagrams show the #21 lead cal ground. See your power source operating manual being extended and
