IM10092 RETURN TO MAIN MENU LN-25™ PIPE February, 2011 For use with machines having Code Number: 11779 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. And, most importantly, think before you act and be careful.
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 L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode 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 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™ PIPE (K2614-10) INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 40 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 GEARING K2614-10 FCAW WFS RANGE WIRE SIzES WFS RANGE WIRE SIzES 50 – 700 ipm (1.3 – 17.7m/min) .023 – 1/16" (0.6 – 1.6mm) 50 – 700 ipm (1.3 – 17.7m/min) .030 - 5/64 (0.8 - 2.0mm) PHYSICAL DIMENSIONS HEIGHT 14.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS The LN-25™ PIPE 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 LN-25™ PIPE work clip when the welding power source is on. • Do not attach the work clip to the wire feeder.
A-3 A-3 INSTALLATION SHIELDING GAS CONNECTION CAbLE CONNECTIONS WARNING There is one circular connector for the gun trigger on the front of the LN-25™ PIPE . Function 5-pin trigger connector for push-guns only. Pin Wiring A B C D E 5 volt supply Not used Trigger 83% WFS switch 5 volt supply 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-4 A-4 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-5 A-5 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-6 A-6 INSTALLATION POWER SOURCE TO LN-25™ PIPE CAbLE CONNECTION DIAGRAMS CV Power Sources with Stud Connectors and Remote/Local Switch (See Figure A.6) Work Air Vantage 500 Vantage 300, 400, 500 Commander 300 Ranger 225 Ranger 225GXT Ranger 3 Phase Ranger 10,000 Ranger 305G, 305D Ranger 250, 250 LPG Work clip Electrode LN-25™ PIPE Jumper FIGURE A.
A-7 A-7 INSTALLATION Work Work clip Electrode CV-300 CV-250 LN-25™ PIPE Jumper CV Power Source with Twist-Mate Connectors and Remote/Local Switch. (See Figure A.8) FIGURE A.8 CV-305 V350-Pro LN-25™ PIPE Electrode Work clip Work K# Description K2614-10 KP1695-XX KP1696-XX KP1697-XX See Magnum Literature LN-25™ PIPE 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™ PIPE as designed is a simple, robust feeder. Standard features include a calibrated wire feed speed dial, 2 step/trigger interlock 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 7 1 8 2 9 10 3 WIRE FEED SPEED KNOb Wire Feed Speed, CV Operation When Across the Arc models are operated with CV power sources, the wire feed speed will remain a constant value, independent of arc voltage changes, as along as the arc voltage does not drop below the values per the following table.
b-4 b-4 OPERATION POWER-UP SEQUENCE SET-UP MENU All of the LED’s will briefly illuminate during power-up. If the gun trigger is activated during power up, the feeder will not operate until the gun trigger is released. Preparation for WFS Calibration: WIRE FEED SPEED/AMPERAGE DISPLAY • Set the display to the desired wire feed speed (example: 400 inches per minute) Idle The left display shows the preset wire feed speed. The right display shows OCV. The wire feed speed LED is lit.
b-5 OPERATION WIRE FEED SPEED UNITS WFS CALIbRATION WITH DIGITAL METERS O O WFS LN-25™ PIPE, CCC OO A US V To change the wire feed speed units: Rotate the WFS knob to the left to use “inches/minute” for the wire feed speed units. US V A OO LN-25™ PIPE, CCC O O WFS O O WFS LN-25™ PIPE, CCC OO A EU r o V To calibrate the wire feed speed, before entering the set-up menu.
b-6 OPERATION 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-7 b-7 OPERATION INTERNAL CONTROLS FIGURE b.
b-8 OPERATION INTERNAL CONTROLS DESCRIPTION (See Figure B.2) 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. Trigger Interlock operation allows welding to continue when the trigger is released for comfort on long welds. Place the toggle switch in the DOWN position for 2 Step operation or in the UP position for Trigger Interlock operation.
b-9 b-9 OPERATION REAR CONTROLS: 3 2 1 ITEM Electrode Lead Shielding Gas Inlet Gas Purge Pushbutton DESCRIPTION 3 2 1 1 2 3 ITEM 1 2 3 DESCRIPTION Gas Purge Pushbutton Shielding Gas Inlet Electrode Lead GAS PURGE PUSHbUTTON 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.
C-1 ACCESSORIES FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS (See Parts Pages) 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. K1840-xx Weld Power Cable, Twist-Mate to Lug. Includes: Twist-Mate to Lug, 1/0 cable of length "xx". Includes: Lug to Lug, 3/0 Cable of length "xx" for lengths up to 60' (18.3m).
C-2 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-3 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. K435 Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2 in (51 mm) spindles. Includes: Spindle Adapter made from 2 coil retainers.
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 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 RECOMMENDED COURSE OF ACTION ERROR CODES 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. Verify a high quality electrode is being used. 5.
E-3 E-3 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-4 E-4 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.
F-2 DIMENSION PRINT LN-25™ PIPE F-2
• 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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