LN-9 Wire Feeder
LN-9 Wire Feeder
Safety
Electric Shock can kill
ARC Rays can burn
Fumes and Gases can be dangerous
Iii
Cylinder may explode if damaged
Précautions DE Sûreté
Master Table of Contents for ALL Sections
Table of Contents Installation Section
Installation
Technical Specifications LN-9
Width Height
Attaching the Wire Reel Stand
Installing the LN-9F Roll and 4-ROLL Models
Mounting the Wire Feed Unit
Mounting the Unit
LN-9S Wire Feed Unit
Power Input Cable Assembly
Electrical Connections LN-9N, S and LN-9F
Routing the Electrode
Figure A.2 Strain Relief Clamp
Figure A.4 LN-9F Control BOX Bottom View
Figure A.5 for DC-250, DC-400 and CV-400, CV-500 l
Connecting the Power Input Cable Assembly to Power Sources
Can kill
Figure A.6 Connection of LN-9 to DC-600 Power Sources
Figure A.7 Connection of LN-9 to DC-1000 Power Sources
Installation
Work Cable Connection
Machine Grounding
Direct Work Lead Connection
Table A.1 Work Cable Sizes
Figure A.9 GUN Cable Connections
Connecting the GUN Cable to the Wire Feeder
LN-9 Wire Feeder
Table of Contents Operation Section
Operation
Safety Instructions
DC Constant Voltage Power Sources
General Description
Recommended Processes and Equipment
Controls and Settings
Figure B.1 Wire Feeder Controls for LN-9N, NE, S, SE
LN-9F Control BOX Bottom View
Figure B.2 Wire Feeder Controls for LN-9F
Avoiding Grounding Lead Protector GLP Shutdown
Circuit Protection and Automatic Shutdown
Automatic Shutdown
Figure B.3 2 Roll Wire Feed Mechanism
Drive Roll Installation and Pressure Setting
Setting the Idler Roll Spring Pressure 2-ROLL Wire Drives
Setting the Idler Roll Pressure 4-ROLL Wire Drives
Operation
Figure B.4 Installing Drive Rolls on a 4-ROLL Feeder
Loading and Feeding READI-REELS or Spools
Wire Loading
Electrode Feeding and Brake Adjustment
When Using the Extension Assembly models LN-9NE and LN-9SE
Loading a 15 to 30 LB. Spool 12 Diameter
Figure B.6 Loading a 50 or 60 LB. Coil
Electrode Feeding
Adjust the Power Source
Pulse Power 500, DC650 PRO
SAM
Starting Characteristics
Adjust the LN-9 Controls
Voltage Control Response
Select Acceleration
Procedure AT END of Coil
Security of Weld Procedure Settings
Making a Weld
Table of Contents Accessories
Power Input Cable Assemblies K196, K595, K596
Optional Equipment and Accessories
Wire Reel Stands and Mountings
Auxiliary Equipment Contacts
Wire Reel Door KIT M-11514
Attaching the Wire Reel Stands
50-60 LB. Wire Reel Assembly for Customer Mounting K299
Spindle for READI-REELS and 2 I.D. Spools K162-H
Table C.1 LN-9 GUN and Cable Assemblies
GUN and Cable Assemblies
60% Duty
Process Model Electrode Rating
Burnback Delay KIT K202
Wire Feeder Accessories
Dual Procedure KIT K319
Pulse Power Filter Conversion KIT K442-1
Undercarriage K163
Swivel Platform K178-1
Continuous Flux Feed Tank K320
K320 Flux Tank Loading
Power Extended Wire Drive K392
Mechanized Travel Power Pack K161-CABLE Length
Magnetic Separator K58
Mechanized Hand Travel Unit K110
Kit Roll Solid Steel Electrode
Table C.2 Drive Roll and Guide Tube Kits
Cored Electrode
Aluminum Electrode
Table of Contents Maintenance
Safety Precautions
Routine Maintenance
Periodic Maintenance
Figure D.1 LN-9 Connectors
GUN and Cable Maintenance
Figure D.3 General Component Locations
Table of Contents Theory of Operation Section
Theory of Operation
Power Input Circuits
Figure E.3 Trigger and Shutdown Circuit
Trigger and Shutdown Circuit
Figure E.4 ARC VOLTAGE, Wire Speed Control and Metering
ARC VOLTAGE, Wire Speed Control and Metering
Printed Circuit Board Functions
LN-9 Wire Feeder
Table of Contents Troubleshooting & Repair Section
HOW to USE Troubleshooting Guide
Troubleshooting & Repair
PC Board can be damaged by static electricity
PC Board Troubleshooting Procedures
Troubleshooting Guide
Observe Safety Guidelines
Detailed in the beginning of this manual
Function Problems
Trigger
Troubleshooting & Repair
Troubleshooting Guide
Troubleshooting & Repair
Trigger Interlock Function Problems
Perform the T1 Transformer
Perform the T2 Transformer
Troubleshooting & Repair
Perform Out of Voltage Range
Feeding Problems
Welding Problems
Troubleshooting & Repair
Meter Function Problems
Bypass
Starting Problems
Troubleshooting & Repair
Symptoms Misadjustments Course of Action
Problems Possible Areas
T1 Transformer Test
Description
Materials Needed
T1 Transformer Test
Test Procedure
Figure F.2 Secondary Leads #601 and #602 AT Lead Splices
T2 Transformer Test
T2 Transformer Test
Figure F.3 Protection Circuit Troubleshooting Nameplate
Circuit Breaker
Lead Lead
Wire Drive Motor and Tach Feedback Test
Wire Drive Motor and Tach Feedback Test
Apply 115 VAC power
Figure F.7 Leads #525, #510, #555 on Control PC Board
Tach Feedback Test Procedure
Voltmeter Accuracy Test
Figure F.8 Voltmeter Connection Point
Voltmeter Accuracy Test
Return Return to Section TOC
Meter Circuit Accuracy Test
Figure F.9 Meter PC Board Locations and Cover
Meter Circuit Accuracy Test
Figure F.10 Meter PC Board Test Points
Test Meter PC Board Accuracy. For LN9-H
Test Meter PC Board Accuracy. All Models
Metric Model Metric Range SET M/MIN Reading Test Voltmeter
Test Meter PC Board Accuracy. Metric Models Only
Wire Speed Accuracy Test
Check for the proper drive roll revolutions per minute
Wire Speed Accuracy Test
OUT of Voltage Range Shut Down Test
Figure F.11 Voltage PC Board with Jumpers
OUT of Voltage Range Shut Down Test
Section TOC
General Power Supply Tests
Also perform the T1 Transformer Test
General Power Supply Tests
General Power Supply Checks
Digital Meter and Meter PC Board Removal Replacement
Replacement
Digital Meter and Meter PC Board Removal
Meter PC Board Removal
Replacement Procedure
Digital Meter Removal Procedure
Reed Switch CR2 Removal and Replacement
Replacement
Reed Switch CR2 Removal and Replacement
T1 Transformer Removal and Replacement
Figure F.16 Primary Lead #31 AT R1 Resistor
T1 Transformer Removal and Replacement
Lead
NUT and Screw Control PC Board 1CR Relay Phillips Screws
Terminal
Tach PC Board Removal and Replacement
Figure F.21 Tach Assembly Cover Screws
Tach PC Board Removal and Replacement
Phillips Screw Disc NUT Tach PC Board
Figure F.24 Tach Component Assembly
Reassembly
Drive Motor Removal and Replacement
Figure F.25 TOP Motor Plate Screws
Drive Motor Removal and Replacement
Nuts and Washers 4-ROLL Feeders
Mylar Insulator Glastic Mounting Board Bolts
Mounting Screws Insulators Gear BOX Assembly
Retest After Repair
Retest the LN-9 wire feeder
LN-9 Wire Feeder
Electrical Diagram Section
LN-9 Wire Feeder
LN-9
Electrical Diagrams
Operating Schematic
21145
Meter Board L6687 Schematic
20031
Trigger Board M13861 Schematic
19852
Tachometer Schematic