Lincoln Electric LN-9 GMA manual

IM355-C June, 2010 )165CH 5?5=4B >=/ >D 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. %T$%* $)* "" %&( * %( (& (*) &apos[...]

%( $$ ?>F5A54 5@D9?<5=C 1.a. T urn the engine off before troubleshooting and maintenance 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 outdoors. _______________________[...]

)*/ 99 99 ARC RA Y S can bur n. 4.a. Use a shield with the proper filter and cov er plates to pr otect your ey es from spar ks and the ray s of the arc when welding or observing open arc welding. Headshield and filt er lens should conform to ANSI Z87 . I standards . 4.b . Use suitab le clothing made from durable flame-r esistant material t[...]

)*/ 999 999 FOR ELECTRIC ALL Y pow er ed equipment. 8.a. T urn of f input power using the disconnect switch at the fuse bo x befor e working on the equipment. 8.b . Install equipment in accordance with the U.S . National Electrical Code , all local codes and the manufactur er ’ s recommendations . 8.c. Ground the equipment in accordance [...]

)*/ 9E 9E &(K+*%$)  )S(*K Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse él[...]

E E Thank Y ou f or selecting a QU ALITY product by Lincoln Electr ic. We want you to t ake pride in operating this Lincoln Electric Company pr oduct ••• as much pr ide as we hav e in br inging this pr oduct to you! Read this Operator s Manual completel y befor e at tempting to use this equipment. Sa ve this manual and keep it handy for quick[...]

* " % %$*$*) E9 E9 Page )165CH .................................................................................................................................................i-iv =BC1;;1C9>= ..........................................................................................................................[...]

* " %T%$*$*) (cont’d) E99 E99 Drive Roll Installation ..................................................................................................................B-9 Changing Drive Rolls for 2-Roll Wire Feeders .....................................................................B-9 Changing Drive Rolls for 4-Ro[...]

* " %T%$*$*) (cont’d) E999 E999 Gun and Cable Maintenance ......................................................................................................D-2 Proper Speed Sensor Motor Mounting .................................................................................D-2 Gun Cable Connector Requirements ..[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A *$"  )& *%$) $&+* &%-( Supplied by power source: 1 15 V AC, 50/60 Hz., 350 V A -(  )& 80 to 980 inches per [...]

$)* ""$ * "$ #  (%"" $ (%"" #%")  ** $ * -( (")* $  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 m[...]

(%+*$ * "*(% 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 t[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A +(P )*($ (" "#& %$$*$ * &%-( $&+* " ))#" /*%* &q[...]

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 ch[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A FIGURE A.4 – CONNECTION OF LN-9 GMA TO DC-250, DC-400, and CV/CVI POWER SOURCES Above diagram shows electrode connected positive. T o change polarity , turn power off, reverse the electrode and work leads at the p[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A FIGURE A.5 – CONNECTION OF LN-9 GMA TO DC-600 POWER SOURCES Above diagram shows electrode connected positive. T o change polarity , turn power off, reverse the electrode and work leads at the power source and posi[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A FIGURE A.6 – CONNECTION OF LN-9 GMA TO DC-1000 POWER SOURCES Above diagram shows electrode connected positive. T o change polarity , turn power off, reverse the electrode and work leads at the power source, positi[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A FIGURE A.7 – CONNECTION OF LN-9 GMA TO PULSE POWER 500 POWER SOURCES Above diagram shows electrode connected positive. T o change polarity , turn power off, reverse the electrode and work leads at the power source[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A FIGURE A.8 – CONNECTION OF LN-9 GMA TO IDEALARC R3S-400, R3S-600, R3S-800 POWER SOURCES Above diagram shows electrode connected positive. T o change polarity , turn power off, reverse the electrode and work [...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A FIGURE A.9 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES N.A. Welding cable must be sized for current and duty cycle of application. N.B. Diagram shows electrode positive. T o change polarity , turn power ?[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A #$ (%+$$ 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[...]

$)* "" *%$   "$ #  1=4"$ #-9A5 5545A %$$*$ * +$ " *% * -( ( A variety of gun and cable assemblies are available for the LN-9 GMA models. See the Accessories sec[...]

%%!$ +&#  )"$ ) /"$( <1H 5G?;>45 96 41<1754  • Gas under pressure is explosive. •· Always keep gas cylinders in an upright position and always keep them chained to the undercarriage or a stationary support. See American National Standard [...]

  "$ #  1=4"$ #-9A5 5545A %&( *$ $)*(+*%$) Read and understand this entire section of operating instructions operating the machine. )*/  &(+*%$) "*( )%! 31= :9;; • Do not touch e[...]

$("  )(&*%$ 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 s[...]

 %$)* $* ,%" *  &%-( )%+() 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 i[...]

%&( *%$   "$ #  1=4"$ #-9A5 5545A %$*(%")$ )**$) 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[...]

+( P -( ( %$*(%") %( "$# %&( *%$   "$ #  1=4"$ #-9A5 5545A[...]

%&( *%$   "$ #  1=4"$ #-9A5 5545A +( P -( ( %$*(%") %( "$#[...]

%&( *%$   "$ #  1=4"$ #-9A5 5545A (+* (!($ (%+$$ " &(% **%( "& ()* )-*  These protection circuit devices are located on the fr[...]

If such a grounding lead fault occurs, the meter will still be on and will be reading. The trigger circuit will not operate, however . T o release the circuit, press the "GLP Reset" button. See Figure B.3 or B.4 for the location of this button. The following precautions are recommended to avoid GLP shutdown: • Do =>C allow the electr[...]

(, (%""$)* "" *%$ $$ (, (%"") %( (%"" -( () T o 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 foll[...]

CLAMPING  COLLAR DRIVE ROLL HALVES SPACER (IF REQ'D) KEY OUTPUT SHAFT GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE LARGE RADIUS DRIVE  ROLL INCOMING GUIDE TUBE SMALL RADIUS IDLE ROLL CLAMPING  COLLAR DRIVE ROLL HALVES SPACER (IF REQ'D) KEY OUTPUT SHAFT GUIDE TUBE[...]

$$ (, (%"") %( (%"" -( () T o 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 [...]

%&( *%$   "$ #  1=4"$ #-9A5 5545A CLAMPING COLLAR SPACER (IF REQUIRED) DRIVE ROLL HALVES OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE IDLE ROLL SMALL RADIUS MIDDLE GUIDE TUBE DRIVE ROLL LARGE RADIUS GUIDE TUBE DETAIL KEY OUTPUT SHAFT CLAMPING COLLAR [...]

%&( *%$   "$ #  1=4"$ #-9A5 5545A -( "%$ ">149=7 1  C> "2  C>  :7 (5149(55; &13:175 +B9=7 C85 #>;454 &;1BC93 !?[...]

"%$   *%  "   *% ! )&%%"  #*( %(    "  ! $$()" %" The Spindle should be located in the "%-( mou[...]

"%$ $ " %") %$ R )&$" ! >A ! -9A5(55; )C1=4  +)* " -( ("  (! The mount for standard 50 and 60 pound electrode coils includes a two position brake assembly[...]

$"*(% $(!  +)*#$* 1. T urn 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 fr[...]

%&( *%$   "$ #  1=4"$ #-9A5 5545A " (%""&())+( )**$ The idle roll pressure is set at the factory backed out two turns from full pressure for 2-roll feeders, three turns from full pressure for 4-roll feed[...]

#!$  *)* -"$  +)*$ "$ #  ()&%$) $ )* (*$ (*()*)  +)* * &%-( )%+(   >A  1. Connect electrode lead to t[...]

,%" *  %$*(%"()&%$) The LN-9 GMA is provided with selectable voltage con- trol response. Proper setting depends on the power source and process being used. Refer to the appropri- ate power source connection diagram for the proper connection of the jumpers located on the LN-9 GMA V oltage Board. T o change the v[...]

#!$  -" 1. Inch the electrode through the gun and cable and then cut the electrode within approximately 3/8" of the end of the contact tip for solid wire and within approximately 3/4" of the extension guide for cored wire. 2. Connect the work cable to the metal to be welded. The work cable must make good elect[...]

+."( / '+&#$* %$* *) The power for 1 15 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. *+($ *[...]

 ** $ * -((" )* $) The mounting hardware for mounting the stands is included with the LN-9 GMA. Screws and washers are inserted in their respective mounting holes. T o 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 [...]

+$,()"-( (")* $ ! Includes a 2" (51mm) O.D. Spindle with adjustable brake and two locations for mounting the spindle to allow for the mounting of 50 - 60lb, 10 - 30 lb, 13 - 14lb, and 8" O.D. coils with proper spindle adapters. (See OPERA TION section) Capable of [...]

-( ())%() +($! *#(!* ! Provides a precise control of the electrode burnback at the end of the weld. Prevents crater sticking and provides proper stickout for starting the next weld. Recommended especially when welding with small (0.023-1/16") diameter wir[...]

))%()   "$ #  1=4"$ #-9A5 5545A #  *#( !*! 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[...]

))%()   "$ #  1=4"$ #-9A5 5545A )-,"&" *%(# ! 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. Recommend[...]

! #$*)& ( *%( 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 along wit[...]

))%()   "$ #  1=4"$ #-9A5 5545A * "  P(, (%""$+ *+ !*) -9A5)9I5 !9C (>;; (>;; )>;94 )C55;;53CA>45 0.023” - 0.025” (0.6 mm) [...]

)*/  &(+*%$) "*(T)%! 31=:9;; • Only qualified personnel should perform this maintenance. • T urn the input supply power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. (%+*$ #$*$$ (,[...]

+$$ " #$*$$ For instructions on periodic maintenance for the weld- ing gun and cables, refer to the manual for your specif- ic model of welding gun. &(%&( )& )$)%( #%+" #%+$*$ The LN-9 GMA Speed Sensor Module is a three lead Hall-Effect switch [...]

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. QR 91<5C5A>;5 C> 25>=35=CA93 C> -9A5)9I5   9= << 91<5C5A-9C89= [...]

*(%+")%%*$   "$ #  1=4"$ #-9A5 5545A 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[...]

*(%+")%%*$   "$ #  1=4"$ #-9A5 5545A &(%"#) )/#&*%#) Drive rolls turn but wire will not feed, or wire feeding is rough or uneven. &%))"()% #) +)*#$*) 1. Check that the gun cab[...]

*(%+")%%*$   "$ #  1=4"$ #-9A5 5545A &(%"#) )/#&*%#) Gun trigger will not feed wire. Digital meter is not lit. &%))"()% #) +)*#$*) 1. Check to see if the circuit breaker is tr[...]

*(%+")%%*$   "$ #  1=4"$ #-9A5 5545A &(%"#) )/#&*%#) Gun trigger will not feed wire. Meter is "on" and reads SET value of VOL TS or WIRE SPEED. &%))"()% #) +)*#$*) 1[...]

*(%+")%%*$   "$ #  1=4"$ #-9A5 5545A &(%"#) )/#&*%#) Gun trigger works and arc can be struck. Unit then shuts down while welding, or voltage output too low to establish arc (LN-9 ACTUAL VOL TS meter reading is low , zero or negat[...]

*(%+")%%*$   "$ #  1=4"$ #-9A5 5545A &(%"#) )/#&*%#) V ariable or "hunting" arc. &%))"()% #) +)*#$*) 1. Check for worn or incorrect sized contact tip. Replace tip if[...]

*(%+")%%*$   "$ #  1=4"$ #-9A5 5545A &(%"#) )/#&*%#) Poor arc striking with sticking or "blast-offs", weld porosity , narrow and ropy-looking bead, or electrode stubbing into plate while welding. &%))"[...]

  "$ #  1=4"$ #-9A5 5545A 1-10-97G L10247 LN-9 GMA 601 602 510C 518 510 517 519 560 561 562 1 4 3 6 2 5 11 7 8 9 10 12 (J8) (P8) 601 602 510A 510B 518 518 510 517 519 560 561 562 1 2 3 4 5 6 7 8 9 10 11 12 518 562 518 510 C2 517 561 560 519 C3 C1 S6 513 516 512 514 511 N.O.[...]

(#)   "$ #  1=4"$ #-9A5 5545A 1-10-97G L10250 LN-9F GMA A B C D E 622 623 (J4) WELD CURRENT REED SWITCH 628529 CR2 WIRE FEED MOTOR MODULE X1 BLACK RED BLUE HALL EFFECT INPUT CABLE GUN CABLE 510 525 555 529 628 BLACK RED BLUE 541 539 32A 67 7A BLACK WHITE 7A32[...]

(#)   "$ #  1=4"$ #-9A5 5545A "$ #  #$)%$ &($*[...]

(#)   "$ #  1=4"$ #-9A5 5545A "$ #  #$)%$ &($*  %  -( (, +$*[...]

(#)   "$ #  1=4"$ #-9A5 5545A "$ #$)%$ &($*  %  %$*(%"  %.[...]

$%*)  [...]

- ($$  ,)%  &(+%$  **$*%$ - ($+$  *$JO% )?1=9B8 A5=38 5A<1= &>ACD7D5B5 1?1=5B5 89=5B5 !>A51= A1293 READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIE[...]

"$ #  -(( - ($$  ,)%  &(+%$  **$*%$ - ($+$  *$JO% )?1=9B8 A5=38 5A<1= &>ACD7D5B5 1?1=5B5 89=5B5 !>A51= A1293 LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PR[...]

• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]