IM677-A RED-D-ARC LN-25 PORTABLE CV/CC SEMIAUTOMATIC WIRE FEEDER February, 2005 For use with machines having Code Numbers: 10731 11146 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 ARC RAYS can burn. 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-freegloves 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 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 iv PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. 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: 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse.
v v Thank You for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
TABLE OF CONTENTS SAFETY ...............................................................................................................................................i-iv INSTALLATION .......................................................................................................................SECTION A Technical Specifications.....................................................................................................................A-1 Safety Precautions .................................
INSTALLATION A-1 A-1 TECHNICAL SPECIFICATIONS – LN-25 OPERATING ARC VOLTAGE VOLTAGE Constant Voltage (CV) or Constant Current (CC) 15-40 VDC (110VDC Maximum OCV) RATED C CURRENT RATED URRENT Rated current without contactor 500 Amps 60% Duty Cycle Rated current with contactor 300 Amps 60% Duty Cycle WIRE SPEED WIRE F EED RANGE S PEED 50 – 700 Inches Per Minute (IPM) RECOMMENDED WIRE SIZES WIRE ELECTRODE D IAMETERS ⁄16” .045” to ⁄64” .035” to 1⁄16” .
INSTALLATION A-2 SAFETY PRECAUTIONS WARNING WARNING ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Do not touch metal portions of the LN-25 lead clip when welding power source is on. • Unless an optional output control or contactor is used with the LN-25, the electrode circuit (including welding wire, wire drive and welding gun) is electrically hot when the welding power source is on. The gun trigger controls wire feed only.
A-3 INSTALLATION A-3 c. Place “Set to Same Polarity As Electrode Cable Connection” switch at appropriate position. c. Set ELECTRODE POLARITY switch to constant voltage polarity required by electrode. d. Place power source toggle switch in “Output Control at DC(CV) -400” position, unless a remote control is connected to 75, 76 and 77 on the power source terminal strip. d.
INSTALLATION A-4 Install the barbed fitting and union nut to the 5⁄8-18 female inert gas fitting on the front panel of the LN25 case. Connect the 3⁄16” I.D. gas hose from the gun cable to the barbed fitting. When the gun is to be removed, this fitting can be easily detached by loosening the union nut. WELD CABLE CONNECTION A-4 WIRE FEED DRIVE ROLL AND GUIDE TUBE KITS WARNING Turn off welding power source before installing or changing drive roll and/or guide tubes.
OPERATION B-1 SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live part or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASSES can be dangerous. • Keep your head out of fumes. • Use enough ventilation or exhaust at the arc, or both, to remove fumes from your breathing zone and general area. WELDING SPARKS can cause fire or explosion.
OPERATION B-2 LN-25 INSTRUMENTS AND CONTROLS Refer to Figure B.1 for control locations. REMOTE ARC VOLTAGE CONTROL (OPTIONAL) B-2 NOTE: 1. The Voltmeter will read zero if the LN-25 work clip lead is not connected to work, even if the electrode is electrically “hot” to work. 2. The Voltmeter will read below zero if the LN-25 polarity switch is not set to the same polarity as the electrode. WIRE SPEED DIAL RANGE SWITCH WIRE SPEED DIAL 3.
OPERATION B-3 WORK CLIP LEAD B-3 AWG #14 #12 #10 #6 WARNING ELECTRIC SHOCK can kill. • Do not touch metal portions of the LN-25 lead clip when welding power source is on. Maximum Length 25 Ft(7.6m) 50 Ft(15.2m) 100 Ft(30.5m) 200 Ft(61m) GAS FITTING (OPTIONAL) Provides gas output connection to the welding gun for the GMAW process. Refer to K430-2 Gas Solenoid Kit in the Accessories Section.
OPERATION B-4 SEQUENCE OF OPERATION LOADING ELECTRODE WARNING ELECTRIC SHOCK can kill. • Unless an optional output control or internal contactor is used with the LN-25, the electrode circuit is electrically “Hot” when the power source is on. • Turn off the Welding power source while mounting electrode coils. MOUNTING 22 TO 30 LB READI-REEL® COILS The LN-25 will require an optional K363-P ReadiReel® Adapter which is required to load Lincoln 22 to 30 lb Readi-Reel coils. a.
OPERATION B-5 B-5 FIGURE B.2 READI-REEL INSTALLATION MOLDED ADAPTER 2" O.D. SPINDLE RETAINING SPRING BRAKE HOLDING PIN (MUST ENGAGE HOLE IN ADAPTER RIB) GROOVES READI-REEL INSIDE CAGE WIRES LOADING WIRE DRIVE a. Turn the reel or spool until the free end of the electrode is accessible. b. While tightly holding the electrode, cut off the bent end and straighten the first six inches. Cut off the first inch.
OPERATION B-6 B-6 3. If the only result is drive roll slippage, shut off the power source, then loosen the gun cable clamping screw in the gearbox conductor block and pull the gun cable forward about six inches. There should be a slight waviness in the exposed wire. If there is no waviness, the pressure is too low. Increase the pressure setting 1⁄4 turn, lock the gun cable in place and repeat the above steps.
OPERATION B-7 B-7 MAKING A WELD Arc Volts Used Desired In/Min SETUP 16 18 50 60 70 80 90 109 131 153 175 197 100 110 120 130 140 30 32 34 97 117 136 156 175 88 80 73 67 63 58 105 95 88 81 75 70 123 111 102 94 88 82 140 127 117 108 100 93 158 143 131 121 113 105 55 66 77 88 98 51 62 72 82 93 219 241 263 284 306 194 214 233 253 272 175 193 210 228 245 159 175 191 207 223 146 160 175 190 204 135 148 162 175 188 125 138 150 163 175 117 128 140 152 163 109 120 131 142 153 103 113 124 134
OPERATION B-8 g. Be sure the proper contact tip for the wire size being used is in the gun, and the gun is safe from work contact. (Use the LN-25 insulated gun holder.) h. Turn on the welding power source, as well as the shielding gas supply (if used). WARNING • Unless an optional output control or internal contactor is used, the electrode is electrically “hot” when the power source is on. The gun trigger controls wire feed only. WARNING CYLINDER may explode if damaged.
OPERATION B-9 CAUTION Do not use LN-25 models below Code 9200 with any TIG or Square Wave welding power sources. Do not use LN-25 models equipped with internal contactors with non-Lincoln TIG or Square Wave welding power sources. Damage to the LN-25 circuit can occur as a result of the high output inductance typically associated with these power sources. TIG high frequency power should never be applied to the LN-25.
ACCESSORIES C-1 LN-25 MODELS-K449-2 WARNING KIT NO. K430-2: Solenoid Kit CYLINDER may explode if damaged. OPTIONAL ACCESSORIES WARNING ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn Welding power source off before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off at the fuse box before working in the terminal strip. • Only qualified personnel should install, use or service this equipment.
ACCESSORIES C-2 C-2 The following Figures C.1 and C.2 should serve as a guide to determine if a particular gun or switch can be connected to the LN-25. GUN CABLE CONNECTOR REQUIREMENTS TO PERMIT PROPER CONNECTION TO LINCOLN LN-25 WIRE FEEDER. LN-25 Cable Connector for .023 through .052 Wire (For all other dimensions, see above) FIGURE C.1 NOTE: Connector part with .749/.747 diameter should be made from brass if it is to be part of the welding current carrying circuit. Wire Size “A Dia.
MAINTENANCE D-1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off at the fuse box before working in the terminal strip. • Only qualified personnel should install, use or service this equipment. ROUTINE MAINTENANCE DRIVE ROLLS AND GUIDE TUBES After feeding every coil of wire, inspect the drive roll section.
D-2 MAINTENANCE The module is properly mounted to the gearbox as shipped from the factory. If the device is ever removed or replaced, proper mounting technique is as follows: 1. Be sure all power to the LN-25 is shut off at the power source. 2. Check that the module mounting plate is screwed securely to the side of the gearbox. 3. Gently screw the module into the mounting plate until it just touches and stops against the rotating part inside the gearbox. 4.
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 PROBLEMS (SYMPTOMS) TROUBLESHOOTING POSSIBLE CAUSE E-2 RECOMMENDED COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is pulled 1. Power source must be on and open circuit voltage (OCV) present at weld terminals. 2. LN-25 work clip may not be connected. 3. LN-25 polarity switch must match electrode polarity. 4. Jumper plug on control or option board may be loose or missing. 5. The power source O.C.V. must be above 15 VDC. But not more than 110 VDC.
E-3 PROBLEMS (SYMPTOMS) TROUBLESHOOTING POSSIBLE CAUSE E-3 RECOMMENDED COURSE OF ACTION FEEDING PROBLEMS Rough wire feeding or wire not feeding but drive rolls turning. 1. Gun cable kinked and/or twisted. 2. Wire jammed in gun and cable. 3. Incorrect size or installation of drive roll and guide tubes. 4. Drive roll loose. 5. Gun cable dirty. If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Authorized Field Service Facility. 6.
E-4 PROBLEMS (SYMPTOMS) TROUBLESHOOTING POSSIBLE CAUSE E-4 RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Solenoid does not close when trigger is pulled or purge button is pressed. Wire feeds properly. 1. Make certain that plugs J2 and J3 are connected to the control board securely. WELD PROBLEMS Variable or “hunting” arc. 1. Worn and/or melted contact tip -Replace. 2. Worn work cable or poor work connection. 3. Loose electrode connections. -Check for loose or faulty connections.
N.B. WIRE SPEED 10K R1 631 VM J5 67 E D C B 5 7 4 512 624 3 1 5 500 621 N.G. GUN CABLE S4 S3 WIRE FEED MODE SWITCH * N.F. SWITCH J7 N.F. 3 * N.H. N.B., N.D., J13 500 530 * 2 B 4 R * SWITCH EFFECT HALL U 1 N.B. 2 1 CV S1 CONNECTOR CAVITY NUMBER VV MODE SWITCH WIRE FEED S3 3 6 5 2 4 1 1 4 * * 12 530A 12 S5 13 512 13 8 11 1 6 5 500A 530 606 621 622A 8 11 1 6 5 N.L.
LN-25 6 J3 J14 16 8 10 621 667 C D N.D. J5 E N.F. S1 R1 CW 1 4 5 2 3 6 3 1 2 4 S2 N.L. S2 N.B. N.D. LO J2 J1 J3 J4 7 15 9 16 13 12 10 14 8 11 1 6 5 3 2 4 S3 VV 3 J16 2 R 4 HALL EFFECT SWITCH U B 1 1 J15 624 500A 530 606 621 622A 607 622 512 530A 500 N.H. N.G. N.H. N.G. N.H. N.G. OPTIONAL REMOTE KIT PLUG 2 N.A. 8 1 9 10 4 3 11 2 6 12 7 5 13 14 WIRE FEED N.B. MODE SWITCH CV GUN CABLE WIRE SPEED DIAL RANGE SWITCH HI SOLENOID P.C.
DIMENSIONS F-3 F-3 LN-25 PHYSICAL DIMENSIONS 16.60 14.00 7.40 .25 21.
● 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 protec- tion. 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. ● Mantenga el material com- bustible fuera del área de trabajo.
● Turn power off before servicing. ● Keep your head out of fumes. ● Use ventilation or exhaust to ● Do not operate with panel open or guards off. WARNING 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. ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio. ● No operar con panel abierto o guardas quitadas.
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