IM10080-A RED-D-ARC August 2013 LN25™ PRO EXTREME DUAL POWER For use with machines having Code Numbers: 11750, 12164 RETURN TO MAIN MENU OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.
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.
SAFETY v 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.
SAFETY vi 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 one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products.
viii TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ..............................................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – RED-D-ARC LN25™ PRO EXTREME DUAL POWER (K2614-7) INPUT VOLTAGE and CURRENT INPUT AMPERES INPUT VOLTAGE ± 10% Across the Arc configuration Control Cable configuration 15-110 VDC 24-42 VAC 4A RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 60% rating 450 GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW GEARING Standard Speed FCAW WFS RANGE WIRE SIZES WFS RANGE WIRE SIZES 50 – 700 ipm (1.3 – 17.7m/min) .023 – 1/16" (0.6 – 1.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS The RED-D-ARC LN25™ PRO EXTREME DUAL POWER is rated IP23 and is suitable for outdoor use. 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 TRIGGER CONNECTIONS SHIELDING GAS CONNECTION There is one circular connector for the gun trigger on the front of the RED-D-ARC LN25™ PRO EXTREME DUAL POWER. Note – if the gun trigger is already depressed when the feeder is powered up, the feeder will not activate. Release and then press the gun trigger to begin welding. The 83% wire feed speed reduces the wire feed speed to 83% of the original set value when activated.
A-5 A-5 INSTALLATION WIRE DRIVE CONFIGURATIONS 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. • Do not operate with covers, panels or guards removed or open.
A-6 A-6 INSTALLATION GUN BUSHING, THUMB SCREW AND SET SCREW (See Figure A.2a for Code 12164) The gun bushing is not interchangeable with other bushings. It is designed to be mechanically mounted in the feed plate and then bolted directly to the feederʼs internal electrical welding buss bar. It accepts Magnum Pro guns (Tweco #2 to #4). This bushing should be removed only for service replacement. It is secured to the feed plate with an S11604-10 set screw torqued between 35 to 45 in.-lbs.
A-7 A-7 INSTALLATION PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING • 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. • Do not operate with covers, panels or guards removed or open.
A-8 A-8 INSTALLATION 1. Squeeze the release bar on the retaining collar and remove it from the spindle. 2. Place the spindle adapter on the spindle, aligning the spindle brake pin with the hole in the adapter. 3. Place the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool. An indicator mark on the end of the spindle shows the orientation of the brake tab. Be certain the wire feeds off of the spool in the proper direction. 4.
A-9 A-9 INSTALLATION POWER SOURCE TO RED-D-ARC LN25™ PRO DUAL POWERR CABLE CONNECTION DIAGRAMS ACROSS THE ARC SET-UPS CC Power Sources with Output Terminals Always Hot (See Figure A.
A-10 A-10 INSTALLATION CV Power Sources with Stud Connectors and no Remote/Local Switch(See Figure A.7) RANGER 250, 250 LPG RANGER 305G, 305D RANGER 10,000 RANGER 3 PHASE RANGER225, 225 GXT COMMANDER 300 VANTAGE 300, 400, 500 AIR VANTAGE 500 FIGURE A.7 Electrode RED-D-ARC LN25™ PRO EXTREME DUAL POWER Work clip Work Place CV/CC switch in the feeder in the "CV" position.
A-11 A-11 INSTALLATION CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) FIGURE A.9 Jump er CV-250 CV-300 RED-D-ARC LN25™ PRO EXTREME DUAL POWER Electrode Work Wor k clip K# K2614-7 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 DEFINITION OF WELDING TERMS General Functional Description The RED-D-ARC LN25™ PRO EXTREME DUAL POWER have adjustable WFS range for improving the knob sensitivity. The low range is great for critical welds with Innershield wires, and the upper range is suitable for general purpose welding. Selection of the WFS range is through the set-up menu.
B-3 B-3 OPERATION The serviceability of a product or structure utilizing the RED-D-ARC LN25™ PRO EXTREME DUAL POWER wire feeder is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the RED-D-ARC LN25™ PRO EXTREME DUAL POWER wirefeeder. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.
B-4 B-4 OPERATION CONSTANT CURRENT WIRE WELDING (See Figure B.2) 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-5 B-5 OPERATION CASE FRONT CONTROLS POWER-UP SEQUENCE Figure B.3 All of the LEDʼs will briefly illuminate during power-up. 1. WIRE FEED DISPLAY SPEED/AMPERAGE Idle The left display shows the preset wire feed speed. The right display shows OCV. The wire feed speed LED is lit. If the wire feeder is connected for electrode negative welding, then the voltage display shows a minus sign.
B-6 B-6 OPERATION 2. WIRE FEED SPEED KNOB 5. SET-UP MENU Use the Wire Feed Speed Knob to adjust the rate of wire feed speed. Preparation for WFS Calibration: Because the wire feeder is powered by the arc voltage, the full range of wire feed speed may not be available at low voltages. While welding, the display will show actual wire feed speed. If the actual WFS is less than set WFS, then the arc voltage may be too low for procedure.
B-7 OPERATION B-7 RUN-IN WFS CALIBRATION “Run-in” refers to the wire feed speed during the time from when the trigger is pulled to when an arc is struck. Measurements for adjusting the WFS calibration must be made before entering the set-up menu. When first entering WFS Calibration, the calibration factor displayed is based upon the position of the knob and does not reflect the actual calibration factor stored in memory. When Run-in is “ON”, the wire feed speed is reduced until an arc is struck.
B-8 OPERATION B-8 LEFT DISPLAY SELECTION AMPERAGE CALIBRATION The left display can show either amperage or actual WFS during welding. Note that actual WFS is not the same as preset WFS. For example, the preset WFS may be set to 400 ipm, but the arc voltage is only 15V. The actual WFS will be approximately 280 ipm because there is not enough arc voltage to run at 400 ipm. Measurements for adjusting the Amperage calibration must be made before entering the set-up menu.
B-9 B-9 OPERATION INTERNAL CONTROLS FIGURE B.
B-10 OPERATION INTERNAL CONTROLS DESCRIPTION (See Figure B.4) B-10 3. PRESSURE ARM (See Installation Section) 4. OPTIONAL TIMER KIT The optional Timer Kit provides control of preflow time, burnback, and postflow time. 1. 2 STEP - TRIGGER INTERLOCK SWITCH The 2 Step - Trigger Interlock switch changes the function of the gun trigger. 2 Step trigger operation turns welding on and off in direct response to the trigger.
B-11 B-11 OPERATION REAR CONTROLS: FIGURE B.
B-12 OPERATION 1. GAS PURGE PUSHBUTTON (See Figure B.5) 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. 2. FLOW METER (See Figure B.5) The flowmeter shows the flow rate of shielding gas and has a valve to adjust the flow. The flow meter is scaled for CO2, Ar, and Ar/CO2 blends.
C-1 ACCESSORIES FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS USED • See Parts Pages K2330-2 Timer Kit K2596-2 Plastic Case 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.
C-2 ACCESSORIES K1797-xx K2335-1 K484 K1520-1 K1798 Control Cable Adapter for Competitive Power Sources Jumper Plug Kit 42 Volt Transformer Kit Includes: 14 pin to 14 pin wire feeder to power source control cable. Includes: Adapter control cable for connecting a Lincoln 42 VAC wire feeder to a 24 VAC Miller power source. Requires the digital meter/remote voltage control kit. Includes: 14 pin circular connector with jumper for leads 24.
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 (For Code 11750 only) 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.
C-4 ACCESSORIES K1500-4 (For Code 11750 only) 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 (For Code 11750 only) 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.
D-1 MAINTENANCE SAFETY PRECAUTIONS 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. • Do not operate with covers, panels or guards removed or open.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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 RECOMMENDED COURSE OF ACTION Fault Code Digital Display Models Error Codes Description Possible Adjustments Err 81 Motor overload, long term. 1. The wire drive motor has over- 1. Check that the electrode slides easily through the gun and cable. heated. 2. Remove tight bends from the gun and cable. 3. Check that the spindle brake is not too tight. 4.
ENHANCED DIAGRAM E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE Output Problems The feeder does power up - no display, no 1. The work sense lead is disconnected or is cold feed. 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-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Output Problems Wire feed speed consistently oper- 1. The jumper lead for normal 1. Properly connect the normal ates at the wrong value. The speed speed/extra torque is connected speed/extra torque jumper. changes when the wire feed speed improperly. 2. Install the proper pinion gear in knob is adjusted. 2.
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.
F-2 F-2 17.19 16” CIRCLE 12” x 18” ELLIPSE 8.65 14.81 23.
NOTES RED-D-ARC LN25™ PRO EXTREME DUAL POWER
P-670 P-670 PARTS LIST FOR Red-D-Arc LN25™ PRO Extreme Dual Power This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electricʼs official Parts Book (BK-34) for the latest pages.
P-670-A P-670-A ILLUSTRATION OF SUB-ASSEMBLIES 5 2 3 1 4 RED-D-ARC LN25™ PRO EXTREME DUAL POWER Oct-13
P-670-A.1 P-670-A.1 Red-D-Arc LN25™ PRO Extreme Dual Power For Codes: 11750 & 12164 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. PAGE NO. CODE NO. 1 2 3 4 5 Control Box Assembly Spindle & Mast Assembly Wire Drive Assembly Case Assembly SUB ASSEMBLY PAGE NAME Miscellaneous Items Sub Assembly Item No.
MISCELLANEOUS ITEMS P-670-B.2 P-670-B.2 (THESE ITEMS ARE NOT ILLUSTRATED) # Indicates a change this printing. DESCRIPTION Gun Adapter Bushing (Lincoln Adapted Guns) (Code 11750 Only) Use only the parts marked “x” in the column under the heading number called for in the model index page. PART NO. QTY.
NOTES RED-D-ARC LN25™ PRO EXTREME DUAL POWER
P-670-C P-670-C Case Front Assembly 3B 3A 4 1 2 7A 5 6 4A 8 11A 11B 12 21 20A RED-D-ARC LN25™ PRO EXTREME DUAL POWER Oct-13
P-670-C.1 P-670-C.1 # Indicates a change this printing. ITEM DESCRIPTION 1 2 3A 3B 4 4A 4B 5 6 7A 7B 8 9 11A 11B 12 15 20A 20B 21 Case Front Assembly (G6320-4), Includes: Case Front Nameplate Preset P.C.
P-670-D P-670-D Control Box Assembly 7A 7C 6 14A 16A 2 20A 23 14A 21A 1 17A 9A 13A 4B 13B 8A 4A 13C 3A 22C 9B 3B 12K 25A 11B 11C 11D 26 10A 12F 25B 12G 12A 12B 11E 22D 22B 22A RED-D-ARC LN25™ PRO EXTREME DUAL POWER Oct-13
P-670-D.1 P-670-D.1 # Indicates a change this printing. ITEM DESCRIPTION 1 2 3A 3B 4A 4B 5 6 7A 7B 7C 7D 8A 8B 9A 9B 9C 9D 10A 10B 11A 11B 11C 11D 12 12A 12B 12C 12D 12E 12F 12G 12H 12J 12K 13 13A 13B 13C 14 14A 16A 16B 16C 17A 17B 18 19A 19B 19C Control Box Assembly (G6321-3), Includes: Control Box Control Box Decal Control P.C. Board Assembly #10-24 HLN Motor Filter P.C.
P-670-D.2 P-670-D.2 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9 20 Cable Connector Assembly, Includes: 20A Cable Clamp 21A Flex Tube 21B Hose Clamp (Not Shown) 22A Current Transducer 22B Insulating Tube 22C #10-24 x 1.
NOTES RED-D-ARC LN25™ PRO EXTREME DUAL POWER
P-670-E P-670-E Spindle & Mast Assembly 2 1 8 7 3B 3A 8 9 10 11 5 RED-D-ARC LN25™ PRO EXTREME DUAL POWER 12 Oct-13
P-670-E.1 P-670-E.1 # Indicates a change this printing. ITEM DESCRIPTION 1 2 3A 3B 5 7 8 9 10 11 12 13 Spindle & Mast Assembly (G5572-2), Includes: Spindle Mast Spindle Shaft Thread Forming Screw External Tooth Lock Washer Bushing Spindle Friction Washer Keyed Washer Compression Spring Thumb Screw Retaining Collar Assembly Busing (Not Shown) Use only the parts marked “x” in the column under the heading number called for in the model index page. PART NO. QTY.
P-670-F P-670-F Wire Drive Assembly 3A 3B 3C 4B 1 28 25 15A 15B 26 2H 13 4E 4F 2F 10 14 8 8A 9 27 18 7A 7C 2L 7B 2B 19C 19B 19A 30 2C 2D 2E 31 RED-D-ARC LN25™ PRO EXTREME DUAL POWER 6A 6B 6C 6D Oct-13
P-670-F.1 P-670-F.1 # Indicates a change this printing.
P-670-F.2 P-670-F.2 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
NOTES RED-D-ARC LN25™ PRO EXTREME DUAL POWER
P-670-G P-670-G Case Assembly 20A 6 1A 5 8 13 4 13 20 12 1B 9 11 7 RED-D-ARC LN25™ PRO EXTREME DUAL POWER Oct-13
P-670-G.1 P-670-G.1 # Indicates a change this printing.
NOTES RED-D-ARC LN25™ PRO EXTREME DUAL POWER
NOTES RED-D-ARC LN25™ PRO EXTREME DUAL POWER
• Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO • Keep flammable materials away. • Wear eye, ear and body protection. • Mantenga el material combustible • Protéjase los ojos, los oídos y el electrode with skin or wet clothing. • Insulate yourself from work and ground. • No toque las partes o los electrodos bajo carga con la piel o ropa mojada. • Aislese del trabajo y de la tierra.
• Keep your head out of fumes. • Use ventilation or exhaust to • Turn power off before servicing. • Do not operate with panel open or guards off. remove fumes from breathing zone. • Los humos fuera de la zona de res- piración. • Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. • Gardez la tête à l’écart des fumées. • Utilisez un ventilateur ou un aspira- • Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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