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Lincoln Electric Semiautomatic Wire Feeders LN-9, Service Manual

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Lincoln Electric Semiautomatic Wire Feeders LN-9 Service Manual Download Page 53

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Section E-1

Section E-1

LN-9 Wire Feeder

Theory of Operation

.............................................................................................................

Section E

General Description ...............................................................................................................E-2

Power Input Circuits...............................................................................................................E-2

Trigger and Shutdown Circuit ................................................................................................E-3

Arc Voltage, Wire Speed Control and Metering.....................................................................E-4

Printed Circuit Board Functions.............................................................................................E-5

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

INPUT

CONNECTOR

TO 

VOLTAGE

BOARD

TO

CONTROL

BOARD

METER

BOARD

VOLTS
SPEED

SWITCH

T1

CIRCUIT

BREAKER

R1

TRIGGER

CONNECTOR

TRIGGER

BOARD

F
U
S
E

T2

WIRE FEED

MOTOR

THERMOSTAT

C

O

N

T

R

O

L

B

O

A
R

D

VOLTAGE

BOARD

P
O

W

E

R

B

O

A

R

D

GROUND

LEAD

PROTECTOR

WIRE

FEED

MOTOR

TACH

BOARD

WIRE
SPEED
CONTROL

VOLTAGE

CONTROL

POLARITY

SWITCH

VOLTAGE SENSING

VOLTAGE CONTROL

POWER SOURCE OUTPUT TRIGGER

(#2 &#4)

S
H

U
T
D
O

W

N

+ 15VDC

+ 15VDC

WIRE SPEED CONTROL

GEAR

BOX

TRIGGER SIGNAL

TRIGGER SIGNAL

R
E
F
E
R
E
N
C
E

V
O

L
T
A
G

E

WORK

ELECTRODE VOLTAGE SENSING

24VAC

28VAC

10VAC

FIGURE E.1 – LN-9 BLOCK LOGIC DIAGRAM

Summary of Contents for Semiautomatic Wire Feeders LN-9

Page 1: ...nd most importantly think before you act and be careful SERVICE MANUAL World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors Sales and Service through subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 For use with machines having Code Numbers 9134 9842 9958 10316 10327 LN 9 Wire Feeder Return to Master TOC...

Page 2: ...BLE 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 Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A...

Page 3: ... Ground the work or metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be ...

Page 4: ...g area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent...

Page 5: ... soudage à l aide d écrans appropriés et non inflamma bles 4 Des gouttes de laiter en fusion sont émises de l arc de soudage Se protéger avec es vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zone...

Page 6: ...al Description B 3 Recommended Processes and Equipment B 3 Controls and Settings B 4 Drive Roll Installation and Pressure Setting B 9 Wire Loading B 14 Making a Test Weld and Adjusting Response and Starting Characteristics B 18 Procedure at End of Coil B 20 Security of Weld Procedure Settings B 20 Accessories Section C Auxiliary Equipment Contacts C 2 Optional Equipment and Accessories C 2 Mainten...

Page 7: ...he Wire Feed Unit A 3 Mounting the Control Box A 3 Connecting the Wire Feed Unit to the Control Box A 3 Routing the Electrode A 4 Electrical Connections LN 9 and LN 9F A 4 Power Input Cable Assembly A 4 Connecting the Power Input Cable Assembly to the LN 9 or LN 9S A 4 Connecting the Power Input Cable Assembly to the LN 9NE or LN 9SE A 5 Connecting the Power Input Cable Assembly to the LN 9F A 6 C...

Page 8: ... 85o C 40o F to 185o F WIRE DIAMETERS 030 through 3 32 0 8 through 2 4 mm Solid Electrode 045 through 120 1 2 through 3 0 mm Cored Electrode 035 through 1 16 0 9 through 1 6 mm Aluminum PHYSICAL DIMENSIONS LENGTH WIDTH HEIGHT TOTAL WEIGHT LESS ELECTRODE LN 9 2 Roll 12 15 in 11 56 in 12 19 in 36 lbs 308 4 mm 293 4 mm 309 4 mm 16 3 kg LN 9 4 Roll 12 15 in 11 56 in 12 19 in 38 lbs 308 4 mm 293 4 mm 3...

Page 9: ...l not be bent sharply as it comes from the unit MOUNTING THE CONTROL BOX The same control box is used for both the 2 Roll and 4 Roll wire feed unit It contains two keyhole slots and one slot for mounting Mount the box at some conve nient location close to the wire feed unit This will enable the 16 foot control cable assembly supplied with both the LN 9F 2 Roll and 4 Roll to reach between the contr...

Page 10: ...onnec tion NOTE Use of an LN 9 with a Pulse Power 500 or a DC650 PRO requires a K442 1 Pulse Power Filter Kit CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE LN 9N or LN 9S WIRE FEED UNIT The K196 K595 or K596 cable assembly consists of an electrode cable and multiconductor control cable The control cable has a MS type plug on the wire feed er end To install 1 See Figure A 1 Connect the MS type p...

Page 11: ...ectrode cable of the input cable assembly to the brass block on the hand crank 4 Insert the connector on the conductor sheath of the extension assembly into the brass block of the hand crank assembly Tighten the locking screw with a 3 16 hex allen wrench 5 At the wire drive unit connect the amphenol of the extension control cable to the receptacle on the back of the LN 9 6 Remove the ingoing guide...

Page 12: ...on If a 22 1 2 foot extension is used cut off 22 1 2 feet of the flux hose to give the correct length of 41 1 2 feet The conductor cable of the extension assembly is 22 1 2 feet long tip to tip and can be used to measure the length cut off If you tape the flux hose to the extension cables or the gun cable be careful not to deform or collapse the flux hose CONNECTING THE POWER INPUT CABLE ASSEMBLY ...

Page 13: ... diagram Figure A 5 for DC 250 DC 400 and CV 400 CV 500 l Figure A 6 for DC 600 Figure A 7 for DC 1000 Figure A 8 for Pulse Power 500 Depending on the power source and process you are using the jumpers on the LN 9 voltage board may have to be changed As shipped the LN 9 is connect ed for use with the DC 250 DC 400 CV 400 CV 500 I and DC 600 For other power sources refer to the appropriate connecti...

Page 14: ...k lead circuit is short and connections can be expected to be reliable then control cable lead 21 does not need to be extended and can be directly connected to terminal 21 on the terminal strip Note that this is not the preferred connection because it adds error to the wire feeder voltmeter reading N C Tape up bolted connection if lead 21 is extended N D Connect the control cable ground lead to th...

Page 15: ...tly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience this extended 21 lead should be taped to the welding work lead This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 9 s which have a direct work lead jack N D Tape up bolted connection N E Connect the LN 9 control cable ground lead to...

Page 16: ...nnection replaces the need to employ the remote work lead accessory on any LN 9 which has a direct work lead jack N C Tape up bolted connection N D Connect the LN 9 control cable ground lead to the frame terminal marked near the power source terminal strip The power source must be properly grounded N E If using an older automatic control cable with leads 75 76 77 connect lead 75 to 75 on terminal ...

Page 17: ...nal marked near the power source terminal strip The power source grounding terminal marked and located near the power source input power connections must be properly connected to elec trical ground per the power source Operating Manual N E Connect control leads t terminal strip as follows LN 9 A to 75 B to 77 C to 78 N F The LN 9 voltage control jumpers must be connected as follows White jumper on...

Page 18: ...source terminal strip or Dual Process Kit terminal strip This extended lead must be connected directly to the work When using a Dual Process Kit you must extend the lead individually for each LN 9 As an alternative LN 9 models are provided with a quick connect terminal splice connection in the 21 lead between the input Amphenol connector of the LN 9 and its polarity switch See the LN 9 wiring dia ...

Page 19: ...and tighten the lock ing screws with a 3 16 Allen wrench or handscrew if provided Keep this connection clean and bright Connect the control cable polarized Amphenol plug into the mating 5 cavity receptacle on the front panel of the wire drive section INSTALLATION A 13 A 13 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC ...

Page 20: ...OTES A 14 A 14 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 21: ... Feeders B 9 Setting the Idler Roll Spring Pressure 2 Roll Wire Drives B 10 Changing Wire Feed Rolls and Guide Tubes for 4 Roll Wire Feeders B 11 Setting the Idler Roll Pressure 4 Roll Wire Drives B 11 Wire Loading B 14 Loading and Feeding Readi Reels or Spools B 14 Loading a 22 to 30 lb Readi Reel Package B 14 Loading a 15 to 30 lb Spool B 15 Loading 50 and 60 lb Coils and Brake Adjustment B 16 L...

Page 22: ...uctions operating the machine ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable materi...

Page 23: ...ls and guide tubes Drive roll kits are avail able for the same electrode sizes as the 2 roll feeders RECOMMENDED PROCESSES AND EQUIPMENT When combined with the broad selection of quality welding equipment and accessories the LN 9 pro vides a versatile precision welding system to meet the specific needs of Outershield Innershield or sub merged arc welding processes The capabilities of the LN 9 2 Ro...

Page 24: ... TRIGGER INTERLOCK SWITCH This switch is located on the front rail on the LN 9 model and on the front panel of both the LN 9F 2 Roll and 4 Roll control box The three position switch serves a dual purpose 1 Hot Cold Wire Feed In the center position the wire will be electrically cold when feeding with the gun trigger In either the up or down positions the wire will be hot when feeding with the gun t...

Page 25: ...n TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOLTS CONTROL METER READING SWITCH DIGITAL METER SET ACTUAL PUSHBUTTON CIRCUIT BREAKER GROUNDING LEAD PROTECTOR GLP RESET SWITCH HOT COLD TRIGGER INTERLOCK SWITCH WIRE FEED DIRECTION SWITCH ELECTRODE POLARITY SWITCH WIRE SPEED CONTROL ...

Page 26: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE B 2 WIRE FEEDER CONTROLS FOR LN 9F LN 9F CONTROL BOX BOTTOM VIEW ...

Page 27: ...ng 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...

Page 28: ...s approximately 7 volts i e 27 1 2 to 34 1 2 volts at nominal input voltage If the LN 9 con trols are set for 29 volts and the input voltage to the R3S goes up it may not be possible for the LN 9 con trol circuit to hold the 29 volts The welding will shut down By changing to the 27 volt triangle setting the range will be approximately 23 1 2 to 30 1 2 volts and at high input voltage there will be ...

Page 29: ...ls with a larger chamfer on one side instead of gear teeth This larger chamfer side must face the gearbox when installed The side with the smaller chamfer and wire size stencil must be installed facing out 5 Remove the large ingoing guide from rear brass block by loosening screw OPERATION B 9 B 9 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section T...

Page 30: ...uide tube the idle roll spring pressure is set too high When set during a stoppage the drive rolls will slip If the electrode is removed from the cable there will be a slight waviness in the electrode for about a foot beyond the slip marks on the electrode If there is no waviness the pressure is set too low For Aluminum Wire the idle roll pressure should be adjusted as follows 1 With low idle roll...

Page 31: ...E DRIVES Because every feeding situation is different the 4 roll wire drive does not have graduated markings with wire sizes indicated on it A recommended starting pressure is indicated below for each applicable wire size and type Depending on the particular application these starting pressures may need to be adjusted up or down Some of the vari ables that affect tension settings are type and bran...

Page 32: ...to 1 3 turn more idle roll pressure This pressure setting should be optimum for feed ing and to avoid bird nesting by allowing the drive roll to slip on the wire if a gun cable jam or stop page occurs If using harder or larger dia alu minum wires more idle roll pressure if necessary can be tolerated However if the pressure required to properly feed the aluminum wire also permits bird nesting or ex...

Page 33: ...Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE B 4 INSTALLING DRIVE ROLLS ON A 4 ROLL FEEDER ...

Page 34: ...so that it will rotate in a clockwise direction when feeding wire de reels from the bottom of the coil 4 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 5 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 6 Slide the cage all the way onto the adapter until the retaining spring pops u...

Page 35: ... tube before feeding electrode through the gun When the electrode is cut off the start end of the electrode is usually too large to fit through the tip 6 Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped Do not overtighten WHEN USING THE EXTENSION ASSEMBLY models LN 9NE and LN 9SE 1 Slide the ingoi...

Page 36: ...s in the cover and secure it by bending it back Cut and remove the remaining tie wires 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 Re...

Page 37: ...g 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 ben...

Page 38: ...owing steps should remedy this difficulty 1 The electrode stickout when starting should be as close to procedural length as possible and the tip of the electrode should be clean and held nearly touching the work 2 Install the R3S voltage triangle to the position higher than the desired arc voltage provided it does not result in out of range shutdown of the LN 9 while welding See Automatic Shutdown...

Page 39: ...he electrode being used does not give satisfactory starting because of stubbing or blasting off slower acceleration can be obtained by modifying the LN 9 models as follows 1 Turn OFF the control power to the LN 9 at the power source 2 Remove the screws holding the control section cover in place and swing it open 3 Move the jumper plug on the Control PC board from pin F to pin S 4 Reassemble START ...

Page 40: ... of the LN 9 voltage and wire feed speed controls 1 Once the procedure is set the security panel of the LN 9 can be locked to prevent access to the con trol knobs 2 The control range of the procedure control knobs can be limited to either about 3 or about 15 of the full range control by installing a knob rotation stop screw to either or both of the control knobs This stop screw is installed in the...

Page 41: ...3 14 lb Innershield Coils K378 C 3 50 60 lb Wire Reel Assembly for Customer Mounting K299 C 3 Gun and Cable Assemblies C 4 Wire Feeder Accessories C 5 Burnback Delay Kit K202 C 5 Dual Process Kit K317 C 5 Dual Process Kit K318 C 5 Dual Procedure Kit K319 C 5 Pulse Power Filter Conversion Kit K442 1 C 5 Swivel Platform K178 1 C 6 Undercarriage K163 C 6 Continuous Flux Feed Tank K320 C 6 K320 Flux T...

Page 42: ...LIES 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 Amphe...

Page 43: ...trode 30 lb and 22 lb to a 2 spindle One piece construc tion Made from a durable molded plastic Designed for easy loading adapter remains on spindle for quick changeover Included with K377 small mounting stand K438 Adapts 50 60 lb Lincoln Readi Reel coils to a K162 H spindle or similar 2 inch spindle suitable for 60 lb spools Two piece construction made from a durable flame retardant molded plasti...

Page 44: ...4 0 9 2 0 mm solid 300 amps 300 amps Magnum K479 2 035 5 64 0 9 2 0 mm solid 400 amps 400 amps Innershield K126 062 3 32 1 6 2 4 mm Innershield 350 amps K115 120 for 120 and 7 64 3 0 and 2 8 mm 450 amps K115 3 32 for 3 32 2 4 mm 450 amps K115 5 64 for 068 5 64 1 7 2 0 mm 450 amps K116 120 for 120 and 7 64 3 0 and 2 8 mm 600 amps K116 3 32 for 3 32 2 4 mm 600 amps K206 3 062 3 32 1 6 2 4 mm Innersh...

Page 45: ...d but hot to the other elec trode This kit can also be connected to provide the same polarities on each feeder but the electrode circuit of the one not being used will be cold to work and to the other electrode Install the kit according to instructions included NOTE The K317 and K318 Dual Process Kits also include mode change capability but only when using the DC 600 power source This feature perm...

Page 46: ...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 thr...

Page 47: ...l fluxes 700 Series 800 Series and 900 Series Do not use the magnetic separator with any stainless steel alloy or hardsurfacing flux except H 535 The magnetic separator removes some of the alloying elements from these fluxes thus changing their characteristics MECHANIZED HAND TRAVEL UNIT K110 Carries K114 Squirtgun along the joint at a preset trav el speed to help the operator make better welds 10...

Page 48: ...035 0 8 0 9 mm KP502 035 KP545 035 045 0 052 1 2 1 4 mm KP502 052 KP545 052 1 16 1 6 mm KP502 1 16 KP545 1 16 068 3 32 1 7 2 4 mm KP502 3 32 KP545 3 32 Cored Electrode 045 0 052 1 2 1 4 mm KP502 052C KP545 052C 1 16 062 1 6 mm KP502 1 16C KP545 1 16 068 3 32 1 7 2 4 mm KP502 3 32 KP545 3 32 7 64 120 2 0 3 0 mm KP502 120 KP545 120 7 64 Soft Jacket 2 8 mm KP502 7 64H __________ Aluminum Electrode 03...

Page 49: ... OF CONTENTS MAINTENANCE Maintenance Section D Routine Maintenance D 2 Drive Rolls and Guide Tubes D 2 Wire Reel Mounting 50 and 60 lb Coils D 2 Wire Reel Mounting Readi Reels and Spools D 2 Periodic Maintenance D 2 Control Box D 2 Wire Drive Motor and Gear Box D 2 Gun and Cable Maintenance D 3 Gun Cable Connector Requirements D 3 ...

Page 50: ...n instructions See Table C 2 in the Accessories section for drive roll and guide tube kits WIRE REEL MOUNTING 50 AND 60 LB COILS To prolong the life of the reel shaft periodically coat it with a thin layer of grease No maintenance of the brake assemblies is needed If the brake shoe wears through to metal replace the brake assembly WIRE REEL MOUNTING READI REELS AND 10 THROUGH 30 LB SPOOLS No routi...

Page 51: ...32 125 1 8 Drill 1 16 or 062 078 5 64 Drill 045 052 062 1 16 Drill 030 035 055 54 Drill All dimensions in inches and millimeters 1 2 Amp AC 24 Volts Inductive 1 2 Amp DC 24 Volts Inductive MAINTENANCE D 3 D 3 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FI...

Page 52: ... Return to Master TOC FIGURE D 3 GENERAL COMPONENT LOCATIONS 1 CONTROL PC BOARD 2 TRIGGER PC BOARD 3 T1 TRANSFORMER 4 POWER PC BOARD 5 BOX ASSEMBLY 6 DRIVE IDLE ROLL ASSEMBLY 7 GEAR BOX 8 DRIVE MOTOR 9 TACHOMETER 10 VOLTAGE PC BOARD LOCATED UNDER RIGHT COVER 11 LEFT COVER ASSEMBLY 12 WIRE SPEED VOLTAGE CONTROL BOX 13 RIGHT COVER ASSEMBLY 14 DIGITAL METER 10 11 12 13 14 6 9 7 5 4 1 2 3 8 ...

Page 53: ...R TO VOLTAGE BOARD TO CONTROL BOARD METER BOARD VOLTS SPEED SWITCH T1 CIRCUIT BREAKER R1 TRIGGER CONNECTOR TRIGGER BOARD F U S E T2 WIRE FEED MOTOR THERMOSTAT C O N T R O L B O A R D VOLTAGE BOARD P O W E R B O A R D GROUND LEAD PROTECTOR WIRE FEED MOTOR TACH BOARD WIRE SPEED CONTROL VOLTAGE CONTROL POLARITY SWITCH VOLTAGE SENSING VOLTAGE CONTROL POWER SOURCE OUTPUT TRIGGER 2 4 S H U T D O W N 15V...

Page 54: ...C Return to Master TOC Return to Master TOC FIGURE E 2 POWER INPUT CIRCUITS NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INPUT CONNECTOR TO VOLTAGE BOARD TO CONTROL BOARD METER BOARD VOLTS SPEED SWITCH T1 CIRCUIT BREAKER R1 TRIGGER CONNECTOR TRIGGER BOARD F U S E T2 WIRE FEED MOTOR THERMOSTAT C O N T R O L B O A R D VOLTAGE BOARD P O W E R B O A R D GROUND LEAD PROTECTO...

Page 55: ...ground fault pro tector is reset THEORY OF OPERATION E 3 E 3 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE Unshaded areas of Block Logic Diagram are the subject of discussion FIGURE E 3 TRIGGER AND SHUTDOWN CIRCUIT INPUT CONNECTOR TO VOLTAGE BOARD TO C...

Page 56: ...age to comply with the command from the con trol board A three digit meter is provided to read both arc voltage and wire feed speed Either the preset or the actual welding parameters can be displayed THEORY OF OPERATION E 4 E 4 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retu...

Page 57: ...tes for wire feed speed are con trolled by the control board as well as the SET speed and actual speed signals for the digital meter circuitry VOLTAGE BOARD The voltage board compares the SET voltage values to the actual voltage values and makes any necessary correction by sending the appropriate signal to the Lincoln CV power source If for any reason the arc voltage cannot be controlled to the SE...

Page 58: ...NOTES E 6 E 6 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 59: ...t Accuracy Test F 37 Wire Speed Accuracy Test F 42 Out of Voltage Range Shut Down Test F 44 General Power Supply Tests F 47 Replacement Procedures Digital Meter and Meter PC Board Removal and Replacement F 50 Reed Switch CR2 Removal and Replacement F 53 T1 Transformer Removal and Replacement F 55 Tach PC Board Removal and Replacement F 60 Drive Motor Removal and Replacement F 64 Retest After Repai...

Page 60: ...SSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machin...

Page 61: ...ich could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag If the PC Board uses protective shorting jumpers don t remove them until installation is complete If you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test th...

Page 62: ...vated The digital meter does NOT light The drive rolls do not turn 1 Make sure 115VAC is being applied to the LN 9 at the input connector Pin C is lead 31 and pin D is lead 32 2 Check the 5 amp circuit breaker Reset if tripped 3 The F101 1 2 amp fuse located on the power PC board may be blown 1 Check for loose or faulty lead connections between the input connector the T1 transformer and the power ...

Page 63: ...If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The wire feed coasts when the gun trigger is r...

Page 64: ...800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS No wire feed when gun trigger is activated The drive rolls do not turn The digital meter does light but reads only the SET voltage and wire speed values 1 The Ground Lead Protector may have tripped Reset and clear possible fault between electrode circuit and feeder frame 2 The gun trigge...

Page 65: ... PROBLEMS The wire feeds when the gun trig ger is activated but there is no arc voltage 1 Make sure the inch switch is in a Wire Hot position 2 Check the welding cables for loose or faulty connections 3 Put a jumper wire from 2 to 4 on the power source terminal strip Machines with 14 pin amphenols pin C to pin D If the arc voltage is not present at the output terminals the power source is faulty I...

Page 66: ...EMS The SET speed is adjustable and steady The actual speed is uncon trollable The meter displays the actual speed correctly or reads EEE 1 Contact your local Lincoln Authorized Field Service Facility 1 While the motor is running carefully unplug the 15 pin molex plug from the control board If the motor continues to run the power PC board may be faulty Replace If the motor stops the control PC boa...

Page 67: ... errat ic like the SET speed 1 Check for loose or faulty con nections on leads 631 632 and 633 between the speed control potentiometer R2 and the control PC board 1 Remove power to the LN 9 and disconnect the plug to the con trol PC board Check the resis tance of the speed control potentiometer R2 When mea sured from the wiper lead 632 to lead 633 the resis tance should vary smoothly from 0 to 10 ...

Page 68: ...N PROBLEMS The wire feeds when the interlock switch is in the ON position No welding or gun trigger activation 1 Check to see if the reed switch 2CR is stuck closed 1 Check the 2CR reed switch for sticking and associated leads 529 and 628 for shorts 2 The power PC board may be faulty Replace With the interlock switch in the ON position the wire feed stops when the gun trigger is released 1 Check l...

Page 69: ...ot adjustable over the entire range of control The actual voltage is also erratic like the SET voltage 1 Check for loose or faulty con nections on leads 634 635 and 636 between the voltage control potentiometer R3 and the voltage PC board 1 Remove power to the LN 9 and disconnect Plug J1 from the voltage PC board Check the resistance of the voltage control potentiometer R3 When measured from the w...

Page 70: ... leads are not shorted to the electrode or work cables 1 Disconnect lead 500 from the trigger board If the breaker still trips when the gun trigger is activated the trigger board may be faulty Replace 2 Disconnect any accessory that may be connected to terminals 7 and 32A See the Wiring Diagram If the problem is resolved the accessory may be faulty Replace 3 Perform the Wire Drive Motor Test 4 The...

Page 71: ... This can happen due to metallic wire shavings build up 1 Remove input power to the LN 9 Replace the 1 8 amp fuse and switch the LN 9 polarity switch to the NEG position Make a resistance check from the following leads to the LN 9 case grounding screw Lead 500 510 525 522 526 530 and 628 The resistances should be above 1000 ohms If any test is below 1000 ohms that circuit has low resistance to cas...

Page 72: ...s being used 2 Make certain the voltage control switch on the Lincoln CV power source is set in the Remote position 3 Make sure the 21 lead in the control cable has continuity to the work piece 4 Check the 1 8 amp fuse on the LN 9 voltage PC board Replace if faulty 5 Be sure the welding power source is compatible with the LN 9 and operating properly Make sure duty cycle of power source is not bein...

Page 73: ...eed or wire feeding is rough 1 Check or replace the gun cable It may be kinked clogged or twisted 2 Make certain the drive rolls and guide tubes are correct for the wire being used 3 Check or replace the gun con tact tip 4 The electrode wire may be rusty or dirty Replace if necessary 1 If conditions are extremely dirty install a wiper on the wire before it enters the guide tube Use a piece of clot...

Page 74: ...he welding cables for loose or faulty connections 3 The gun cable may be faulty Check or replace 4 Check cable liner for proper size 5 The gun contact tip may be worn Check or replace 6 The welding power supply may be faulty Check or replace 1 Put the power source in Machine Control for voltage and check if welding perfor mance improves If the problem is resolved check or replace the control cable...

Page 75: ...e correct for the welding procedure being used 2 Check the welding cables for loose or faulty connections 3 The gun cable may be faulty Check or replace 4 The gun contact tip may be worn Check or replace 5 The welding power source may be faulty Check or replace 1 Jumper the BYPASS terminals on the voltage PC board 2 Put the power source in Machine Control and check if welding performance improves ...

Page 76: ... slotted disc in the tach housing is secure and aligned 2 Perform the Meter Circuit Accuracy Test 3 The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 93...

Page 77: ...place CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 The actual volts reading does NOT match the SET volts reading within a few tenths of a volt while welding One reading may be errati...

Page 78: ...oltage PC board Adjust the weld voltage from the power source for the process being used If the correct volt age cannot be set the power source may be faulty 3 Check for correct control cable connections to the power source 4 The control cable may be faulty Check or replace 5 The start trimmer on the LN 9 voltage PC board may be set too low See Starting Characteris tics in the Operation section of...

Page 79: ...ould be only slightly higher than the weld voltage See Starting Charac teristics in the Operation section of this manual 2 Put the Lincoln power source in the Machine Control mode Jumper the BYPASS pins on the LN 9 voltage PC board Adjust the weld voltage from the power source for the process being used If the correct volt age cannot be set the power source may be faulty 3 Check for correct contro...

Page 80: ... on the voltage PC board It should be slightly higher than the weld voltage See Starting Charac teristics in the Operation section of this manual 3 Put the Lincoln power source in the Machine Control mode Jumper the BYPASS pins on the LN 9 voltage PC board Adjust the weld voltage from the power source for the process being used If the symptoms persist the power source may be faulty 4 Check for cor...

Page 81: ... machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you pro...

Page 82: ...ad 532 from the power PC board terminal See Figure F 1 Electric Shock can kill With power applied there are high voltages inside the wire feeder Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied 4 Apply power 115VAC to the T1 transformer primary leads 31 and 532 See Figure F 1 and the Wiring Diagram 5 Using the volt ohmmeter check for 28VAC at s...

Page 83: ...lace the probes at the lead splices See Figure F 2 7 With 115VAC applied to the primary leads 532 and 31 if either or both of the sec ondary voltages are missing or low the T1 transformer may be faulty Replace the transformer 8 After the test is completed disconnect the 115VAC from the T1 transformer primary leads Reconnect lead 532 to the power PC board terminal Close the left side cover assembly...

Page 84: ...machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you pro...

Page 85: ...TECTION CIRCUIT TROUBLESHOOTING NAMEPLATE PROTECTION CIRCUIT TROUBLESHOOTING NAMEPLATE TEST PROCEDURE 1 Remove input power to the LN 9 wire feed er 2 Using the phillips head screw driver remove the screws holding the left side cover assembly 3 Lift the right side cover assembly 4 Using the Phillips head screw driver remove the two screws from the protection circuit troubleshooting name plate Remov...

Page 86: ...tinued 4 Locate the T2 transformer primary lead 32A connected to the 5 amp circuit break er Remove lead 32A from the circuit break er See Figure F 4 and the Wiring Diagram 5 Lift the left side cover assembly 6 Locate T2 transformer primary lead 531 connected to the R1 2 ohm resistor See the Wiring Diagram See Figure F 4 FIGURE F 4 T2 PRIMARY LEADS 32A AT 5 AMP CIRCUIT BREAKER AND 531 AT R1 RESISTO...

Page 87: ...igure F 4 8 Using the volt ohmmeter check for approx imately 24VAC at the T2 transformer sec ondary leads 621 and 620 Place the probes where the leads connect on the trig ger PC board See Figure F 5 9 With 115VAC applied to the primary leads 531 and 32A if the secondary voltage is missing or low the T2 transformer may be faulty Replace the T2 transformer 10 After the test is completed disconnect t...

Page 88: ...technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance ...

Page 89: ...TEST continued FIGURE F 6 LEAD 539 541 626B AND 627B AT POWER PC BOARD TERMINAL STRIP LEAD 539 LEAD 541 LEAD 626B LEAD 627B TEST PROCEDURE 1 Remove input power to the LN 9 wire feed er 2 Remove any electrode wire or disengage the drive rolls 3 Using the phillips head screw driver remove the screws from the left side cover assem bly 4 Lift the left side cover assembly 5 Locate leads 539 541 626B an...

Page 90: ...en the gun trigger is activated or the gun terminals are jumpered together see the Wiring Diagram the field voltage polarity should reverse from the idle state Normal is 115VDC independent of motor speed 9 If the above voltages are present and the motor does not operate the motor motor brushes or gear box may be faulty If the armature or field voltages are missing or not correct the power board or...

Page 91: ... and perform the General Power Supply Test 3 With gun trigger activated or the gun termi nals jumpered together see the Wiring Diagram check leads 555 to 510 for the presence of between 4 5 10 5VDC The motor must be running This is the feedback voltage from the tach PC board to the control PC board This voltage is depen dent upon motor speed If the feedback voltage is missing or does not vary with...

Page 92: ...ator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 21...

Page 93: ...ued FIGURE F 8 VOLTMETER CONNECTION POINT TEST PROCEDURE Perform the following checks with the LN 9 wire feeder connected to a Lincoln CV welding power source according to the proper connection dia gram See the Installation section of this man ual See Figure F 8 for this test 1 Lift the right side cover assembly 2 Connect the test meter see Materials Needed between the brass conductor block on the...

Page 94: ...r and while weld ing compare the SET volts and ACTUAL volts meter readings Depending upon the arc volt age characteristics of the welding process being used the ACTUAL reading may vary somewhat around an average value The average ACTUAL reading should match the SET reading within 0 5 volts If not refer to the Meter Circuit Accuracy Test 5 If no further tests are required remove the jumper from the...

Page 95: ...validate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 ...

Page 96: ...TEST PROCEDURE 1 Remove input power to the LN 9 wire feeder 2 Lift the right side cover assembly and remove the two screws holding the meter cover to the right side assembly Carefully remove the meter cover See Figure F 9 3 Locate and gain access to the meter PC board See Figure F 9 4 Apply input power to the wire feeder ELECTRIC SHOCK can kill With power applied there are high voltages inside the...

Page 97: ...F 10 Note The coating will have to be removed from the test points 6 Test for DC volts on the meter PC board Check for 4 75 to 5 25 VDC from TP5 to lead 510C See Figure F 10 NOTE The coating will have to be removed from the test points If the display is NOT lit and the correct DC volt age is present at TP5 to lead 510C the digital meter may be faulty Replace the digital meter If AC voltage IS pres...

Page 98: ...oard Accuracy All Models 1 Use a test meter with at least 3 1 2 digits and 5 accuracy 2 Connect the probe to leads 517 and the probe to lead 510C NOTE The coating will have to be removed from the test points 3 With the meter in SET volts adjust the voltage control until the LN 9 meter matches the set tings in the table below If the test meter does not match the readings the meter PC board may be f...

Page 99: ...If the test meter does not match the readings the meter PC board may be faulty Replace the meter PC board TROUBLESHOOTING REPAIR F 41 F 41 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC METER CIRCUIT ACCURACY TEST continued METRIC MODEL METRIC RANGE SET M MI...

Page 100: ...perator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call...

Page 101: ...ive rolls This measured length should be 53 0 8 inches 1 35 02 meters If not there may be a problem with the wire or the wire feed path See the Troubleshooting Guide Feeding Problems in this section of the manual Also check for correct drive roll tension adjustment B Check for the proper drive roll revolutions per minute 1 Adjust the LN 9 wire speed control for the LN 9 actual speed meter readings...

Page 102: ... or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you...

Page 103: ...the BYPASS pins on the LN 9 voltage PC board See Figure F 11 On older voltage boards these pins may be labeled B This should disable the shut down circuit ELECTRIC SHOCK can kill With power applied there are high voltages inside the wire feeder Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied 5 Connect to a Lincoln Electric CV power source per ...

Page 104: ...he electrode Also check the 1 8 amp fuse on the voltage PC board 9 Check the polarity switches in the LN 9 and the Lincoln power source and their associat ed leads Set the switches to the same polarity as the electrode See the Wiring Diagram 10 If the ACTUAL voltage reading is different from the SET voltage reading the power source may not be capable of producing the required arc voltage the contr...

Page 105: ...rator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 2...

Page 106: ...te the power PC board and the control PC board in the wire feeder main assembly locate the voltage PC board in the left side cover ELECTRIC SHOCK can kill With power applied there are high voltages inside the wire feeder Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied 5 Apply power 115VAC to the wire feeder at the correct pins See the Wiring D...

Page 107: ...Y FROM PLUG POWER 525 13 5 15 5 VDC BOARD TO 510 CONTROL 10 BOARD 9 CONTROL P C CHECK 10 VDC BOARD SUPPLY FROM CONNECTOR POWER 500 9 2 10 8 VDC PLUG BOARD TO 510 CONTROL 14 BOARD 9 VOLTAGE P C CHECK BOARD UPPER 15 VDC CONNECTOR SUPPLY FROM PLUG NEXT TO POWER 525 13 5 15 5 VDC F AND S BOARD TO 510 PINS VOLTAGE 4 BOARD 6 VOLTAGE P C BOARD UPPER CONNECTOR 510 PLUG NEXT TO 6 F AND S CHECK 10 VDC PINS ...

Page 108: ...n or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before yo...

Page 109: ... SCREWS MOUNTING SCREWS METER DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT continued METER PC BOARD REMOVAL PROCEDURE 1 Remove input power to the LN 9 wire feeder 2 Locate and remove the two screws on the top left and right side of the meter panel assem bly See Figure F 12 FIGURE F 13 METER REMOVAL WITH SHORT LEADS 3 Lift the right side cover assembly 4 Carefully remove the meter enclo...

Page 110: ...the prongs on the meter when you reassem ble DIGITAL METER REMOVAL PROCEDURE 1 Using the phillips head screw driver remove the meter shield frame and bezel assembly 2 With the 5 16 nut driver remove the two nuts screws and lockwashers holding the digital meter to the cover assembly 3 Carefully remove the digital meter REPLACEMENT PROCEDURE 1 With the 5 16 nut driver fasten the digital meter to the...

Page 111: ...e technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistanc...

Page 112: ...plices from leads 529 and 628 to the reed switch leads 7 Using the slot head screw driver and 11 32 wrench remove the screws and nuts from the lead splices Note the position of the reed switch in the energizer for reassembly 8 Carefully slide the reed switch assembly from the copper energizer REPLACEMENT 9 Slide the reed switch into the energizer Position it according to step 7 10 With the slot he...

Page 113: ... and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 38...

Page 114: ...to the LN 9 2 Using the phillips head screw driver remove the screws holding the left side cover assem bly 3 Lift the cover 4 Disconnect primary lead 532 from the power PC board terminal 5 Disconnect the primary lead 31 from the R1 2 ohm resistor See Figure F 16 Upon reassembly this lead will have to be soldered onto the R1 resistor T1 TRANSFORMER REMOVAL AND REPLACEMENT continued FIGURE F 16 PRIM...

Page 115: ...ESHOOTING REPAIR F 57 F 57 LN 9 Wire Feeder 6 Disconnect leads 526 and 527 from the power PC board terminals See Figure F 17 T1 TRANSFORMER REMOVAL AND REPLACEMENT continued FIGURE F 17 LEADS 526 AND 527 AT POWER PC BOARD LEAD 526 LEAD 527 7 Disconnect yellow leads 601 and 602 from the lead splices See Figure F 18 FIGURE F 18 LEADS 601 AND 602 AT LEAD SPLICES LEAD 601 LEAD 602 ...

Page 116: ...eeder 8 Remove the two phillips head screws from the control PC board mounting panel 9 Using the 11 32 wrench remove the nut and screw from the top of the PC board mounting panel 10 Remove the clip holding the 1CR relay then unplug the relay from the power PC board See Figure F 19 T1 TRANSFORMER REMOVAL AND REPLACEMENT continued FIGURE F 19 1CR RELAY REMOVAL 1CR RELAY CONTROL PC BOARD NUT AND SCRE...

Page 117: ...ire gently prying up the control PC board mounting panel Be sure to clear all leads REPLACEMENT 15 Position the T1 transformer and use the 5 16 wrench to attach it with the two nuts and washers 16 With the 5 16 wrench mount the terminal strip 17 Plug the 1CR relay into the power PC board and attach the clip See Figure F 19 18 Mount the power PC board mounting panel with the two phillips head screw...

Page 118: ...perator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call...

Page 119: ...ster TOC PROCEDURE 1 Remove input power to the LN 9 wire feeder 2 Using the Phillips head screw driver remove the screws holding the left side cover assem bly 3 Lift the cover assembly 4 Using the slot head screwdriver remove the two screws from the tach assembly cover See Figure F 21 Remove the cover TACH PC BOARD REMOVAL AND REPLACEMENT continued FIGURE F 21 TACH ASSEMBLY COVER SCREWS TACHASSEMB...

Page 120: ...nd 555 See Figure F 22 TACH PC BOARD REMOVAL AND REPLACEMENT continued FIGURE F 22 CONTROL PC BOARD LEADS LEADS 510 525 555 FIGURE F 23 REMOVAL OF ROTATING DISK LOCKING SCREW DISC NUT TACH PC BOARD PHILLIPS SCREW 6 Hold the nut in place with the 3 8 wrench With the phillips head screw driver remove the locking screw from the rotating disc See Figure F 23 7 Carefully remove the rotating disc and ta...

Page 121: ...w on the printed circuit board See Figure F 24 Note that the tach PC board must be held in place when aligning the rotating disc in the sensor window Press down on the tach PC board with your finger to simulate the cover 9 Use the 3 8 wrench to hold the nut in place Attach the rotating disc with the phillips screw 10 Attach leads 510 525 and 555 to the control PC board 11 Secure the tach assembly ...

Page 122: ...cian or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before ...

Page 123: ...stor Note the position of the insulators for reassembly 5 Using the Phillips head screwdriver remove the 9 pin amphenol connector 6 Set the resistor and the amphenol connector aside as far as the lead lengths will allow This is necessary to gain access to one of the three screws that mount the glastic base to the floor assembly 7 Remove the tach PC board and rotating disc See the Tach PC Board Rem...

Page 124: ...screws that hold the glas tic mounting to the LN 9 floor assembly See Figure F 26 NOTE Four roll drive units have nuts and wash ers also Screw heads are located under the Mylar insulator 12 Remove motor leads 626 627 539 541 527 and 528 from their terminal locations Remove the green motor ground lead See Figure F 25 Free the leads from the harness to allow movement of the motor Cut or untape any n...

Page 125: ... and wire drive assembly partially out of the LN 9 box assembly See Figure F 27 14 Using the 1 2 wrench remove the four bolts and associated washers holding the glastic mounting board and mylar insulator to the gear box assembly NOTE Four roll drive units will require the removal of a 1 2 bolt mounting the reed switch copper energizer to the glastic plate FIGURE F 27 MOTOR AND WIRE DRIVE REMOVAL G...

Page 126: ... bolts and washers On four roll units install the 1 2 bolt for the reed switch copper energizer 19 From the right side slide the motor and gear box assembly into the LN 9 Attach the glas tic mounting to the floor with the screws Four roll units have nuts and washers 20 Connect motor leads 626 627 539 541 527 and 528 to their terminals Attach the green motor ground lead Install any cable ties cut e...

Page 127: ...ving or replacing any mechanical part that could affect the wire feeder s electrical characteristics OR If you repair or replace any electrical compo nent The wire feeder must meet the following standards under retest Wire Feed Speed LN 9 50 600 IPM Wire Feed Speed LN 9H 80 960 IPM Voltmeter Refer to Voltmeter Accuracy Check Wire Speed Meter Refer to Meter Circuit Accuracy Test Gas Solenoid If Use...

Page 128: ...OTES F 70 F 70 LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 129: ... Master TOC Return to Master TOC Return to Master TOC Electrical Diagram Section Section G Wiring Diagram G 2 Operating Schematic G 3 Meter Board L6687 Schematic G 4 Trigger Board M13861 Schematic G 5 Tachometer Board Schematic G 6 TABLE OF CONTENTS ELECTRICAL DIAGRAM SECTION ...

Page 130: ...NOTES LN 9 Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 131: ...1 529 628 WELD CURRENT REED SWITCH CR2 67 INPUT CABLE GUN CABLE T2 1 GROUNDING STUD BLACK ONE MAGNETICALLY A B C D E 622 623 TRIGGER CONNECTOR CASE GND BURNBACK P C BOARD OPTIONAL DELAY P C BOARD JUMPER CONNECTOR IS REMOVED AND HARNESS CONNECTOR IS PLUGGED INTO OPTIONAL CONTACTOR DROP OUT ELECTRICAL SYMBOLS PER E1537 CONNECTOR CAVITY NUMBER CONNECTIONS AS VIEWED FROM BACK OF RHEOSTATS CONNECTION F...

Page 132: ...EGULATOR DIGITAL METER 24 3K OHM 1 4W 1 R402 R403 R406 R407 R408 R409 2 80K OHM 1 4W 1 7 68K OHM 1 4W 1 2K OHM TRIMMER METER CIRCUIT C501 C502 C503 C504 C505 C506 C507 C508 C509 C510 C511 C512 C513 C514 C515 C516 C517 C518 C519 THRU C522 1 MFD 022 MFD 022 MFD 39 MFD 022 MFD 022 MFD 27 MFD 022 MFD 022 MFD 39 MFD 022 MFD D501 THRU D518 CR501 DZ501 DZ502 DZ503 20V 1W S P D T 24VDC 1 AMP 15V 1W 5 1V O...

Page 133: ...UMBER UNLESS OTHERWISE SPECIFIED TOLERANCE ON 2 PLACE DECIMALS IS O2 Ch ge Sht No OR CIRCUITRY OF WITHOUT AFFECTING NOTES CIRCUIT BOARD MAY CHANGE SINCE COMPONENTS OR CIRCUITRY ON BOARD OF A COMPLETE A PRINTED MATERIAL TOLERANCE t TO AGREE ON HOLES SIZES PER E 2056 TP4 7 68K R6 1K CW R7 102K R8 10K CW R9 B9 B5 B6 C7 B8 B7 C4 B2 510A 510C ACTUAL 518 2K CW R2 24 3K R1 2 8K R3 27 10V C3 9 J14 6 510B ...

Page 134: ...H VOLTAGE NET SHOW THE EXACT COMPONENTS S MFD RESISTORS Ohms CODE NUMBER EARTH GROUND CONNECTION UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED 022 50V COMMON CONNECTION 1A 400V 1 4W SCHEMATIC SCALE DIODES UNLESS OTHERWISE SPECIFIED CAPACITORS 12 20 90 LN 9 TRIGGER P C BOARD 20031 NONE CONTROLS HAVING A COMMON NOTES 11 1 91A 2 25 94C 5 20 94A 2 10 95D G 5 Return to Section TOC Return to Sec...

Page 135: ...2 50V AUSTRALIA CAPACITORS CHK Ch ge Sht No FRANCE CONTROLS HAVING A COMMON CODE NUMBER DIODES ELECTRICAL SYMBOLS PER E1537 GENERAL INFORMATION 510 555 1 00K R1 5 15 92N G 6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for li...

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