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Lincoln Electric IM355-C LN-9 GMA Operator's Manual

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RETURN TO MAIN MENU
IM355-C
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
• 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

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  • Page 1 RETURN TO MAIN MENU IM355-C 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.

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Safety

    SAFETY...
  • Page 4 SAFETY...
  • Page 5 PRÉCAUTIONS DE SÛRETÉ 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 Protegez-vous contre la secousse électrique: Les circuits à...
  • Page 6 Thank You...

  • Page 7: Table Of Contents

    TAbLE OF CONTENTS Safety ...i-iv Installation...Section A Technical Specifications ...A-1 Installing the LN-9GMA 2-Roll and 4-Roll Models ...A-2 Attaching the Wire Reel stand...A-2 Mounting the Unit ...A-2 Installing the LN-9F GMA 2-Roll and 4-Roll Models ...A-2 Mounting the Wire Feed Unit...A-2 Mounting the Control Box ...A-2 Connecting the Wire Feed Unit to the Control Box ...A-2 Routing the Electrode ...A-3...
  • Page 8 TAbLE OF CONTENTS Drive Roll Installation ...B-9 Changing Drive Rolls for 2-Roll Wire Feeders ...B-9 Changing Drive Rolls for 4-Roll Wire Feeders...B-11 Wire Loading ...B-13 Loading a 22 to 30 lb. Reddi-Reel Package...B-13 Loading a 10 to 30 lb. Spool ...B-14 Loading 50 and 60 lb.
  • Page 9 TAbLE OF CONTENTS Gun and Cable Maintenance ...D-2 Proper Speed Sensor Motor Mounting...D-2 Gun Cable Connector Requirements ...D-3 Troubleshooting...Section E How to Use Troubleshooting Guide ...E-1 Troubleshooting Guide ...E-2 Diagrams...Section F LN-9 GMA Wiring Diagram...F-1 LN-9F GMA Wiring Diagram ...F-2 LN-9 GMA Dimension Print ...F-3 LN-9F GMA Dimension Prints ...F-4 Parts...P127, P125, P107 &...

  • Page 10: Installation

    TECHNICAL SPECIFICATIONS Supplied by power source: 115 VAC, 50/60 Hz., 350 VA 80 to 980 inches per minute (2.03 to 24.9 meters per minute) VOLTAGE CONTROL RANGE OPERATION: - 20 - 40 STORAGE: - 40 0.023 through 1/16 0.045 through 5/64 LN-9 GMA (2 ROLL) LN-9 GMA (4 ROLL) LN-9F GMA Control Box...

  • Page 11: Installing The Ln-9Gma 2-Roll And 4-Roll Models

    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).

  • Page 12: Routing The Electrode

    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.

  • Page 13: Connecting The Power Input Cable Assembly To Power Sources

    FIGURE A.2 – STRAIN RELIEF CLAMP CONNECTING THE POWER INPUT CAbLE ASSEMbLY TO THE LN-9F CONTROL 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.
  • Page 14 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.
  • Page 15 FIGURE A.4 – CONNECTION OF LN-9 GMA TO DC-250, DC-400, and CV/CVI POWER SOURCES ELECTRIC SHOCK can kill. 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.
  • Page 16 FIGURE A.5 – CONNECTION OF LN-9 GMA TO DC-600 POWER SOURCES ELECTRIC SHOCK can kill. 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.
  • Page 17 FIGURE A.6 – CONNECTION OF LN-9 GMA TO DC-1000 POWER SOURCES ELECTRIC SHOCK can kill. 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.
  • Page 18 FIGURE A.7 – CONNECTION OF LN-9 GMA TO PULSE POWER 500 POWER SOURCES ELECTRIC SHOCK can kill. 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.
  • Page 19 FIGURE A.8 – CONNECTION OF LN-9 GMA TO IDEALARC R3S-400, R3S-600, R3S-800 POWER SOURCES ELECTRIC SHOCK can kill. 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 screw.
  • Page 20 FIGURE A.9 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES ELECTRIC SHOCK can kill. 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.

  • Page 21: Machine Grounding

    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.

  • Page 22: Connecting The Gun Cable To The Wire Feeder

    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.

  • Page 23: Hooking Up Gma Shielding Gas

    HOOKING UP GMA SHIELDING WARNING CYLINDER damaged. • 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. FIGURE A.11 – SHIELDING GAS HOOKUP INSTALLATION See American National Standard Z-49.1, "Safety in Welding and Cutting,"...

  • Page 24: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions operating the machine. SAFETY PRECAUTIONS OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yourself from the work and ground.

  • Page 25: General Description

    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 •...

  • Page 26: Dc Constant Voltage Power Sources

    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.

  • Page 27: Controls And Settings

    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.
  • Page 28 OPERATION FIGURE b.3 – WIRE FEEDER CONTROLS FOR LN-9 GMA LN-9 GMA and LN-9F GMA Wire Feeder...
  • Page 29 OPERATION FIGURE b.4 – WIRE FEEDER CONTROLS FOR LN-9F GMA LN-9 GMA and LN-9F GMA Wire Feeder...

  • Page 30: Circuit Protection And Automatic Shutdown

    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.
  • Page 31 If such a grounding lead fault occurs, the meter will still be on and will be reading. The trigger circuit will not operate, however. To release the circuit, press the "GLP Reset" button. See Figure B.3 or B.4 for the location of this button.

  • Page 32: Drive Roll Installation

    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.
  • Page 33 FIGURE b.5 – INSTALLING DRIVE ROLLS ON A 2-ROLL FEEDER DRIVE ROLL HALVES GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT LN-9 GMA and LN-9F GMA Wire Feeder OPERATION CLAMPING COLLAR SPACER (IF REQ'D) OUTPUT SHAFT LARGE RADIUS OUTGOING GUIDE TUBE IDLE ROLL SMALL...

  • Page 34: Changing Drive Rolls For 4-Roll Wire Feeders

    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.
  • Page 35 FIGURE b.6 – INSTALLING DRIVE ROLLS ON A 4-ROLL FEEDER DRIVE ROLL HALVES GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT LN-9 GMA and LN-9F GMA Wire Feeder OPERATION CLAMPING COLLAR SPACER (IF REQUIRED) OUTPUT SHAFT LARGE RADIUS OUTGOING GUIDE TUBE IDLE ROLL SMALL...

  • Page 36: Wire Loading

    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.

  • Page 37: Loading A 10 To 30 Lb. Spool

    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 lb.

  • Page 38: Loading 50 And 60 Lb. Coils

    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.

  • Page 39: Loading And Feeding 13-14 Lbs. Innershield Coils

    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.

  • Page 40: Idle Roll Pressure Setting

    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.

  • Page 41: Adjust The Power Source

    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. 2. Set toggle switch to same polarity as the electrode cable connection. 3.

  • Page 42: Voltage Control Response

    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 proper connection of the jumpers located on the LN-9 GMA Voltage Board.

  • Page 43: Making A Weld

    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.

  • Page 44: 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.
  • Page 45 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.
  • Page 46 ACCESSORIES UNIVERSAL WIRE REEL STAND (K1524-1) Includes a 2" (51mm) O.D. Spindle with adjustable brake and two locations for mounting the spindle to allow for the mounting of 50 - 60lb, 10 - 30 lb, 13 - 14lb, and 8" O.D. coils with proper spindle adapters. (See OPERATION section) Capable of being mounted on the top of a suitable power source or surface without the need for any other mounting kit.

  • Page 47: Gun And Cable Assemblies

    GUN AND CAbLE ASSEMbLIES A variety of standard Lincoln and Magnum gun and cable assemblies are available for the LN-9 GMA in TAbLE C.1 – LN-9 GMA GUN AND CAbLE ASSEMbLIES Process Model Gas Metal Arc (GMA) K426 K427 Magnum K470 Magnum K471 Magnum K478 Magnum K479...
  • Page 48 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 0 to 1.5 seconds.
  • Page 49 SWIVEL PLATFORM (K178-1) For all LN-9 GMA wire reel stand combinations. For mounting wire feeder-wire reel stand assembly on top suitable Lincoln Idealarc Recommended input cable assembly length is 10 feet (3m) when using the K178-1. Bolt the platform to the lift bail according to instructions supplied with the platform (M16260).
  • Page 50 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 along with the flux to be processed.
  • Page 51 TAbLE C.2 – DRIVE ROLL AND GUIDE TUbE KITS Wire Size Solid Steel Electrode 0.023” - 0.025” (0.6 mm) 0.030” (0.8 mm) 0.035” (0.9 - 1.0 mm) 0.045” and 0.052” (1.2 - 1.4 mm) 0.062” (1.4 - 1.6 mm) 0.068” (1.7 mm) 5/64”...

  • Page 52: Maintenance

    SAFETY PRECAUTIONS WARNING 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-...

  • Page 53: Gun And Cable 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.

  • Page 54: Gun Cable Connector Requirements

    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.

  • Page 55: Troubleshooting

    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.

  • Page 56: Troubleshooting Guide

    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.
  • Page 57 Observe Safety Guidelines detailed in the beginning of this manual. PRObLEMS (SYMPTOMS) Gun trigger will not feed wire. Digital meter is not lit. 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.
  • Page 58 Observe Safety Guidelines detailed in the beginning of this manual. PRObLEMS (SYMPTOMS) Gun trigger will not feed wire. Meter is "on" and reads SET value of VOLTS or WIRE SPEED. 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.
  • Page 59 Observe Safety Guidelines detailed in the beginning of this manual. PRObLEMS (SYMPTOMS) 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 VOLTS meter reading is low, zero or negative when trigger is closed).
  • Page 60 Observe Safety Guidelines detailed in the beginning of this manual. PRObLEMS (SYMPTOMS) Variable or "hunting" arc. 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. TROUbLESHOOTING POSSIbLE AREAS OF MISADJUSTMENT(S)

  • Page 61: Welding Problems

    Observe Safety Guidelines detailed in the beginning of this manual. PRObLEMS (SYMPTOMS) Poor arc striking with sticking or "blast-offs", weld porosity, narrow and ropy-looking bead, or electrode stubbing into plate while welding. 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.

  • Page 62: Diagrams

    510A 510C 510B DIAGRAMS LN-9 GMA WIRING DIAGRAM 530A 510A 510B 524A 530A 530B LN-9 GMA and LN-9F GMA Wire Feeder...

  • Page 63: Ln-9F Gma Wiring Diagram

    DIAGRAMS LN-9F GMA WIRING DIAGRAM YELLOW 530A 524A LN-9 GMA and LN-9F GMA Wire Feeder...

  • Page 64: Ln-9 Gma Dimension Print

    DIAGRAMS LN-9 GMA DIMENSION PRINT LN-9 GMA and LN-9F GMA Wire Feeder...

  • Page 65: Ln-9F Gma Dimension Prints

    DIAGRAMS LN-9F GMA DIMENSION PRINT (1 OF 2) WIRE DRIVE UNIT LN-9 GMA and LN-9F GMA Wire Feeder...
  • Page 66 DIAGRAMS LN-9F DIMENSION PRINT (2 OF 2) CONTROL bOX LN-9 GMA and LN-9F GMA Wire Feeder...
  • Page 67 NOTES...
  • Page 68 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
  • Page 69 LN-9 GMA WIRE FEEDER WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
  • Page 70 • 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...

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