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RETURN TO MAIN INDEX SVM138-A June, 1998 LN-9 GMA Wire Feeder For use with machines having Code Numbers: 9100 and Above Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation.
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.
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
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WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
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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...
MASTER TABLE OF CONTENTS Safety ...i-iv Installation...Section A Technical Specifications ...A-2 Installing the LN-9GMA 2-Roll and 4-Roll Models ...A-3 Installing the LN-9F GMA 2-Roll and 4-Roll Models ...A-3 Electrical Connections - LN-9 GMA and LN-9F GMA...A-4 Machine Grounding...A-12 Work Cable Connection ...A-12 Connecting the Gun Cable to the Wire Feeder ...A-13 Hooking Up GMA Shielding Gas...A-14 Operation...Section B...
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MASTER TABLE OF CONTENTS Troubleshooting ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures...F-3 Troubleshooting Guide ...F-4 Electrical Diagrams ...Section G Parts ...P289 Series RETURN TO MAIN INDEX LN-9 GMA Wire Feeder (cont’d)
Section A-1 - INSTALLATION SECTION - Installation Technical Specifications ...A-2 Installing the LN-9GMA 2-Roll and 4-Roll Models ...A-3 Attaching the Wire Reel stand...A-3 Mounting the Unit ...A-3 Installing the LN-9F GMA 2-Roll and 4-Roll Models ...A-3 Mounting the 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...
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...
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).
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.
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.
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INSTALLATION Figure A.8 is a connection diagram for connecting the LN-9 GMA to V300 power sources. The connection is made with a K596 cable assembly, which has an amphenol connection rather than a terminal strip con- nection at the power source. Depending on the power source and process you are using, the jumpers on the LN-9 GMA voltage board may have to be changed.
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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.
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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.
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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.
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A-10 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.
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A-11 FIGURE A.8 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES ELECTRIC SHOCK can kill. ELECTRODE CABLE TO LN-9 GMA TO WORK INVERTEC POWER SOURCE WITH 110/115V AUX. N.A. Welding cable must be sized for current and duty cycle of application. N.B.
A-12 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.
A-13 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.
A-14 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.10 – SHIELDING GAS HOOKUP INSTALLATION See American National Standard Z-49.1, "Safety in Welding and Cutting,"...
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.
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 •...
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.
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.
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.
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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.
B-10 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.
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B-11 FIGURE B.5 – INSTALLING DRIVE ROLLS ON A 2-ROLL FEEDER DRIVE ROLL HALVES GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT OPERATION CLAMPING COLLAR SPACER (IF REQ'D) OUTPUT SHAFT LARGE RADIUS OUTGOING GUIDE TUBE IDLE ROLL SMALL RADIUS LN-9 GMA Wire Feeder B-11 DRIVE ROLL...
B-12 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.
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B-13 FIGURE B.6 – INSTALLING DRIVE ROLLS ON A 4-ROLL FEEDER DRIVE ROLL HALVES GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT OPERATION CLAMPING COLLAR SPACER (IF REQUIRED) OUTPUT OUTPUT SHAFT SHAFT LARGE RADIUS OUTGOING GUIDE TUBE IDLE ROLL SMALL RADIUS LN-9 GMA Wire Feeder B-13 DRIVE...
B-14 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.
B-15 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.
B-16 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.
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B-17 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.
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.
B-19 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.
B-20 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.
B-21 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.
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.
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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.
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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.
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...
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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.
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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).
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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.
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-...
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.
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.
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Section E-1 -THEORY OF OPERATION SECTION- 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 POWER SOURCE OUTPUT TRIGGER (#2 ) TRIGGER CIRCUIT CONNECTOR BREAKER...
THEORY OF OPERATION GENERAL DESCRIPTION The LN-9 GMA is a semiautomatic wire feeder that allows the user to preset the arc voltage and wire feed speed. The wire feed speed is internally monitored and regulated to the preset condition. When the LN-9 GMA is coupled to an appropriate Lincoln constant voltage FIGURE E.2 –...
THEORY OF OPERATION FIGURE E.3 – TRIGGER AND SHUTDOWN CIRCUIT POWER SOURCE OUTPUT TRIGGER (#2 ) TRIGGER CIRCUIT CONNECTOR BREAKER INPUT CONNECTOR CONTROL BOARD VOLTAGE BOARD METER 10VAC 28VAC BOARD VOLTS SPEED SWITCH TRIGGER AND SHUTDOWN CIRCUIT When the gun trigger switch is activated (closed), the trigger board completes the trigger signal path.
THEORY OF OPERATION FIGURE E.4 – ARC VOLTAGE, WIRE SPEED CONTROL AND METERING POWER SOURCE OUTPUT TRIGGER (#2 ) TRIGGER CIRCUIT CONNECTOR BREAKER INPUT CONNECTOR CONTROL BOARD VOLTAGE BOARD METER 10VAC 28VAC BOARD VOLTS SPEED SWITCH ARC VOLTAGE, WIRE SPEED CONTROL AND METERING The arc voltage, which is sensed at the work piece and motor gear box, is connected through a polarity switch...
THEORY OF OPERATION PRINTED CIRCUIT BOARD FUNCTIONS POWER BOARD The input power (115VAC) is applied to the power board, and from that the power board develops the variable DC armature voltage for the permanent mag- net wire drive motor. The SCR circuitry, used to con- trol the motor armature voltage, is also contained on the power board.
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Section F-1 TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide ...F-4 - F-23 Test Procedures T1 Transformer Test ...F-24 T2 Transformer Test ...F-27 Wire Drive Motor Test...F-31 Hall Effect Test and Alignment...F-34 Voltmeter Accuracy Test ...F-38 Meter Circuit Accuracy Test...F-41...
TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
• 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.
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. POSSIBLE AREAS OF...
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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.
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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.
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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. detailed in the beginning of this manual.
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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.
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"OFF" position. 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.
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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.
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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. detailed in the beginning of this manual.
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Gun trigger is NOT activated. 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.
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PC board repeatedly fails. 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.
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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.
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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.
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"hunting." 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. detailed in the beginning of this manual.
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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. detailed in the beginning of this manual.
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The arc is unstable or oscillating. 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.
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F-19 TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The SET and actual speed meter readings match within a few IPM, but both are in error. SET speed and actual speed meter readings do NOT match within a few IPM. One or both readings may be erratic.
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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. detailed in the beginning of this manual.
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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.
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Welding is good. 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.
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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. detailed in the beginning of this manual.
F-24 TROUBLESHOOTING & REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician 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.
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F-25 TROUBLESHOOTING & REPAIR T1 TRANSFORMER TEST (continued) FIGURE F.1 – LEAD #532 AT POWER PC BOARD LEAD 31 TEST PROCEDURE 1. Remove input power to the LN-9 GMA wire feeder. 2. Using the phillips head screwdriver, remove the screws holding the left side cover assembly.
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F-26 TROUBLESHOOTING & REPAIR T1 TRANSFORMER TEST (continued) FIGURE F.2 – SECONDARY LEADS #601 AND #602 AT LEAD SPLICES 6. Using the volt/ohmmeter, check for 10VAC at secondary leads #601 and #602. Typically, these leads are yellow. Place the probes at the lead splices.
F-27 TROUBLESHOOTING & REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-28 TROUBLESHOOTING & REPAIR T2 TRANSFORMER TEST (continued) FIGURE F.3 – “PROTECTION CIRCUIT TROUBLESHOOTING” NAMEPLATE TROUBLESHOOTING NAMEPLATE TEST PROCEDURE 1. Remove input power to the LN-9 GMA wire feeder. 2. Using the phillips head screwdriver, remove the screws holding the left side cover assembly.
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F-29 TROUBLESHOOTING & REPAIR T2 TRANSFORMER TEST (continued) FIGURE F.4 – T2 PRIMARY LEADS #32A AT 5 AMP CIRCUIT BREAKER AND #531 AT R1 RESISTOR CIRCUIT BREAKER LEAD 32A 4. Locate the T2 transformer primary lead #32A connected to the 5 amp circuit break- er.
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F-30 TROUBLESHOOTING & REPAIR T2 TRANSFORMER TEST (continued) FIGURE F.5 – T2 SECONDARY LEADS #621 AND #620 ON TRIGGER PC BOARD WARNING Electric Shock can kill. • With 7. Insulate the T2 transformer primary leads #531 and #32A and apply 115 VAC power. See the Wiring Diagram and Figure F.4.
F-31 TROUBLESHOOTING & REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-32 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR TEST (continued) FIGURE F.6 – LEAD #539 AND #541 AT POWER PC BOARD TERMINAL STRIP TEST PROCEDURE 1. Remove input power to the LN-9 GMA wire feeder. 2. Remove any electrode wire or disengage the drive rolls.
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F-33 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR TEST (continued) WARNING ELECTRIC SHOCK can kill. • With 6. Apply 115 VAC power. 7. With the gun trigger activated or the gun ter- minals jumpered together (see the Wiring Diagram), check the motor armature volts at leads #541(+) and #539(-).
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TROUBLESHOOTING & REPAIR HALL EFFECT MODULE TEST AND ALIGNMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-35 TROUBLESHOOTING & REPAIR HALL EFFECT MODULE TEST AND ALIGNMENT (continued) FIGURE F.7 – LEADS #525, #510, #555 ON CONTROL PC BOARD HALL EFFECT MODULE FEEDBACK TEST PROCEDURE 1. Remove the input power to the LN-9 GMA wire feeder. 2. Remove any electrode wire or disengage the drive rolls.
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F-36 TROUBLESHOOTING & REPAIR HALL EFFECT MODULE TEST AND ALIGNMENT (continued) WARNING ELECTRIC SHOCK can kill. • With 6. Apply input power to the LN-9 GMA and test for 15VDC at leads #525(+) to #510(-). This is the supply voltage from the control PC board to the hall effect module.
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F-37 HALL EFFECT MODULE TEST AND ALIGNMENT (continued) FIGURE F.8 – HALL EFFECT MODULE LOCATION HALL-EFFECT MODULE HALL EFFECT MODULE ALIGNMENT TEST PROCEDURE The LN-9 GMA wire speed sensor is a three lead hall-effect device encased in an externally threaded housing. It is screwed into a mounting plate on the motor side of the wire drive gear- box.
TROUBLESHOOTING & REPAIR VOLTMETER ACCURACY TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-39 TROUBLESHOOTING & REPAIR VOLTMETER ACCURACY TEST (continued) FIGURE F.9 – VOLTMETER CONNECTION POINT TEST PROCEDURE Perform the following checks with the LN-9 GMA wire feeder connected to a Lincoln CV welding power source according to the proper connection diagram. (See the Installation section of this manual.) See Figure F.9 for this test.
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F-40 TROUBLESHOOTING & REPAIR VOLTMETER ACCURACY TEST (continued) WARNING 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.
TROUBLESHOOTING & REPAIR METER CIRCUIT ACCURACY TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-42 TROUBLESHOOTING & REPAIR METER CIRCUIT ACCURACY TEST (continued) FIGURE F.10 – METER PC BOARD LOCATIONS AND COVER MOUNTING SCREWS TEST PROCEDURE 1. Remove input power to the LN-9 GMA wire feeder. 2. Lift the right side cover assembly and remove the two screws holding the meter cover to the right side assembly.
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F-43 TROUBLESHOOTING & REPAIR METER CIRCUIT ACCURACY TEST (continued) FIGURE F.11 – METER PC BOARD TEST POINTS 510C 5. Test for AC supply to the meter PC board. Check for 8 to 11 VAC from lead #601 to #602. See Figure F.11. NOTE: The coating will have to be removed from the test points.
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F-44 TROUBLESHOOTING & REPAIR METER CIRCUIT ACCURACY TEST (continued) Test Digital Meter Accuracy. (For LN-9 GMA models above code 7980 with separable digital meter and meter boards only). 1. Use a test meter with at least 3-1/2 digits and ± 0.5% accuracy. 2.
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F-45 TROUBLESHOOTING & REPAIR METER CIRCUIT ACCURACY TEST (continued) Test Meter PC Board Wire Feed Speed Accuracy. (Metric Models Only) 1. Use a test meter with at least 3-1/2 digits and ± 0.5% accuracy. 2. Connect the + probe to lead called for in the table below and the - probe to lead #510C.
TROUBLESHOOTING & REPAIR WIRE SPEED ACCURACY TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-47 TROUBLESHOOTING & REPAIR WIRE SPEED ACCURACY TEST (continued) TEST PROCEDURE Perform the following checks with the LN-9 GMA wire feeder connected to a Lincoln CV welding power source according to the proper connection diagram. (See the Installation section of this manual.) A.
TROUBLESHOOTING & REPAIR OUT OF VOLTAGE RANGE SHUT DOWN TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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1/8 AMP FUSE 5. Connect to a Lincoln Electric CV power source per connection diagram. Installation section of this manual. 6. Start welding and observe the ACTUAL volt- age reading on the LN-9 GMA digital meter.
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F-50 TROUBLESHOOTING & REPAIR OUT OF VOLTAGE RANGE SHUT DOWN TEST (continued) 8. If the ACTUAL voltage reading is zero, the sensing leads may be faulty. Check the con- tinuity (zero ohms) of leads #21 and #67. Lead #21 must have continuity to the work- piece, and #67 must have continuity to the electrode.
TROUBLESHOOTING & REPAIR GENERAL POWER SUPPLY TESTS Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-52 TROUBLESHOOTING & REPAIR GENERAL POWER SUPPLY TESTS (continued) TEST PROCEDURE 1. Remove input power to the LN-9 GMA wire feeder. 2. Using the phillips head screwdriver, remove the screws from the left side cover assembly. 3. Lift the left side cover assembly. 4.
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F-53 TROUBLESHOOTING & REPAIR GENERAL POWER SUPPLY TESTS (continued) CHECKPOINT LOCATION DESCRIPTION CONTROL P.C. BOARD CONNECTOR SUPPLY FROM PLUG CONTROL P.C. CHECK - 10 VDC BOARD SUPPLY FROM CONNECTOR PLUG VOLTAGE P.C. BOARD UPPER CONNECTOR SUPPLY FROM PLUG NEXT TO "F"...
TROUBLESHOOTING & REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-55 TROUBLESHOOTING & REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT (continued) METER PC BOARD REMOVAL PROCEDURE 1. Remove input power to the LN-9 GMA Wire Feeder. FIGURE F.13 – METER PANEL ASSEMBLY SCREWS METER 3. Lift the right side cover assembly. FIGURE F.14 –...
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F-56 TROUBLESHOOTING & REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – METER PC BOARD REMOVAL 5. Using the 5/16" nut driver, remove the four nuts mounting the meter PC board to the meter assembly. See Figure F.15. 6.
TROUBLESHOOTING & REPAIR REED SWITCH (CR2) REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-58 TROUBLESHOOTING & REPAIR REED SWITCH (CR2) REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – CR2 REED SWITCH LOCATION AND COMPONENTS LEAD 628 LEAD 529 SELF-TAPPING PROCEDURE 1. Remove input power to the LN-9 GMA wire feeder. 2. Lift the right side cover assembly. 3.
TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the 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.
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F-60 TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.17 – PRIMARY LEAD #31 AT R1 RESISTOR PROCEDURE 1. Remove input power to the LN-9 GMA. 2. Using the phillips head screwdriver remove the screws holding the left side cover assembly. 3.
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F-61 TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued) 6. Disconnect leads #526 and #527 from the power PC board terminals. See Figure F.18. FIGURE F.18 – LEADS #526 AND #527 AT POWER PC BOARD 7. Disconnect yellow leads #601 and #602 from the lead splices.
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F-62 TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued) 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.
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F-63 TROUBLESHOOTING & REPAIR T1 TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – TERMINAL STRIP MOUNTING TRANSFORMER MOUNTING SCREWS 11. Using the 5/16" wrench, remove the nuts and lockwashers mounting the terminal strip to the mounting panel. See Figure F.21. 12.
TROUBLESHOOTING & REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician 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.
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F-65 TROUBLESHOOTING & REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.22 – TOP MOTOR PLATE SCREWS MOTOR GROUND LEAD PROCEDURE 1. Remove input power to the LN-9 GMA wire feeder. 2. Using the phillips head screwdriver, remove the screws holding the left side cover assembly. 3.
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F-66 TROUBLESHOOTING & REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – GLASTIC MOUNTING SCREWS NUTS AND WASHERS (4-ROLL FEEDERS) 11. Remove the three screws and lock washers that hold the glastic mounting to the LN-9 GMA floor assembly. It may be necessary to remove the copper reed switch energizer to access one of the mounting screws.
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F-67 TROUBLESHOOTING & REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.24 – MOTOR AND WIRE DRIVE REMOVAL MYLAR INSULATOR GLASTIC MOUNTING BOARD 12. Lift the right side cover assembly and care- fully lift and slide the motor and wire drive assembly partially out of the LN-9 GMA box assembly.
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F-68 TROUBLESHOOTING & REPAIR DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) 15. With the slot head screwdriver, remove the three screws, lock washers, flatwashers, and insulators holding the drive motor to the gear box assembly. See Figure F.25. Note their positions for reassembly. 16.
F-69 F-69 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR Retest the LN-9 GMA wire feeder: If it fails any test and the test requires removing or replacing any mechanical part that could affect the wire feeder's electrical characteristics. If you repair or replace any electrical compo- nent.
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ELECTRICAL DIAGRAMS TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- Theory of Operation ...Section G Wiring Diagram-LN-9 GMA ...G-3 Wiring Diagram-LN-9F GMA ...G-4 Voltage Board Schematic ...G-5 Power PC Board Schematic...G-6 Trigger PC Board Schematic...G-7 PM Control Schematic...G-8 Meter Board Schematic...G-9 Operating Schematic...G-10 LN-9 GMA Wire Feeder...
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.