IM10031-A RETURN TO MAIN MENU LN-25 TM PRO November, 2010 For use with machines having Code Number: 11620, 11621, 11716, 11717 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety 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 PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY 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. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING and CUTTING 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY 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 suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.
vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
viii TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ..............................................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – LN-25™ PRO (K2613-1, K2613-2) INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 15-110 VDC 4A RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 60% rating 450 100% rating 325 GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING WFS RANGE WIRE SIZES WFS RANGE WIRE SIZES Extra torque K2613-2 30 – 400 ipm (0.8 – 10.1m/min) .023 – 1/16" (0.6 – 1.6mm) 30 – 400 ipm (0.8 – 10.1m/min) .030 - 3/32” (10.3 – 2.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS The handle of the LN-25™ PRO is intended for moving the wire feeder about the work place only. WARNING ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the disconnect switch or fuse box before attempting to connect or disconnect input power lines, output cables or control cables. • Only qualified personnel should perform this installation. • Do not touch metal portions of the work clip when the welding power source is on.
A-3 A-3 INSTALLATION ANALOG CONTROL CABLE K1797-XX The control cable connecting the wire feeder to the power source is specially made for the welding environment. The wire feeder power requires overcurrent protection. Connect the wire feeder only to power sources where the overcurrent protection is no more than 15 amps. Do not use more than 100 ft. (30.5 m) of control cable between the wire feeder and power source.
A-4 A-4 INSTALLATION SHIELDING GAS CONNECTION CABLE CONNECTIONS WARNING There is one circular connector for the gun trigger on the front of the LN-25™ PRO. Function 5-pin trigger connector for push-guns only. Pin Wiring A B C D E Trigger Not used Common Not used Not used C D B E A CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached.
A-5 A-5 INSTALLATION WIRE DRIVE CONFIGURATION (See Figure A.2) CHANGING BUSHING THE GUN RECEIVER WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.
A-6 A-6 INSTALLATION 1. Squeeze the release bar on the retaining collar and remove it from the spindle. PRESSURE ARM ADJUSTMENT WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.
A-7 A-7 INSTALLATION POWER SOURCE TO LN-25™ PRO CABLE CONNECTION DIAGRAMS ACROSS THE ARC SET-UPS CC Power Sources with Output Terminals Always Hot (See Figure A.5) CC Power Source Classics Big Red’s Eagle 10,000 Plus Pipeliner 200D Without Wire Feed module SAE’s Without CV Adapter FIGURE A.5 SAE 400 with CV adapter Engine Driven welder with Wire Feed Module LN-25™ PRO Electrode Work clip Work If the power source has a Remote/Local switch, place the switch in the Local position.
A-8 A-8 INSTALLATION CV Power Sources with Stud Connectors and no Remote/Local Switch. (See Figure A.7) Place CV/CC switch in the feeder in the "CV" position. FIGURE A.
A-9 A-9 INSTALLATION CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) FIGURE A.9 Jumper CV-250 CV-300 CV-305 LN-25™ PRO Electrode Work clip Work Place CV/CC switch in the feeder in the "CV" position.
B-1 B-1 OPERATION SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER WARNING • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.. • Do not touch electrically live part or electrode with skin or wet clothing.
B-2 B-2 OPERATION General Functional Description The LN-25™ PRO as designed is a simple, robust feeder. Standard features include a calibrated wire feed speed dial, 2 step/trigger interlock switch, CV-CC switch, Gas Purge and Cold Feed. DEFINITION OF WELDING TERMS WFS • Wire Feed Speed CC • Constant Current RECOMMENDED PROCESSES • GMAW • FCAW CV • Constant Voltage PROCESS LIMITATIONS GMAW • Gas Metal Arc welding • GMAW-P procedures must be qualified by the customer.
B-3 B-3 OPERATION (See Customer Assistance Policy in the front of this Instruction Manual) CASE FRONT CONTROLS (See Figure B.1) FIGURE B.1 1 5 6 2 3 4 ITEM 1 2 3 4 5 6 DESCRIPTION Analog Voltmeter Wire Feed Speed Knob 5-pin gun trigger connector Work sense lead Thermal LED, Motor Overload Polarity LED 1. ANALOG VOLTMETER The analog voltmeter shows the voltage between electrode and work. On across the arc models, the voltmeter shows open circuit voltage when the wire feeder is not welding.
B-4 B-4 OPERATION 2. WIRE FEED SPEED KNOB The large, calibrated wire feed speed knob makes for easy and accurate adjustment of the wire feed speed. The knob rotates 3/4 turn. Turn the knob clockwise to increase the wire feed speed, and counter clockwise to reduce the wire feed speed. Models with analog voltmeters have a calibrated scale printed around the wire feed speed knob using "in/min" units. A separate decal with "m/min" units is included with these models wire feeder.
B-5 OPERATION 3. 5-PIN GUN TRIGGER CONNECTOR 4. WORK SENSE LEAD 5. THERMAL LED, MOTOR OVERLOAD The thermal light illuminates when the wire drive motor draws too much current. If the thermal light illuminates, the wire drive will automatically shutdown for up to 30 seconds to allow the motor to cool. To start welding again, release the gun trigger, inspect the gun cable, liner (and conduit). Clean and make repairs as necessary. Start welding again when the problem has been safely resolved.
B-6 B-6 OPERATION INTERNAL CONTROLS FIGURE B.
B-7 B-7 OPERATION (See Figure B.2) INTERNAL CONTROLS DESCRIPTION (See Figure B.2) The CV/CC switch sets the wire feed speed control method for the wire feeder. CV CC 2 Step - Trigger Interlock Switch In the CV position, the wire feed speed remains constant during welding. A steady arc voltage is regulated by the power source by adjusting the arc current. The 2 Step - Trigger Interlock switch changes the function of the gun trigger.
B-8 B-8 OPERATION CONSTANT CURRENT WIRE WELDING (See Figure B.3) Most semiautomatic welding processes perform better using constant voltage power sources. Welding codes usually do not address the power source selection or specifically, whether the welding process is to be operated in the constant voltage or constant current mode. Instead, codes typically specify limitations on the current, voltage, heat input and preheat temperature based on the material to be welded.
B-9 B-9 OPERATION REAR CONTROLS: 6 5 4 3 2 1 ITEM connections Optional Water cooled gun Electrode Lead Shielding Gas Inlet Flow Meter Valve Flow Meter Ball Gas Purge Pushbutton DESCRIPTION 6 5 4 3 2 1 1 2 3 4 5 6 ITEM 1 2 3 4 5 6 DESCRIPTION Gas Purge Pushbutton Flow Meter Ball Flow Meter Valve Shielding Gas Inlet Electrode Lead Optional Water cooled gun connections LN-25™ PRO
B-10 OPERATION GAS PURGE PUSHBUTTON POWER-UP SEQUENCE The gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on. The Gas Purge switch is useful for setting the proper flow rate of shielding gas. Flow meters should always be adjusted while the shielding gas is flowing. On feeders with analog voltmeters, the thermal LED will briefly light during power-up.
C-1 ACCESSORIES FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS WIRE TYPE Steel Wires: Cored Wires: Aluminum Wires: ELECTRODE SIZE .023-.030 (0.6-0.8mm) .035 (0.9mm) .045 (1.2mm) .052 (1.4mm) 1/16 (1.6mm) .035,.045 (0.9, 1.2mm) .040 (1.0mm) .030-.035" (0.8-0.9mm) .040-.045" (1.0-1.2mm) .052" (1.4mm) 1/16" (1.6mm) .068-.072" (1.7-1.8mm) 5/64" (2.0mm) 3/32” (2.4mm) .035" (0.9 mm) .040" (1.0mm) 3/64" (1.2mm) 1/16" (1.
C-2 ACCESSORIES K1796-xx AWG 1/0 Co-Axial Power Cable Includes: 1/0 Coaxial weld cable of length "xx". Ends of the weld cable have lug connections. Use for Pulse welding. K2593-xx AWG #1 Coaxial Power Cable Includes: AWG #1 Coaxial weld cable of length "xx". Ends of the weld cable have lug connections. Use for Pulse or STT™ welding. K1803-1 Work and Feeder Cables Package Includes: Twist-Mate to Lug 2/0 cable 14' (1.2m) long with Ground Clamp, and TwistMate to Lug 2/0 Cable 9' (2.7m) long.
C-3 ACCESSORIES K910-1 Ground Clamp Includes: One 300 Amp Ground Clamp. K910-2 Ground Clamp Includes: One 500 Amp Ground Clamp. K1500-1 Gun Receiver Bushing (for guns with K466-1 Lincoln gun connectors; Innershield and Subarc guns) Includes: Gun receiver bushing, set screw and hex key wrench. K1500-2 Gun Receiver Bushing (for guns with K466-2, K466-10 Lincoln gun Includes: Gun receiver bushconnectors; Magnum 200/300/400 ing with hose nipple, set screw and hex key wrench.
C-4 ACCESSORIES K1500-4 Gun Receiver Bushing (for gun Includes: Gun receiver bushwith K466-3 Lincoln gun connec- ing with hose nipple, set screw tors; compatible with Miller® guns.) and hex key wrench. K1500-5 Gun Receiver Bushing (compatible with Oxo® guns.) Includes: Gun receiver bushing with hose nipple, 4 guide tubes, set screw and hex key wrench. K489-7 Gun Receiver Bushing (for Lincoln Fast-Mate guns.) Includes: Gun receiver bushing with trigger connector.
C-5 C-5 ACCESSORIES INSTALLATION OF THE K590-6 WATER COOLING KIT 4. Use a 5/16" nut driver to remove the screws holding the water cooling cover on the case front of the inner module and on the rear of the case. WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the disconnect switch before working on this equipment. • Do not touch electrically hot parts. • Only qualified personnel should install, use or service this equipment.
D-1 MAINTENANCE SAFETY PRECAUTIONS D-1 5. Energize the output circuit of the power source. Adjust the power source output to 20±1 VDC as measured on the reference meter. WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts.
D-2 D-2 MAINTENANCE The LN-25™ PRO flow meter cannot be calibrated. If the flow meter reads incorrectly, check for leaks or kinks in the gas hose. Replace the flow meter if necessary. Wire Feed Speed Validation (See Figure D.1) Calibration of the LN-25™ PRO may be required when the p.c. board, wire feed speed potentiometer or motor is replaced or serviced. Calibration matches the scale on the name plate to the actual wire feed speed. To change the wire feed speed calibration: (See Figure D.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE Output Problems The feeder does power up - no dis- 1. The work sense lead is disconplay, no cold feed. nected or is a poor electrical connection. (Across the arc models) 2. The power source is OFF. 3. The circuit breaker for the wire feeder on power source have tripped. (control cable models) 4. The control cable may be loose or damaged.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Output Problems 7. Incorrect tension arm pressure on 7. Adjust the tension arm per the the drive rolls. Instruction Manual. Most electrodes feed well at a tension arm setting of "3". 8. The spindle brake is too tight. 8. Verify the spool of wire moves with minimal effort. 9. Worn drive roll. 9. Replace the drive rolls if worn or filled with dirt.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
17.19 16” CIRCLE 12” x 18” ELLIPSE 8.65 14.81 23.17 71.32 18. 41 56.8 EL C R I C ” 61 E S P I L L E ” 81 x ” 21 9 1 .
G Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO G Keep flammable materials away. G Wear eye, ear and body protection. G Mantenga el material combustible G Protéjase los ojos, los oídos y el electrode with skin or wet clothing. G Insulate yourself from work and ground. G No toque las partes o los electrodos bajo carga con la piel o ropa mojada. G Aislese del trabajo y de la tierra.
G Keep your head out of fumes. G Use ventilation or exhaust to G Turn power off before servicing. G Do not operate with panel open or guards off. remove fumes from breathing zone. G Los humos fuera de la zona de res- piración. G Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. G Gardez la tête à l’écart des fumées. G Utilisez un ventilateur ou un aspira- G Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
• 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.
