Home

Lincoln Electric IM355-C User's Manual

1. 20 Proced re at End Of en ne een E Ceu B 20 Security of Weld Procedure Settings B 20 TE Section C Auxiliary Equipment Contacts sise C 1 Optional Equipment and Accessories C 1 Power Input Cable Assemblies K196 K595 596 C 1 Wire Reel Stands and Mountings sssusa C 1 Gun and Cable Assemblies C 3 Wire 5 m C 3 gt e Section D FROUTING 5 een che 1 Drive Rolls and Guide Tubes ii D 1 Wire Reel Mounting 50 and 60 Ib Coils 4 D 1 Wire Reel Mounting Readi Reels and Spools D 1 CD PED D 1 Control ER D 1 Wire Drive Motor and Gear Box si D 1 LINCOLN B vii viii TABLE OF CONTENTS cont a and Cable Maint nafice cruce tenet a D 2 Proper Speed Sensor Motor Mounting ss D 2 Gun Cable Connector Requirements A D 3 lte TEE e e el DE Section E How to Use Troubleshooting Guide AAA E 1 Troubleshooting sise E 2 BIEL Section F EN 9 GMA Wiring 1 LN 9F GMA Wiring
2. 3 2 EN 9 GMA Dimension Prilit ioo F 3 LN 9F GMA Dimension etant te state F 4 viii A 1 INSTALLATION TECHNICAL SPECIFICATIONS INPUT POWER A 1 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 OPERATION 12 0 TO 60 0 VDC VOLTAGE CONTROL RANGE TEMPERATURE RANGE 20 C to 40 C 4 F to 104 F 40 C to 40 C 40 F to 104 F STORAGE 40 C to 85 C 40 F to 185 F WIRE DIAMETERS 0 023 through 1 16 0 045 through 5 64 PHYSICAL DIMENSIONS LENGTH WIDTH HEIGHT Recommended Maximum Rated Solid Electrode Cored Electrode TOTAL WEIGHT LESS ELECTRODE LN 9 GMA 2 ROLL 12 15 in 308 4 mm 11 56 in 293 4 mm 12 19 in 309 4 mm 29 3 165 13 3 kg LN 9 GMA 4 ROLL 12 15 in 308 4 mm 11 56 in 293 4 mm 12 19 in 309 4 mm 27 5 lbs 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 8 06 in 204 6 mm 7 5 in 190 4 mm 12 78 in 324 4 mm 15 6 lbs 7 1 kg 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 20 5 lb
3. INCOMING GUIDE TUBE SMALL RADIUS LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 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 NOTE Although an LN 9 GMA model is shown in Figure B 6 the following procedure also applies to LN 9F GMA models 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 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 On new feeders remove the tape and drive keys 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 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 t
4. FEB97 LINCOLN 8 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 Ib 13 1416 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN amp ACCESSORIES GUN AND CABLE ASSEMBLIES A variety of standard Lincoln
5. E 4 E 4 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S WIRE FEEDING PROBLEMS 1 Check to see if the grounding RECOMMENDED COURSE OF ACTION Gun trigger will not feed wire Meter If all recommended possible is on and reads SET value of VOLTS or WIRE SPEED lead protector GLP circuit has tripped Clear any fault discovered between the electrode circuit and the wire feeder frame and then press the GLP Reset areas of misadjustment have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility button See the topic Avoiding Grounding Lead Protector Shutdown in the Operation section 2 Check the gun trigger circuit CAUTION If for any reason you do not understand the test procedures or are unable to perform the necessary tests repairs safely contact your local authorized field service facility before you proceed LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B E 5 E 5 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S WIRE FEEDING PROBLEMS Check to see if the wire feeder or RECOMMENDED COURSE OF ACTION Gun trigger works and arc can be struck Unit then shuts down while If all recommended possible
6. To LN 9 Input Cable Plug Contro Cable Power Source Electrode Cable To Wire Feed Unit To Work Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and properly set the feeder polarity switch N A Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N B Extend lead 21 using 14 AWG or larger insulated wire physically suitable for the installation An S16586 remote voltage sens ing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience this extended 21 lead should be taped to the welding work lead Tape up bolted connection Connect the control cable ground lead to the frame terminal marked H j 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 elec trical ground per the power source Operating Manual Connect control leads t terminal strip as follows LN 9 Ato75 Bto77 Cto78 The LN 9 GMA voltage control jumpers must be connected as follows White jumper on voltage board to pin 5 Blue jumper on voltage board is not connected to any pin Secure loose jumper clear of any possible interference NOTE For proper pul
7. June 2010 LN 9 GMA and LN 9F 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 safe ty in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAU TIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL ISO 9002 S tg A EE ien Court Dee Sien Under Duaiery Program Cartified by ABS Quoiity Evakiationa inc 9002 Requirements NUMBER 30273 A b M 27 es Pul E f A Ca E 2 7 9 LINCOLN E World s Leader in Welding and Cutting Products 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 SAFETY A 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
8. INSERT MIDDLE GUIDE TUBE SMALL RADIUS LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 B 13 OPERATION WIRE LOADING Loading a 22 to 30 Lb 10 to 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter 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 18 Place the Adapter on the spindle g 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 lt Rotate the spindle and adapter so the retaining spring is at the 12 o clock position S 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 29 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 A 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
9. O d LVLSO3HY 5 i HOVENENE OHLNO9 SLIOA 2 LG BORER LEE v 6 9 9 9 12 1 Q3103NNOOSIG SI 41 90114 nr i d pou 38114 3ov1dau GHVOS 274 HANIL WWD zr BENE i i MOTIS JHL OL Q3103NNOO SI 310v1d303H 7318 E Or SS3NBVH JHL ANY SI 9114 d vee 10 05 h voes ol o i HOLIMS 1 138 yen 8019 0 gees 0 1 puur 0 9F GMA WIRING DIAGRAM LN o 5 i5 6 969 1 i o 816 31IHM LD 969 i oos QHVO8 274 e gt gt 09 H i 016 i 819 ES MOIS d 018 05 4 Les 18v3 8 1 4313W LG 80 6 48 O d ez es 4 e c 7 HOLIMS 80193136 03348 SLIOA VINO 46 1 Xx a LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN jo DIAGRAMS LN 9 GMA DIMENSION PRINT 7 50 190 5 12 15 308 6 816495 Dimensions in inches and
10. 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 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B A 13 INSTALLATION 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 10 Make sure the connector is fully seated and tighten the plastic 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 FOR GMA GUN CABLES Install the barbed fit
11. millimeters 11 14 86B Only for LN 9 GMA models with gas hose fittings LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B F 4 F 4 DIAGRAMS LN 9F GMA DIMENSION PRINT 1 OF 2 WIRE DRIVE UNIT of Wire 88 Ge 169 4 7 50 190 5 281 7 13 Dia 4 holes for mounting L7375 1 23 87 Outlet Gas Fitting 3 18 80 7 j Trigger Connector 1 72 43 6 Dimensions in inches and millimeters LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 DIAGRAMS LN 9F DIMENSION PRINT 2 OF 2 CONTROL BOX 1 57 39 9 H 28 2 holes for R 7 1 mounting 11 26 286 0 M13660 264 2 Dimensions in inches and millimeters 11 6 87E 3 LN 9F amp LN 9FH LN 9F GMA LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B NOTES LINCOLN amp Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO WEE SIR Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich
12. A 50 60 LB 22 7 27 2 KG COIL USING K1504 1 COIL REEL For 50 60 Ib 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 b1 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 FEEDING ELECTRODE AND BRAKE ADJUSTMENT 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 2 While tightly holding the electrode cut off the bent end Straighten the first six inches Cut off the first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a birdnest 3 Insert the free end through the incoming guide tube 4 Press the gun trigger or cold inch if used and push the electrode into the drive roll USE THE COLD TRIGGER SWITCH POSITION OR COLD INCH OPTION WHEN LOADING WHEN INCHING WITH A HOT
13. Adapter must also be installed according to the connection diagram and instructions provided in the Invertec Manual LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B A 6 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 4 404 4 1 08 11 1010 4 Only qualified persons should install can kill use or service this machine N F LN 9 Input Cable Plug 2 Power Source Control Cable 75 76 77 i CV Output Terminals on DC 250 Negative Positive 1 1 N B amp N C 2 Electrode Cable to Wire Feed Unit Work Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and 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 lea
14. BOX BOTTOM VIEW LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B B 7 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 DIGITAL METER A three digit digital meter is provid ed to set and monitor the welding procedure The arc voltage is displayed in volts and the wire feed speed is displayed in inches minute or meters minute METER READING SWITCH VOLTS AND WIRE SPEED CONTROLS This four position rotary switch is located to the right of the digital meter on LN 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 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 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
15. Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie tincelles 7 Quand on ne soude pas poser la pince une endroit isol 10 de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou atres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fum es toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment roxique ou autres produits irritants PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFOR MATEUR ET REDRESSEUR Relier a la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le
16. GMA 4 B 2 K436 LN 9F GMA 2 Roll and K583 1 LN 9F GMA 4 B 2 DC Constant Voltage Power Sources si B 3 COMtPOIS AMG 8 EE B 4 Circuit Protection and Automatic Shutdown ss B 7 Avoiding Grounding Lead Protector GLP Shutdown B 7 LINCOLN B vii TABLE OF CONTENTS cont a Brive Roll deeg eege a eee ea 9 Changing Drive Rolls for 2 Roll Wire B 9 Changing Drive Rolls for 4 Roll Wire Feederzs B 11 Errem B 13 Loading a 22 to 30 Ib Reddi Reel Package ee B 13 Loading a 10 to 30 16 5 EE B 14 50 00 6 5 508 15 Loading and Feeding 13 14 Ibs Innershield Coils seeesseeseeeseeesreerireeressrrssrrresrrresrsene B 16 Idle ROM Presstre Setting dance grade ne rte ete ne B 17 2 Wire B 17 4 RoIl Wire B 17 Making a Test Weld and Adjusting Response and Starting B 18 Adjust the Power SOUFCO ciere cei ere Lana adu sa dee Ex e Ua EE ge ka ulna ades B 18 Adjust the LN9 GMA Controls B 18 Voltage Control Hesponse iii B 19 Starting Characteristics 1r etre e Rex dera taints eg dex ee S RR B 19 Making Weld
17. GUN TRIGGER THE ELEC TRODE AND DRIVE MECHANISM ARE ALWAYS HOT TO WORK AND GROUND AND COULD REMAIN HOT SEVERAL SECONDS AFTER THE GUN TRIGGER IS RELEASED 5 Inch the electrode through the gun 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 OPERATION 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 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 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 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 o
18. This kit can also be connected to provide the same polarities on each feeder but the electrode circuit of the one not being used will be cold to work and to the other electrode Install the kit according to instructions included NOTE The K317 and K318 Dual Process Kits also include mode change capability but only when using the DC 600 power source This feature permits one feeder to weld in CV Innershield mode and the other feeder to weld in CV Submerged Arc mode as well as both in the same mode When using the Pulse Power 500 power source the K317 or K318 Dual Process Kits can be used only if the procedures are close enough to use the same mode setting The K317 or K318 cannot switch modes on the Pulse Power 500 An LN 9 GMA may not be used with an LN 7 or LN 8 although two LN 9 GMAs may be used together 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
19. along with the flux to be processed It is important to remove these magnetic particles from the flux which is to be reused in the continuous flux feeding system If the magnetic material is not removed it will gather around the nozzle of the gun and impede or shut off the flux flow when making rela tively long welds or when welding continuously The magnetic particles can also cause porosity in the weld Fit the magnetic separator into the funnel or hopper Pour the flux to be reclaimed into the top pan of the separator The separator is designed so that the flux flows around three permanent magnets The magnets remove all magnetic particles When the magnets become covered with their full load they automatically stop the flux flow When the flux flow stops remove the separator from the funnel or hopper Turn it over and open the panel that covers the magnets Remove the magnetic particles by brushing or by using an air blast WHEN USING COMPRESSED AIR BE CAREFUL TO PROTECT YOURSELF AND OTHERS IN THE AREA FROM FLYING PARTICLES NOTE The magnetic separator is used with all Lincoln mild steel fluxes 700 Series 800 Series and 900 Series Do not use the mag netic separator with any stainless steel alloy or hardsurfacing flux except H 535 The mag netic separator removes some of the alloying elements from these fluxes thus changing their characteristics LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B TABLE C 2 DRIVE ROLL
20. 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 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 400 500 Figure A 5 for DC 600 Figure A 6 for DC 1000 Figure A 7 for Pulse Power 500 Figure A 8 for R3S 400 R3S 600 R3S 800 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 INSTALLATION Figure A 9 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 400 500 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
21. dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispostifis de s ret leur place LINCOLN B V V for selecting a QUALITY product by Lincoln Electric We want you hank OU to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such information or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibili
22. input cable assembly It is easily mounted to the basic wire feed unit by three bolts The reel mounting spindle is the pull knob type with a built in brake The brake pad is adjustable for proper braking at low or high wire feed speeds 50 60 LB READI REEL MOUNTING STAND K445 The assembly includes a framework to which is attached a 2 O D spindle with adjustable brake and 50 60 Ib Readi Reel Adapter Includes a lift bail and cable clamp for fastening the input cable assembly and easily mounts to the LN 9 GMA feeder Does not include dust shield Can also be used for up to 60 Ib spools with 2 I D LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 2 ACCESSORIES ATTACHING THE WIRE REEL STANDS 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 1 Remove the three 3 8 in hex head bolts from the back of the wire feed unit 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 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
23. it across the reel hub locking the reel in place 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 To adjust the brake position remove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a fric tion fit LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 B 16 OPERATION FEEDING ELECTRODE AND BRAKE ADJUSTMENT 1 Turn the reel until the free end of the electrode is accessible 2 While tightly holding the electrode cut off the bent end Straighten the first 6 inches 3 Cut off the first inch Insert the free end through the incoming guide tube 4 Insert the free end through the incoming guide tube 5 Press the gun trigger or cold inch if used and push the electrode into the drive roll If the elec trode is not properly straightened it may not feed or may not enter the outgoing guide tube causing a birdnest 6 Inch the electrode through the gun 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 ALWAY
24. joint The end of the electrode should be slightly over the joint Lower the welding helmet close the gun trigger and begin welding Hold the gun so that the con tact tip to weld distance gives the correct electrical stickout as required for the procedure being used To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out PROCEDURE AT END OF COIL When the wire on the reel is used up follow this pro cedure for removing the old wire from the conductor cable and loading a new reel 1 Cut the end of the electrode off at the gun end Do not break it off by hand since this puts a slight bend in the wire and makes it difficult or impossible to pull it back through the nozzle Uncouple the gun conductor cable from the wire drive unit Lay the cable out straight Using pliers to grip the wire pull it out of the cable from the connector end Do not pull it from the gun end Put the conductor cable back on the wire drive unit after the electrode has been removed Load a new reel of wire and feed it through the cable as described earlier in this section SECURITY OF WELD PROCEDURE SETTINGS 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 The control range of the procedure con
25. kit SPINDLE FOR READI REELS AND 2 I D SPOOLS K162 H 60 Lb Maximum Capacity The 2 O D spindle kit is for use with the K303 The shaft for the standard 50 60 pound wire coils is removed from the mounting framework and the K162H is installed in its place Includes an easily adjustable friction brake for control of overrun When used with Readi Reels a Readi Reel Adapter is required When used with 8 O D spools a K468 Spindle Adapter is available 14 Lb Innershield coils can be mounted to the spindle using the K435 Adapter Replaces the K162 30 Lb Spindle Kit Install the spindle according to instructions included with the kit K162 30lb 13 6 kg M14573 Mounting instructions K162H 60 Ib 27 2 kg M15241 Mounting instructions CAUTION DO NOT USE COILS OR SPOOLS HEAVIER THAN 30 LBS ON THE ORIGINAL K162 SPINDLE LN 9 GMA and LN 9F GMA Wire Feeder READI REEL ADAPTERS K363 P Adapts Lincoln Readi Reel coils of electrode 30 Ib and 22 Ib to a 2 spindle One piece construc tion Made from a durable molded plastic Designed for easy loading adapter remains on spindle for quick changeover Included with K377 small mounting stand K438 Adapts 50 60 lb Lincoln Readi Reel coils to a K162 H spindle or similar 2 inch spindle suitable for 60 Ib spools Two piece construction made from a durable flame retardant molded plastic Designed for minimum loading downtime the coils easily load with insid
26. more cables and the single 4 0 stub behind the clamp so that only the single electrode lead is under the clamp 3 See Figure A 1 Pass the single electrode cable through the hole provided in the back corner of the wire section and fasten it to the conductor block of the copper strap along the side of the wire drive unit FIGURE A 1 INPUT CONTROL CABLE AND ELECTRODE CABLE CONNECTIONS CONDUCTOR BLOCK CONTROL CABLE ELECTRODE CABLE LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 A 4 INSTALLATION FIGURE A 2 STRAIN RELIEF CLAMP CONTROL CABLE STRAIN NZ RELIEF CLAMP ELECTRODE CABLE CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE LN 9F CONTROL BOX 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 FIGURE A 3 LN 9F GMA CONTROL BOX BOTTOM VIEW GLP RESET 9 PIN MS TYPE CONNECTOR 14 PIN MS TYPE CONNECTOR INPUT CABLE TO POWER SOURCE CONTROL CABLE TO WIRE FEED CIRCUIT BREAKER CONNECTING THE POWER INPUT CABLE ASSEMBLY TO POWER SOURCES Turn input supply power to the power source OFF before connecting the LN 9 GMA or LN 9F GMA wire feeder Connect to
27. new control panel is provided On the other end of the control cable is a small selector toggle switch and a mounting bracket A K302 Extension Control Cable is required when using the K319 with any LN 9F model Install the kit according to instructions included PULSE POWER FILTER CONVERSION KIT K442 1 Required for any LN 9 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 Install the kit according to instructions included LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 C 6 ACCESSORIES SWIVEL PLATFORM K178 1 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 8m when using the K178 1 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 CONTINUO
28. tight metal to metal electri cal contact Poor work lead connections can activate the grounding lead protector and or result in poor weld ing performance TABLE A 1 WORK CABLE SIZES Current Copper Work Cable Size AWG 60 Duty Cycle Up to 50 length 50 100 length 300 Amps 0 00 400 Amps 00 000 500 Amps 00 000 600 Amps 000 0000 DIRECT WORK LEAD CONNECTION Lincoln specified procedures give voltage readings taken between the work and the gun cable brass con nection block of the LN 9 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 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
29. von den Elektroden und dem Erdboden e Nao toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra VisBHtrte FROHALATMHEUTE OMLMPT ApPoStreBx 6 ss e Bo BIER UM SHSE SE au su ysa ij AAS ASA Ae i paal Alay JANI A A el UL yall DUS daa Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo e Gardez a l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUBODOMTOBEER THREW 4A CEET ET bt Een e jj 228 AIX We OSa JH ALI Al 2 Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo HAUSHERMRELTTF RRR ex 19 Sol sare FZHR dil die Lily aay d a READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZA
30. 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 prod ucts 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 Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b LINCOLN B SAFETY WELDING and CUTTING ZZ SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no
31. wire feed speeds the LO position will result in an over range meter reading of E EE which indicates that the HI range with single decimal place resolution should be used Similarly EEE will be displayed on the English position if the set ting exceeds 999 inches minute The procedure adjustments can be made before or during the weld This feature permits the operator to set the welding voltage and wire speed before welding and without assistance Once set the control circuits of the LN 9 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 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 SET ACTUAL PUSHBUTTON After the weld has been started the ACTUAL voltage or wire speed can be read by pressing the pushbutton to the left of the meter The METER READING switch must be set in the desired position When the pushbutton is not being operated the meter continues to read the SET value CIRCUIT PROTECTION AND AUTOMATIC SHUTDOWN CIRCUIT BREAKER The circuit breaker normally trips only when excessive loading in the wire feed cable or a defective motor or control component causes an overload After allowing a minute for coo
32. your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH limits Do not
33. 2 Mounting he cem Ets A 2 Installing the LN 9F GMA 2 Roll and 4 Roll Models eseeeeeeseeseeeeeressrrsrrresrssrnrsrrssrressrresrnns A 2 Mounting the Wire Feed Unit iius e dete xerit A 2 Mounting the Control Box iii A 2 Connecting the Wire Feed Unit to the Control Box A 2 Routing the Electrode 3 Electrical Connections LN 9 GMA and LN 9F A 3 Power Input Cable 1 1 sise A 3 Connecting the Power Input Cable Assembly to the LN 9 GMA Wire Feed Unit A 3 Connecting the Power Input Cable Assembly to the LN 9F GMA Wire Feed Unit A 4 Connecting the Power Input Cable Assembly to Power Sources A 4 Machine na 12 Work Gable COmmeCtiony Iran x Cut da due set E A 12 Direct Work Cable sise A 12 Connecting the Gun Cable to the Wire Feeder A 13 GMA Gun 13 Hooking Up GMA Shielding GaS 22255082 EE A 14 Re net en Section B Operating INSIMUCTIONS ee B 1 Safety Precautions etant B 1 General DescriptiORi te 2 Recommended Processes and Equipment B 2 K424 LN 9 GMA 2 Roll and K568 1 LN 9
34. 202 i 3LIHM 69 9 10301 3 QuvO8 I d 39 110 95 171503 IOHLNOO 03348 SHIM 15 3 dng 8 1 HOLIMS 1 148 lt 1 109 9 195 298 418 HOLIMS 80193135 03348 SL10A ues 14 H 09 gt 2d LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN jo NYI NN9 3189 08 08 40 3018 LNINOdWOD 5 NIYJAWNN ALIAVO IX 3718 Nid 2L onge Svo IMNON aay N e E orr er IP or gr or eir ONILVHFBOMAS NEZH HHMI EHNEN HOL VES 86 NYS 568 H S3OHhOS H3HIO S3OHnOS H3MOd 3dAL O Q NOILOJNNOO HOLIMS 1 EE H D q 2 ECH vi f zuo 869 625 LN3NOdWOO 40 ONIHSNE OL Q3193NNOO 54009 TIY NO IN3S34d LON Q3193NNOOSIG SI NOILdO JHL 4 uadAnr 0 1438 7074 39v L10A IHL OL Q3193NNOO 51 90114 SS3NHVH 274 431114 035109 1YNOILdO JHL NAHM SI 90114 3 OL Q3103NNOO O3ddIHS OL QHVOS 724 TOHINOO EN 7 9 Nid OL 03193 9 O3ddIHS 38 OL H3dWnr 3018 QHVOS 074 ONY S Nid OL Q3193NNOO q3ddlHS 38 OL 3LIHM QHVOS 274 39VILTOA VN SALON u3 v3u8 Linouno 1V1SO3HE 40 MOVE SV
35. 9NIONnOHO SS v 26 es 3 3 RE Fu 829 009 129 0291 94 HO103NNOO ARR 1fidNI 0 79 01 9 338 220 03140009 ATLHOIL VS JVS ONY WYS 868 53005 YIMOd 3dAL ATIVOLISNOVIN 53981108 7270 905 169 1 225 753009 41143 NO 1N3S3Ud LON ON SL 099 1 L 925 Q3193NNOOSIO SI NOLLdO i 7 SE 31 90719 HAdWAP 3ov 1d3d QuvO8 074 SOVLIOA IHL OL OH1NOO Wd 06 G3L93NNO9 SI 9079 SS3NHYH 2 4 83114 HIMOd 0387109 1 40 JHL N3HM SI 91114 i uaawne SE we x er O d H3MOd Wd 8199 O14 Nid OL 8665 ON Q3103NNOO Q3ddlHS 38 OL QuvOB 274 TOHLNOO EN us i 3 If VOIS 199 008 ess 11111117 8 Nid OL 03103 0 38 OL Han a CHVOA 2 4 3OV L10A ONY 5 Nid OL 03103 YOLOANNOD 9 G gdldS 38 OL QUVOB O d SOVIIOA 9999191 g S3LON i 1 1803 JO HOVE WOH CAMAIA SY SNOLLOSNNOO B H38NNN ALIAVO HOLOANNOO y 16813 81080148 1001610219 L 6 t 9 eL 5 m Wee 92 v iX lt 8 i
36. AND GUIDE TUBE KITS ACCESSORIES C 8 2 Roll ii 4 Roll Solid Steel Electrode 0 023 0 025 0 6 mm KP653 025S KP655 025S 0 030 0 8 mm KP653 0305 KP655 030S 0 035 0 9 1 0 mm KP653 035S KP655 035S 0 045 and 0 052 1 2 1 4 mm KP653 0528 KP655 0525 0 062 1 4 1 6 mm KP653 1 16 KP655 1 16 0 068 1 7 mm KP655 3 32 5 64 2 0 mm KP655 3 32 3 32 2 4 mm 2 KP655 3 32 Cored Electrode 0 035 0 9 1 0 mm KP653 035C KP655 035C 0 045 and 0 052 1 2 1 4 mm KP653 052C KP655 052C 0 062 1 4 1 6 mm KP653 1 16 KP655 1 16 0 068 1 7 mm KP653 3 32 KP655 3 32 5 64 2 0 mm KP653 3 32 KP655 3 32 3 32 2 4 mm KP653 3 32 KP655 3 32 Aluminum Electrode 0 035 0 9 1 0 mm KP654 035A KP656 035A 3 64 1 2 mm KP654 3 64A KP656 3 64A 1 16 1 6 mm KP654 1 16A KP656 1 16A LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 D 1 D 1 MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill Only qualified personnel should perform this maintenance Turn the input supply power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts ROUTINE MAINTENANCE DRIVE ROLLS AND GUIDE TUBES After feeding any coil of wire inspect the drive roll sec tion Clean it as necessary Do not use a solvent for cleaning the idle rolls s because
37. C Saal AUS dl babes ai gly gail Kall caulas agil LA LN 9 GMA WIRE FEEDER ERE LINCOLN e World s Leader in Welding and Cutting Products 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
38. D TO CL 103443 TIVH AE ang 418 J 3 J 006 iex 0i 829 9 0 4 015 4 lt lt m 018 oes voss k oos 128 46 01 y 8088 1 lt QONnOHO HOLIMS HOLIMS ONO AT8W3SSV 90 183INI q3au 919 1 TANVd G100 LOH 008 HOLIMS 1 2 ANNOYS 04 104199 ATBNSSSY QN 22 41 ves Vee UH vee 0 28 JU 0l Q3193NNO9SIQ SI YIWIL A 9nd IYNOILdO Sd O d HAINIL 04 HOVANENE VND TYNOILdO VND JHL OL 03103 SI 310v1d303H SS3NUVH JHL ONY IWNOLLdO d G3AONN3H SI 914 xovaNuna 109 209 VOLS 1 gt sols i us 215 Las ET L8v0L 6 9c GS 215 497 7158 Dr 119 91114 1VISO3H4 oir YIAN 8 141803 TIOHINO9 SLIOA 109 Hi e 209 H lt t et 209 n pe 298 eu 8 v 8 7299 2701 er lt 1 3 8 19 2 1 09s 6 VOIS Laois us DEEE 819 298 815 019 56 u3dWnr
39. E 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 and LN 9F GMA Wire Feeder LINCOLN 8 C 1 C 1 ACCESSORIES AUXILIARY EQUIPMENT CONTACTS 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 TURN THE INPUT POWER TO THE POWER SOURCE OFF AT THE DISCONNECT SWITCH BEFORE PERFORMING THE FOLLOWING WORK LN 9 GMA MODEL 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 tangular hole in the control section sheet metal near the wire feed motor 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 NOTES 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 Z4 and 31 on the po
40. For most applica tions best wire feeding will occur when both idle roll pressures are set the same FIGURE B 9 IDLE ROLL PRESSURE SETTING FOR TWO ROLL FEEDERS ADJUSTMENT KNOB LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 B 18 OPERATION MAKING A TEST WELD AND ADJUSTING LN 9 GMA RESPONSE AND STARTING CHARACTERISTICS ADJUST THE POWER SOURCE DC 250 DC 400 or DC 600 1 Connect electrode lead to terminal of desired polarity Set toggle switch to same polarity as the electrode cable connection Set toggle switch to Output Control Remote Set mode switch to the desired position for the process to be used CV 400 500 1 Connect electrode lead to terminal of desired polarity 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 Set toggle switch to Output Control Remote R3S 400 R3S 600 R3S 800 1 Connect electrode lead to terminal of desired polarity Set toggle switch to same polarity as the electrode cable connection Set the toggle switch to Remote Install voltage triangle to a position as close as possible to desired arc voltage NOTE Since the LN 9 GMA cannot control the fixed OCV of R3S power sources starting difficulties may be experienced when strik ing the arc of processes which use a low voltage or a narrow voltage range The following steps should re
41. R SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN LINCOLN B Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria eta Lh p5o5gmtmdio5ctuc OTD SMS OF RRS wh Bak HR SSS 2878 87I amp MASH Ash 7 55212 ZEE dall e Lag ayi e EAU oa jaa si MI ou ge uc e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D br
42. RICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information LINCOLN B SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter tou jours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants Secs et sans trous pour isoler les mains b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse c Maintenir le porte lectrode la pince de masse le cable de soudag
43. S HOT TO WORK AND GROUND AND COULD REMAIN HOT SEVERAL SECONDS AFTER THE GUN TRIGGER IS RELEASED LOADING AND FEEDING 13 14 LB INNERSHIELD COILS K378 REEL MOUNTING STAND The K378 small mounting stand for the 14 pound Innershield coil does not have an adjustable brake It has a fixed drag built into the reel spindle To load a 14 pound coil 1 Remove the snap on lid from the plastic canister 2 Remove the center clamping nut and the cover plate from the wire reel 3 Unpack the 14 pound coil of wire Be sure not to bend the side tangs of the coil liner Straighten any tangs that may have been bent 4 Remove the start end of the coil from its holding slot in the coil liner cut off the bent end straighten the first six inches and cut off the first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing tube causing a birdnest Thread it through the canister wire feed liner until about four inches of electrode are exposed 5 Place the coil onto the disc support 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B OPERATION IDLE ROLL PRESSURE SETTING The idle roll pressure is se
44. SNOLLO3NNOO V Lr 13538 ALIAVO HOLOANNOD y 310V1d303H LNdNI 419 1 39 830 46913 Yad 81080148 1V91419373 318V0 HOvL S HOLO3NNOO 4399101 0334 tp anis OSNIGNNOYS 35 0 LINN 0344 34IM 9 9 y gt 229 829 829 lt 629 2 19 E ND yc 229 5 a lt a x a o anis 0314002 ONIGNNOYD ATIVOILINDVN 35 2 gt e YOLOANNOO T INdlNo LJ 19 XA N9 a 829 r 625 KON ze wee vto 005 HOLIMS X00 1831NI HOLIMS HOLIMS 0100 10 oo De 24546 2 goes lo H 0 DI yz 28 008 THO HOLIMS 419 lt 209 L 29 lt q E 1V1S03HH lOHLNOO 03348 V 609 229 129 0201 _ 0 005 Quvo8 24 mm 169 IOBLNOO 1 8 mE TWNINYSL SS T 1 f 8 1112101219 DIAGRAMS K6 1 v 9 3 NERT 909 018 888 829 4 O d 628 4 i YD TOYLNOD Wd ges d r NOILdO t ves d i dHVOS
45. 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 Tape up bolted connection Connect the LN 9 GMA control cable ground lead to the frame terminal marked ai near the power source terminal strip The power source must be properly grounded If using an older automatic control cable with leads 75 76 77 connect lead 75 to 75 on terminal strip connect lead 76 to 74 on terminal strip connect lead 77 to 73 on terminal strip The LN 9 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 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 Alternative 500 amp positive terminal connection provided on DC 1000 models above code 9500 only LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B 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 00 31 Only qualified persons should install can kill use or service this machine
46. UN IN is provided on the new L10068 1 Control PC board 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 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B B 20 B 20 OPERATION MAKING A WELD 1 Inch the electrode through the gun and cable and then cut the electrode within approximately 3 8 of the end of the contact tip for solid wire and within approximately 3 4 of the extension guide for cored wire Connect the 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 Be sure the welding power source and the shield ing gas supply are turned on Position the electrode over the
47. US FLUX FEED TANK K320 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 The kit is a complete continuous flux feeding system including air filter pressure regulator gage tank and 18 foot flux hose It also includes a funnel for filling the tank plus the lift bail assembly required to mount the tank and wire feeder to a K163 undercarriage The tank can also be used as a free standing assembly Install the tank according to instructions included with the K320 kit LN 9 GMA and LN 9F GMA Wire Feeder K320 FLUX TANK LOADING Either turn off the incoming air line or remove the quick disconnect if one has been installed Slightly loosen the tank cap and let the air in the tank escape through the holes in the side of the cap After pressure has been released remove the cap from the tank Using the funnel provided put 100 pounds of flux into the tank 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
48. anchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e x2TTLA 4 UAKRUP PARKII FE e MEMO AHS Aa UY d i A i Ac Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas ONFULPAN ERVALEEE CRHMTFELEUTFEU CHERTARRARS edo ya deis Sa Oo AIR CSIs 13 jual lis Ja ys Aale uad AM Al Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Hx SI Ex ZE A Korean LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 7 018 ECORS ETEMNLCTSU CL TRHORSMEI HT FS Ef EF 3E RB SES MEHR BA RES FR 09 SR PS SE ERG S 75 8978 BOSE ol AZo SSE Giel AA Sei BA
49. and Magnum gun and 10 ft 12 ft and 15 ft cable lengths Choose the gun cable assemblies are available for the LN 9 GMA in 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 Process Model Electrode Rating Gas Metal Arc GMA K426 035 052 0 9 1 3 mm solid 350 amps 045 1 1 2 0 mm cored 350 amps K427 045 1 1 1 6 mm solid 500 amps Ys 4 1 6 2 0 mm cored 500 amps Magnum 470 035 0 9 1 6 mm solid 300 amps 035 0 9 2 0 mm cored 300 amps Magnum 471 035 0 9 1 6 mm solid 400 amps 035 0 9 2 0 mm cored 400 amps Magnum 478 035 6 0 9 1 6 mm solid 300 amps 035 0 9 2 0 mm cored 300 amps Magnum 479 035 0 9 1 6 mm solid 400 amps 0 35 0 9 2 0 mm cored 400 amps Innershield K126 068 1 7 2 0 mm Innershield 350 amps K115 2 0 mm Innershield 450 amps K2069 068 1 7 2 0 mm Innershield 350 amps K2899 2 0 mm Innershield 500 amps K3099 068 1 7 2 0 mm Innershield 250 amps Submerged Arc K112 Ye 1 6 mm Solid 500 amps 07 K466 1 connector kit required 9 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 Innershiel
50. are available for this purpose The screen in the funnel supplied with the tank has much larger openings and its only purpose is to keep paper and slag out of the tank Screw the tank cap back on and tighten it hand tight Reconnect the incoming air line to the tank There will always be a small amount of air and possi ble drops of water coming out of the end of the tube coiled under the tank This is an automatic disposal System in case the plant air has water and dirt in it K310 FLUX SCREEN This unit is designed to fit the top of either the standard fill funnel of a continuous flux feed system or a K58 magnetic separator The unit has a steel screen with 0 065 to 0 075 openings and an air vibrator attached to the frame The vibrator can be used with air line pres sure ranging from 20 psi to 100 psi For ease of handling you should connect the incoming air line to the 1 8 pipe elbow with the aid of a fast dis connect type air coupling It is very important that reclaimed flux to be used in the continuous flux feeding system be passed through the K310 screen or its equivalent FEB97 LINCOLN 8 C 7 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 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
51. at the gun cable is If all recommended possible or wire feeding is rough or uneven kinked and or twisted Keep the areas of misadjustment have cable as straight as possible been checked and the problem Inspect the cable and replace if persists contact your local necessary Lincoln Authorized Field Service Check for wire jammed in the gun Facility and cable Remove wire from the gun and cable feed in new wire Note any obstruction Replace the gun and cable if necessary Check for incorrect drive rolls and guide tubes or incorrect drive roll assembly or pressure setting Be sure the wire diameter being used is stamped on the drive rolls and guide tubes Replace if necessary Check for proper pressure setting and assembly Check to see if the gun cable is dirty Clean the cable per manual instructions Check for worn drive roll or idle roll Replace or reverse split drive roll type Check to see if the electrode is rusty and or dirty Replace the electrode if it is rusty If conditions are extremely dirty or electrode is old solid wire only put a wiper on the wire before it enters the guide tube Use a piece of cloth or felt saturated with Pyroil B held around the wire with a light clamp Check for a worn nozzle liner Replace nozzle liner if necessary Check for partially flashed or melted contact tip Replace the contact tip if necessary A CAUTION If for any reason you do not understand t
52. 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 OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE d 1h To avoid scalding do not remove the 9l 5 radiator pressure cap when the engine is powered equipment Kelte e a 9 1 a Turn the engine off before troubleshooting and maintenance x 5 work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes 47 outdoors AR ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld may be dangerous ing arc or when the engine is running Stop t
53. d guns and vacuum units can be used in these locations Instructions are shipped with the equipment WIRE FEEDER ACCESSORIES BURNBACK TIMER KIT K419 Provides a precise control of the electrode burnback Install the kit according to the M15060 instructions at the end of the weld Prevents crater sticking and included with the kit 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 C 5 C 5 ACCESSORIES GMA TIMER KIT K418 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 O to 1 5 seconds 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 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
54. d 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 Tape up bolted connection if lead 21 is extended 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 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 and LN 9F GMA Wire Feeder LINCOLN B INSTALLATION FIGURE A 5 CONNECTION OF LN 9 GMA TO DC 600 POWER SOURCES WARNING e Turn off input power to the welding power source using the disconnect switch at the fuse box before connect ing the wire feeder fete 4 Only qualified persons should install can k
55. e 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 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 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 The same general procedure can be used on other power sources For example if the LN 9 GMA keeps shutting down and the ot
56. e adapter half on spindle Four twist latches lock adapter halves together Included with K445 50 60 Ib Readi Reel stand 60 LB 27 2 KG COIL ADAPTER K1504 1 Permits 50 60 Ib 22 7 27 2 Kg coils to be mounted to a 2 b1mm spindle SMALL MOUNTING STAND FOR READI REEL COILS OR 2 1 0 SPOOLS K377 30 Lb Maximum Capacity This assembly includes a small frame to which is attached a wire reel spindle similar to the K162 spindle The unit is supplied with the K363 Readi Reel Adapter for use with the Lincoln 22 30 Ib Readi Reel Electrode Coils Without the adapter the unit is capable of han dling up to 30 Ib spools with a 2 I D a 12 max O D and a 4 width For spools with an 8 O D a K468 Spindle Adapter is available 14 Ib Innershield coils can be mounted to the spindle using the K435 Adapter The spindle has an easily adjustable braking system SMALL MOUNTING STAND FOR 13 14 LB INNER SHIELD COILS K378 This assembly includes 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 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 Ib wire reel spindle shaft adjustable brake insulation and mounting hardware Install the assembly according to instructions included with it
57. e et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir e Ne jamais toucher simultan ment les parties sous ten sion des porte lectrodes connect s deux machines Souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enroule le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnementde l arc c Prot ger l autre personnel travailant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier
58. e welding techniques If recommended possible blast offs weld porosity narrow or procedures being used areas of misadjustment have and ropy looking bead or electrode proper See Gas Metal Arc been checked and the problem stubbing into plate while welding Welding Guide 65 100 persists contact your local Innershield Production Welding Lincoln Authorized Field Service Guide 675 Outershield Facility Procedure Guidelines GSP 70 GSP 71 Procedure Guidelines for Pulsed Spray Welding GSP PULSE or How To Make Submerged Arc Welders S604 Check that the wire feed acceleration setting is proper for the process See the topic Starting Characteristics in the Operation section for proper acceleration setting Check that the Voltage Control Response is properly set for the power source and process See the topic Voltage Control Response in the Operation section and the appropriate power Source connection diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the necessary tests repairs safely contact your local authorized field service facility before you proceed LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B DIAGRAMS LN 9 GMA WIRING DIAGRAM 318 0 NNO _ IYO 809 648 HOLIMS Q33H 1N3HHnO 10 3018 IN3NOdWOO 39N3n038 SNIB38IWPN ALIAVO dlON3108 svo anis
59. ear 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 45 angle so the wire feed gun cable will not be bent sharply as it comes from the unit MOUNTING THE CONTROL BOX The same control box is used for both the 2 Roll and 4 Roll wire feed unit It contains two keyhole slots and one slot for mounting Refer to the LN 9F GMA Dimension Print in the Diagrams section of this manu 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 1 Drill the required holes in the mounting surface Partially install 1 4 20 screws 2 Open the control box door by removing the two door screws 3 Mount the box 4 Tighten the screws 5 Close the control box door and replace the door screws CONNECTING THE WIRE FEED UNIT TO THE CONTROL BOX Both the LN 9F GMA 2 Roll and 4 Rol
60. ecific 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 Rated wire size range 023 through 1 16 solid wire electrode 045 through 5 64 Outershield cored electrode 062 through 5 64 Innershield cored electrode Rated wire speed range 80 through 980 inches per minute 2 03 through 24 9 meters per minute LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 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 R3S 400 and R3S 600 may also be used but are lim ited due to narrow voltage range on each tap They are not recommended if input voltage varies LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B B 3 B 4 OPERATION CONTROLS AND SETTINGS 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 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 Sw
61. ed from their mounting struc ture See the Accessories section for information about mounting a K299 wire reel assembly ELECTRICAL CONNECTIONS LN 9 GMA AND LN 9F GMA POWER INPUT CABLE ASSEMBLY 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 CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE LN 9 GMA WIRE FEED UNIT 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 1 See Figure A 1 Connect the polarized plug of the control cable to the mating connector on the back of the wire feeder 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 For cables with more than one electrode cable leave the junction between the two or
62. et 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 RECOMMENDED PROCESSES AND EQUIPMENT The LN 9 GMA is available in four models 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 FIGURE B 1 BASIC LN 9 GMA HOOKUP K424 K568 1 all wire sizes K196 XXX K595 XXX or K596 XXX K436 LN 9F GMA 2 ROLL AND K583 1 LN 9F GMA 4 ROLL 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 Customer s Boom K436 K583 1 all wire sizes W K196 XXX 595 596 oe 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 sp
63. 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 FIGURE B 7a Threaded Locking Collar 2 IN O D SPINDLE ADAPTER RETAINING SPRING BRAKE HOLDING PIN GROOVES READI REEL INSIDE CAGE WIRES THREADED LOCKING COLLAR FIGURE B 7b Retaining Collar 2 IN OD SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR GROOVES READI REEL INSIDE CAGE WIRES RELEASE BAR LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 B 14 B 14 OPERATION LOADING A 10 TO 30 LB 4 5 TO 14 KG SPOOL 12 DIAMETER OR 13 14 LB 6 KG INNERSHIELD COIL 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 Ib 6 Kg Innershield coils a K435 Coil Adapter must be used 1 Depress the Release Bar on the Retaining Collar and remove it from the spindle NOTE Eariler spin dles used a threaded collar Ze 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 5 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 LOADING
64. he digital meter This shield must always be installed If it breaks or becomes damaged replace it by removing the two screws securing its frame installing a new shield and reattaching the frame WIRE DRIVE MOTOR AND GEAR BOX Every year examine the gearbox Paint the gear teeth with molydisulfide filled grease Lincoln specification E2322 Do not use a graphite grease Check the motor brushes Replace if they are worn down to 1 4 or less When ordering feed motor brush es give all information from the motor nameplate LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 D 2 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 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 techni
65. he engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Exposure to EMF fields in welding may have other health when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark pl
66. he hex head screw 10 11 12 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 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 Close and latch both quick release levers 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 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 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B OPERATION FIGURE B 6 INSTALLING DRIVE ROLLS ON A 4 ROLL FEEDER CLAMPING COLLAR PA DRIVE ROLL HALVES SPACER IF 2 REQUIRED y GELS nS Ir OUTPUT GUIDE TUBE DETAIL RADIUS OUTGOING GUIDE TUBE OUTGOING GUIDE TUBE
67. he test procedures or are unable to perform the necessary tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 WELD or 216 383 2531 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B E 3 E 3 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S WIRE FEEDING PROBLEMS 1 Check to see if the circuit RECOMMENDED COURSE OF ACTION Gun trigger will not feed wire Digital If all recommended possible meter is not lit breaker is tripped Reset the circuit breaker See the topic Circuit Breaker in the Operation section Check to see if the power supply areas of misadjustment have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility fuse is blown Replace the fuse See the topic Power Supply Fuse in the Operation section Check to see if there is 115 VAC supply from the power source Check that power source is on If so check the power source AC fuse 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 necessary tests repairs safely contact your local authorized field service facility before you proceed LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B
68. her 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 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 B 9 OPERATION DRIVE ROLL INSTALLATION CHANGING DRIVE ROLLS FOR 2 ROLL WIRE FEEDERS To change drive rolls on a 2 roll wire feeder refer to Figure B 5 and perform the following steps 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 On new machines remove the tape and the drive key 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 roll
69. ided to Step 3 CONSULT LOCAL AUTHORIZED help you locate and repair possible machine FIELD SERVICE FACILITY misadjustments Simply follow the three step If you have exhausted all of the procedure listed below recommended tests in step 2 consult your local Authorized Field Service Facility Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that your machine may exhibit Find the listing that best describes the symptom that your machine is exhibiting Problems are divided into WIRE FEEDING PROBLEMS or WELDING PROBLEMS Step 2 PERFORM EXTERNAL RECOMMENDED 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 CAUTION If for any reason you do not understand the test procedures or are unable to perform the necessary tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 WELD or 216 383 2531 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 E 2 E 2 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WIRE FEEDING PROBLEMS Drive rolls turn but wire will not feed 1 Check th
70. ill use or service this machine To LN 9 Input Cable Plug Power Source Control Cable Kee 4 2 8 32 1175 76 77 Negative Electrode Cable To Wire Feed Unit t To Work Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and position the switch on power source to proper polarity 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 Tape up bolted connection Connect the LN 9 GMA control cable ground lead to the frame terminal marked near the power source terminal strip power source must be properly grounded 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 o
71. important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page ctii testes i iv 11 14 11 1101 Eee E Section A Technical Specifications erresa rss E eeu es dex Dux ee 1 Installing the LN 9GMA 2 Roll A Pol Models A 2 Attaching the Wire Reel stand otro nh eee e e ne A
72. 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 you use a wire size other than that stamped on the rolls the roll s and guide tubes must be changed 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 See the Operation Section for drive roll installation instructions See Table C 2 in the Accessories section for drive roll and guide tube kits WIRE REEL MOUNTING 50 AND 60 LB COILS WITH 1 SPINDLE 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 WIRE REEL MOUNTING READI REELS AND 10 THROUGH 44 LB SPOOLS AND 50 AND 60 LB COILS WITH K1504 1 ADAPTER No routine maintenance required Do not lubricate the 2 spindle PERIODIC MAINTENANCE CONTROL BOX Every six months open and inspect the control section The accumulated dirt should be gently blown off all of the electrical components Be sure the air that is being used is dry Check the contacts of the large plug in relay A spatter resistant shield protects t
73. itch 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 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 HOT COLD TRIGGER INTERLOCK SWITCH This 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 1 Hot Cold Wire Feed In the center position the wire will be electrically cold when feeding with the gun trigger In either the up or down positions the wire will be hot when feeding with the gun trigger 2 Trigger Interlock Function In the down position the trigger interlock will be OFF allowing the gun trigger to function in the normal mode This stops wire feed and welding when the trigger is released In the up position the trigger interlock will be ON The trigger interlock feature functions as follows a When you are no
74. l include the same 16 ft control and electrode cable assembly Connect the wire feed unit to the control box as follows 1 Make certain the cables are protected from any sharp corners that may damage their jackets Mount the cable assembly along the boom so the end with the female amphenol connector pins is at the wire feed unit 2 Connect the cable connector to the receptacle on the back of the wire feed unit connection box 3 At the same end connect the electrode lead to the connection stud of the copper strap along the side of the wire feed unit 4 At the control box end connect the amphenol con 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B A 3 INSTALLATION ROUTING THE ELECTRODE The electrode supply may be either from reels Readi Reels spools or bulk packaged drums or reels Observe the following precautions The electrode must be routed to the wire feed unit so that the bends in the wire are at a minimum The force required to pull the wire from the reel into the wire feed unit must be kept at a minimum The electrode is hot when the gun trigger is pressed and must be insulated from the boom and structure If more than one wire feed unit share the same boom their wire and reels must be insulated from each other and insulat
75. led in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Variable or hunting arc Check for worn or incorrect sized If all recommended possible contact tip Replace tip if areas of misadjustment have necessary been checked and the problem Check for worn or undersized persists contact your local work cables Repair or replace if Lincoln Authorized Field Service necessary Facility Check for loose electrode connections sure the following connections are tight Electrode cable to wire feeder and power source work cable to power source and work gun cable to wire feeder contact block gun nozzle to body and contact tip to nozzle Check whether the Voltage Control Response is properly set for the power source and the process See the topic Voltage Control Response in the Operation section CAUTION If for any reason you do not understand the test procedures or are unable to perform the necessary tests repairs safely contact your local authorized field service facility before you proceed LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B E 7 E 7 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Poor arc striking with sticking or 1 Verify that th
76. ling 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 POWER SUPPLY FUSE The fuse on the PM power board inside the control box protects the power supply circuit When the fuse is blown the digital meter is off and the trigger circuit will not operate VOLTAGE PC BOARD FUSE The 1 8 amp fast blow fuse protects the LN 9 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 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 B 8 OPERATION If such a grounding lead fault occurs the meter will still be on and will be reading The trigger circuit will not operate however To release the circuit press the GLP Reset button See Figure B 3 or B 4 for the loca
77. m WIRE FOR ALL OTHER DIMENSIONS SEE DIAGRAM ABOVE NOTE Connector part with 7459 747 19 0 18 9 diameter should be made from brass if it is to be part of the welding current carrying circuit A Diameter Hole to be Concentric to 749 747 19 0 18 9 Diameter Within 008 20 F I M Wire Size in mm 0 68 5 64 1 7 2 0 125 1 8 3 2 mm Drill 1 16 0 062 1 6 078 5 64 2 0 mm Drill 045 amp 052 1 1 amp 1 3 062 1 16 1 6 mm Drill 023 035 0 6 0 9 055 1 4 mm 54 Drill All dimensions in inches and millimeters FIGURE D 2 SWITCH REQUIREMENTS 1 2 Amp AC 24 Volts Inductive 1 2 Amp DC 24 Volts Inductive To Gun Switch Connect Leads to Pins A amp C 12024 1 L E Part No Amphenol AN3057 10 or equiv 12020 6 L E Part No Amphenol MS 3106A 18 11P or equiv LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 E 1 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING This Troubleshooting Guide is designed to be used by the machine Owner Operator 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 please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment This Troubleshooting Guide is prov
78. medy this difficul ty 1 The electrode stickout when starting should be as close to procedural length as possible and the tip of the electrode should be clean and held nearly touching the work 2 Install the R3S voltage triangle to the position higher than the desired arc voltage provided it does not result in out of range shutdown of the LN 9 GMA while welding PULSE POWER 500 DC650 PRO V300 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 ADJUST THE LN 9 GMA CONTROLS 1 Set the Electrode Polarity switch to same polarity as the electrode lead Check that Feed Direction is set to forward Set the Trigger Interlock switch as desired Set the Meter Reading switch to Wire Speed and adjust the Wire Speed rheostat so the meter reads the desired wire feed speed 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 Load the LN 9 GMA with electrode LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 B 19 OPERATION VOLTAGE CONTROL RESPONSE 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 pro
79. n 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 FIGURE B 8 LOADING A 50 OR 60 LB COIL SPINNER COVER PLATE CARDBOARD COIL LINER TIE WIRE SPRING 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 c Putthe cover plate on the reel so that the four arms of the cover straddle and are in line with the spring loaded arm of the reel 4 Tighten the cover as much as possible by hand DO NOT hammer on the spinner nut arms 5 Cut and remove only the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in backlashing of the coil which may tangle the wire A tangled coil will not feed therefore it must either be untangled or discarded 6 Replace the reel on the wire feeder Grasp the shaft knob pull it out and swing
80. ning the union nut FIGURE A 11 SHIELDING GAS HOOKUP LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 OPERATION e OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions operating the machine SAFETY PRECAUTIONS ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring ee e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause S fire or explosion Keep flammable material away ARC RAYS can burn ie Wear eye ear and body protection LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 B 2 B 2 OPERATION 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 e 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 inl
81. nly or on start board Earlier units to pin B For DC 600 Codes below 8200 connect a jumper from N to P on LN 9 GMA only There is no NPS terminal strip on codes above 8200 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B INSTALLATION FIGURE A 6 CONNECTION OF LN 9 GMA TO DC 1000 POWER SOURCES WARNING e Turn off input power to the welding power source using the disconnect switch at the fuse box before connect ing the wire feeder eg Only qualified persons should install can kill use or service this machine TO LN 9 INPUT CABLE PLUG POWER SOURCE CONTROL CABLE NEGATIVE POSITIVE N B amp N C Lt ELECTRODE CABLE TO WIRE FEED UNIT CONNECT TO WORK Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source position the positive negative switch on power source to correspond to the polarity of the electrode cable connection N A Welding cables must be proper capacity for the current and duty cycle of immediate and future applications Extend lead 21 using 14 or larger insulated wire physically suitable for the installation an 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it separate from the welding work cable connection to work piece For convenience this extended 21 lead should be taped along the welding work cable
82. painted frame Screw The power source must be grounded properly N A On earlier R3S 400 600 amp 800 machines 67 amp 1 terminals were also on the terminal strip 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 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 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 Upper terminal strip 75 76 amp 77 may not appear on older 5 machines and therefore is not compatible for use since there will be no adjustment of voltage by the LN 9 GMA The LN 9 GMA voltage control jumpers must be connected as follows White jumper on voltage board To pin F for open arc process or To pin S for submerged arc process Blue jumper on voltage board later units only or on start board earlier units to pin A LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN 8 A 11 A 11 INSTALLATION FIGURE A 9 CONNECTION OF LN 9 GMA TO V300 POWER SOURCES WARNING e Turn off input power to the welding powe
83. part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld 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 Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard fo
84. per 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 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 d Reassemble STARTING CHARACTERISTICS SELECT ACCELERATION 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 a Turn OFF the control power to the LN 9 GMA at the power source b Remove the screws holding the control section cover in place and swing it open c On machines having an L7253 Control PC board move the jumper plug on the PM Control PC board from pin 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 START VOLTAGE TRIM The s
85. que 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 FIGURE D 1 SPEED SENSOR MODULE LOCATION e d Y P 5 K LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B D 3 MAINTENANCE GUN CABLE CONNECTOR REQUIRE MENTS TO PERMIT PROPER CONNEC TION TO LINCOLN LN 9 GMA AND LN 9F GMA WIRE FEEDER 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 FIGURE D 2 LN 9 GMA CONNECTORS 749 19 0 747 18 9 E D E N 03 45 76 x 45 062R 1 5R Style A A DIA HOLE m 295 7 49 290 7 36 252 6 40 260 6 60 Connector must be insulated in this area 1 00 25 4 1 25 31 7 2 00 51 0 LN 9 CONNECTOR FOR 1 16 5 64 1 6 2 0 MM WIRE 180 4 5 03 x 45 76 x 45 DIA HOLE 495 12 5 DIA Style B LN 9 CABLE CONNECTOR FOR 023 052 0 6 1 3 m
86. r Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing vai CYLINDER may explode if damaged 3 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECT
87. r source using the disconnect Switch at the fuse box before connect ing the wire feeder 4 404 4 1 08 17 1010 Only qualified persons should install can kill use or service this machine E ELECTRODE CABLE 608 AND TO LN 9 GMA ai 14 PIN K442 1 KITS AMPHENOL K596 REMOTE CONTROL CABLE INVERTEC ASSEMBLY POWER SOURCE WITH 110 115V AUX 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 and LN 9F GMA Wire Feeder LINCOLN B INSTALLATION MACHINE GROUNDING 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
88. s 9 2 kg DUTY CYCLE The amount of welding performed in a 10 minute period expressed as a percentage LINCOLN B LN 9 GMA and LN 9F GMA Wire Feeder A 2 INSTALLATION INSTALLING THE LN 9 GMA 2 ROLL AND 4 ROLL MODELS 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 2 Place the wire reel stand mounting bracket in posi tion against the back of the wire feed unit 3 Replace and tighten the screws The long screw and plain washer go into the top hole For 4 Roll feeders one plain washer is used for mounting 60 wire stands and 2 plain washers for mounting 30 stands 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 mounted on a K163 undercarriage See the Accessories section for details A K178 1 swivel platform is available for mounting the LN 9 GMA to the power source See the Accessories section for details INSTALLING THE LN 9F GMA 2 ROLL AND 4 ROLL MODELS MOUNTING THE WIRE FEED UNIT Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the g
89. s from the kit and wipe them clean Wipe the output shaft and locating shoulder clean 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 5 T Back out the guide tube clamping screws Remove the old guide tubes if installed 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 Set the idle roll pressure as detailed in the Idle Roll Pressure Setting procedure detailed later in this section LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B B 10 B 10 OPERATION FIGURE B 5 INSTALLING DRIVE ROLLS ON A 2 ROLL FEEDER SR CLAMPING COLLAR Q SPACER DRIVE IF REQ D ROLL HALVES SHAFT OUTPUT GUIDE TUBE DETAIL OUTGOING GUIDE TUBE OUTGOING GUIDE TUBE INSERT
90. se welding operating with LN 9 The LN 9 GMA must have an L6084 3 or higher superseding part number voltage board installed Standard above code 9100 The Pulse Power Filter board must be installed and connected in the LN 9 per instructions provided with the kit The pulse current sensor assembly with looped copper energizer must be installed Standard above code 9100 Feeder conversion kits are available for all LN 9 GMA model codes below 9100 and above 9100 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B A 10 A 10 INSTALLATION FIGURE A 8 CONNECTION OF LN 9 GMA TO IDEALARC R3S 400 R3S 600 R3S 800 POWER SOURCES WARNING e Turn off input power to the welding power source using the disconnect switch at the fuse box before connect ing the wire feeder aiaeag Only qualified persons should install can kill use or service this machine Add jumper from 75 to 76 using insulated copper wire To LN 9 Input Cable Plug Le LN 9 Control Cable Positive Electrode Cable To Wire Feed Unit Power Source Tape up bolted connection Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and reverse the control switch at the power source and the polarity switch on the LN 9 GMA Connect the control cable ground lead to the frame terminal marked HB near the power source terminal strip or to an un
91. 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 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 Install the kit according to instructions included DUAL PROCESS KIT K318 With Electrode Polarity Change Capability Functions essentially the same as the K317 except that the kit includes two contactors to provide different polarities on the two wire feeders When connected in this manner and one trigger is pressed the other elec trode will be cold to ground but hot to the other elec trode
92. t 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 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
93. t welding the trigger will function in the normal mode which feeds only when the trigger is closed b Once the welding arc has been struck the gun 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 LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B OPERATION FIGURE WIRE FEEDER CONTROLS FOR LN 9 GMA CONTROL METER READING SWITCH WIRE SPEED CONTROL DIGITAL METER SET ACTUAL PUSHBUTTON CIRCUIT BREAKER GROUNDING LEAD PROTECTOR GLP RESET SWITCH HOT COLD XS ELECTRODE INTERLOCK POLARITY SE SWITCH WIRE FEED DIRECTION SWITCH LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B OPERATION FIGURE B 4 WIRE FEEDER CONTROLS FOR LN 9F GMA SET ACTUAL METER READING SWITCH PUSHBUTTON ACTUAL VOLTS WIRE SPEED NC CONTROL LN 9F GMA WIRE FEEDER HOT COLD TRIGGER INTERLOCK SWITCH ELECTRODE POLARITY SWITCH WIRE FEED DIRECTION SWITCH CIRCUIT BREAKER GROUNDING LEAD PROTECTOR GLP RESET SWITCH GLP RESET CIRCUIT BREAKER 9 PIN MS TYPE CONNECTOR 14 PIN MS TYPE CONNECTOR INPUT CABLE TO POWER SOURCE CONTROL CABLE TO WIRE FEED HEAD LN 9F GMA CONTROL
94. tact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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 standards 4 b Use suitable clothing made from durable flame resistant material to protect
95. tart 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 2096 higher than the LN 9 GMA SET level This gen erally gives good starting for steel cored and MIG 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 a Turn off the control power to the LN 9 GMA at the power source 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 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 NOTE f the start trim is set too low stubbing may occur at start requiring increasing the START trimmer by turning the slot CW in the direc tion of the labeled arrow e Re assemble RUN IN FEATURE On new machines above code 10350 a Run in trim mer labeled R
96. ting 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 1 0 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 FIGURE A 10 GUN CABLE CONNECTIONS AMPHENOL CONNECTOR GUN CABLE ASSEMBLY BLOCK LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B A 14 INSTALLATION HOOKING UP GMA SHIELDING GAS CYLINDER damaged may explode if Gas under pressure is explosive Always keep gas cylinders in upright position and always keep them chained to the undercarriage or a stationary support See American National Standard Z 49 1 Safety in Welding and Cutting published by the American Welding Society 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 11 and install as follows 1 Connectthe 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 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 1 0 gas hose from the gun to the barbed fitting When you need to remove the gun you can easily detach this fitting by loose
97. tion of this button The following precautions are recommended to avoid GLP shutdown Do not allow the electrode to contact the case of the wire feeder or uninsulated part of its wire reel stand when the gun trigger is activated Be sure that all work lead connections to the work make tight metal to metal electrical contact Do not allow excess input cable or work cable to be placed closer than 3 feet to the wire feeder Do not coil excess input cable assembly or use an uncoiled assembly as shipped from the factory Instead loop excess length back and forth in 3 to 6 foot straight lengths Coiling the input cable results in a transformer action between the electrode conductor cable and ground lead in the multiconductor cable and the ground lead in the multiconductor control cable This can cause current to flow in the ground lead which will falsely activate the GLP AUTOMATIC SHUTDOWN If the LN 9 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 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 sourc
98. trol knobs can be limited to either about 3 or about 15 of the full range control by installing a knob rotation stop screw to either or both of the control knobs This stop screw is installed in the following man ner a Turn off the input power to the LN 9 GMA unit b Loosen the knob set screw and remove the control knob and the felt seal located behind the knob c Remove the control potentiometer locknut and fiber spacer then open the control panel and remove the potentiometer from the panel d Install a 1 2 long pan or round head 4 sheet metal screw into the 0 10 dia hole located 40 from the center of the potentiometer hole So that the head is on the back side of the panel inside the control box e Remount the control potentiometer with the fiber spacer under the locknut then close and secure the control panel f Replace the felt seal around the fiber spacer so that the 4 screw protrudes between the fiber spacer and the felt seal g Turn on the input power to the LN 9 GMA unit and set the desired procedure by rotating the potentiometer shaft 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 i With finger pressure on the knob against the felt seal carefully retighten the knob set screw NOT
99. ty for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in apply ing these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially
100. ug wires distributor cap or magneto wire as appropriate LINCOLN effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental con
101. welding or voltage output too low to establish arc LN 9 ACTUAL VOLTS meter reading is low zero or negative when trigger is closed power source Electrode Polarity Switches are set properly Set Polarity Switches in proper position See the topic Electrode Polarity Switch in areas of misadjustment have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility the Operation section Check to make sure lead 21 has continuity zero ohms to the work piece Check that the power source voltage control is set for REMOTE R3S or DC power source voltage control switch must be set to REMOTE Check that the LN 9 GMA control cable leads or weld cables are properly connected to the power source Refer to the connection diagram for the Lincoln power source being used Check to see if the 1 8 A fuse on Voltage P C board is blown If it is determine cause of fuse blowing Determine whether the welding power source is able to supply SET voltage If not reset the output range controls of the power source so it can supply SET voltage CAUTION If for any reason you do not understand the test procedures or are unable to perform the necessary tests repairs safely contact your local authorized field service facility before you proceed LN 9 GMA and LN 9F GMA Wire Feeder LINCOLN B E 6 E 6 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detai
102. wer source terminal strip The auxiliary equip ment power requirements should not exceed 15 watts This alternate connection cannot be used with the DC 250 or CV 400 500 I Power Sources 2 Ifthe LN 9 GMA gas solenoid valve is not required the gas solenoid terminals 32A and 7A may be used in conjunction with the K418 GMA Timer 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 OPTIONAL EQUIPMENT AND ACCESSORIES POWER INPUT CABLE ASSEMBLIES K196 K595 K596 Required to connect wire feeder to power source Includes multiconductor control cable and the proper size electrode cable for the welding current to be used Specify length and maximum welding current K196 Input Cable Assemblies For power sources with terminal strip wire feeder connections and stud output terminals K595 Input Cable Assemblies For power sources with MS type Amphenol wire feeder receptacle and stud output terminals K596 Input Cable Assemblies For power sources with MS type Amphenol wire feeder receptacle and Twist Mate output connectors WIRE REEL STANDS AND MOUNTINGS 50 60 LB WIRE REEL MOUNTING STAND K303 The assembly includes a framework to which is attached the 50 60 Ib wire reel a mounting spindle a dust shield a lift bail and a cable clamp for fastening the

Lincoln Electric IM355-C User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents