Lincoln Electric LN-25X Operator'S Manual Download

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CV Power Sources with Stud Connectors and no
Remote/Local Switch

CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch

A-4

INSTALLATION

LN-25X™

Item K#

Description

K4267-2, K4267-3,
K4267-4, K4267-5

LN-25X™

KP1695-xx
KP1696-xx
KP1697-xx

Drive Roll Kit

See Magnum PRO
Literature

Welding Gun

CV power source

Electrode Cable

Work Cable and Ground Clamp

Item K#

Description

K4267-2, K4267-3,
K4267-4, K4267-5

LN-25X™

KP1695-xx
KP1696-xx
KP1697-xx

Drive Roll Kit

See Magnum PRO
Literature

Welding Gun

CV power source

Electrode Cables

Work Cable and Ground Clamp

K484

Jumper Plug Kit* (14-Pin)

Ranger 250

Ranger 250 LPG

Ranger 305G

Ranger 305D

Ranger 10,000

Ranger 3 Phase

Ranger 225

Ranger 225 GXT

Commander 300

Vantage 300

Vantage 400

Vantage 500

Air Vantage 500

Air Vantage 650

SAE 300

Dual Vantage 700

Classic 300

*Not Shown

Summary of Contents for LN-25X

Page 1: ...ed Service and Distributor Locator www lincolnelectric com locator IM10532 A Issue Date May 19 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12869 12870 12871 12872 Save for future reference Date Purchased Code ex 10859 Serial ex U1060512345 LN 25X ...

Page 2: ...N A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted...

Page 3: ... hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it ...

Page 4: ...rm to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes a...

Page 5: ...ent passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy MA 022690 9101 6 j Do not use a welding power source for pipe...

Page 6: ...R CONNECTOR A 7 CHANGING THE GUN RECEIVER BUSHING A 8 PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES A 9 PRESSURE ARM ADJUSTMENT A 9 GUN CONNECTION A 10 SHIELDING GAS CONNECTION A 10 OPERATION B 1 POWER UP SEQUENCE B 1 CASE FRONT CONTROLS B 2 DIGITAL METER OPERATION B 4 SET UP MENU B 5 INTERNAL CONTROLS B 9 REAR CONTROLS B 11 OPTIONS ACCESSORIES C 1 MAINTENANCE D 1 ROUTINE MAINTENANCE D 1 PERIOD...

Page 7: ...ng of the drive rolls and wire guides for quick spool changes Tachometer feedback on the wire drive ensures accurate speed control with all wire types and environmental conditions Bright digital meters which display voltage current and wire feed speed so that the user can accurately set and verify welding parameters Rating of 450 amps at a 60 duty cycle recoMMenDeD processes GMAW FCAW process liMi...

Page 8: ...Width Depth Weight K4267 1 K4267 2 K4267 3 K4267 4 K4267 5 14 8 in 376 mm 8 7 in 221 mm 23 2 in 589 mm 37 lbs 17 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 14 F to 104 F 10 C to 40 C 40 F to 122 F 40 C to 50 C Thermal tests have been performed at ambient temperature The duty cycle duty factor at 40 C has been determined by simulation GEARING WIRE FEED SPEED RANGE W...

Page 9: ...m the work Only use on power sources with open circuit voltages less than 110 VDC SELECT SUITABLE LOCATION For best wire feeding performance place the LN 25X on a stable and dry surface Keep the wire feeder in a vertical position Do not operate the wire feeder on an angled surface of more than 15 degrees Do not submerge the LN 25X The LN 25X is rated IP23 and is suitable for outdoor use The handle...

Page 10: ...P1696 xx KP1697 xx Drive Roll Kit 3 See Magnum PRO Literature Welding Gun 4 Flextec 350X 500X 650X or Ranger 330MPX 5 Welding Cables 6 Work Cable and Ground Clamp Item K Description 1 K4267 2 K4267 3 K4267 4 K4267 5 LN 25X 2 KP1695 xx KP1696 xx KP1697 xx Drive Roll Kit 3 See Magnum PRO Literature Welding Gun 4 CV power source 5 Electrode Cable 6 Work Cable and Ground Clamp 1 1 3 3 5 5 6 6 4 4 2 2 ...

Page 11: ...able 6 Work Cable and Ground Clamp Item K Description 1 K4267 2 K4267 3 K4267 4 K4267 5 LN 25X 2 KP1695 xx KP1696 xx KP1697 xx Drive Roll Kit 3 See Magnum PRO Literature Welding Gun 4 CV power source 5 Electrode Cables 6 Work Cable and Ground Clamp 7 K484 Jumper Plug Kit 14 Pin 1 1 3 3 5 6 5 6 7 6 4 4 2 2 Ranger 250 Ranger 250 LPG Ranger 305G Ranger 305D Ranger 10 000 Ranger 3 Phase Ranger 225 Ran...

Page 12: ...COMBINED LENGTHS OF ELECTRODE AND WORK CABLES 0 to 50Ft 0 to15m 50 to 100Ft 15 to 30m 100 to 150 Ft 30 to 46m 150 to 200 Ft 46 to 61m 200 to 250 Ft 61 to 76m 200 60 2 2 2 1 1 0 200 100 2 2 2 1 1 0 225 20 4 or 5 3 4 or 5 1 1 0 225 40 30 3 3 3 1 1 0 250 30 3 3 3 1 1 0 250 40 2 2 2 1 1 0 250 60 1 1 1 1 1 0 250 100 1 1 1 1 1 0 300 60 1 1 1 1 0 1 0 350 100 2 0 2 0 2 0 2 0 2 0 350 60 1 0 1 0 1 0 2 0 3 0...

Page 13: ... the gun trigger on the front of the LN 25X ELECTRIC SHOCK CAN KILL Do not touch electrically live parts WARNING LN 25X Picture Function Pin Wiring 5 PIN TRIGGER CONNECTOR FOR PUSH ONLY GUNS A 15 VOLT SUPPLY B NOT USED C TRIGGER D 83 WFS SWITCH E 15 VOLT SUPPLY A E C B D ...

Page 14: ...w from the wire drive 4 Remove the welding gun from the wire drive 5 Loosen the socket head cap screw that holds the connector bar against the gun adapter Important Do not attempt to completely remove the socket head cap screw 6 Remove the outer wire guide and push the gun adapter out of the wire drive Because of the precision fit light tapping may be required to remove the gun bushing 7 Disconnec...

Page 15: ...tall a drive roll on each hub assembly secure with the triangular lock 8 Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews 9 Close the idle arm and engage the idle roll pressure arm Adjust the pressure appropriately pressUre arM aDjUstMent ELECTRIC SHOCK CAN KILL Turn the input power OFF at the welding power source before installation or changing driv...

Page 16: ...elding Society Maximum inlet pressure is 100 psi 6 9 bar Install the shielding gas supply as follows 1 Secure the cylinder to prevent it from falling 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this co...

Page 17: ...lder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the LN 25X wirefeeder These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of the LN 25X wirefeeder may not be suitable for all applications and the builder user ...

Page 18: ... wfs 200 in min the feeder will regulate to 0 83 x 200 166 in min The 83 trigger requires a gun with a dual procedure switch This feature is often useful when welding pipe and a cooler procedure is required on the bottom portion 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 automaticall...

Page 19: ...isplay When the Wire Feed Speed LED is illuminated wire feed speed is being displayed When the Amperage LED is illuminated amperage is being displayed Voltage LED The Voltage LED will be illuminated when the Voltage Digital Display is displaying actual voltage or when its displaying with a CrossLinc connection Five Pin Gun Trigger Connector The 5 Pin Gun Trigger Connector is where the trigger that...

Page 20: ...ower source When connected to a power source with CrossLinc When connected to a power source without CrossLinc During Welding The value in the left display will be either amps or actual wire feed speed depending upon the selection chosen in the set up menu The corresponding LED below the display will light Note that actual WFS may not match preset WFS if welding at low voltages with high wire feed...

Page 21: ... speed or arc current Arc hours display on off After weld display hold time True Voltage Technology TVT enable disable CrossLinc enable disable CC or CV power source Wire feed speed calibration Arc voltage display calibration Arc current display calibration The left display will show the menu item and the right display will show the set value The left encoder is used to select the setup menu item ...

Page 22: ...s Off 0 10 10sec Burnback adjustment prevents the wire from sticking to the weld at the end of a weld and helps to condition the wire for the next weld Postflow time POSt Flo OFF 0 10 10 0 OFF Postflow is the time from when the power source output turns off until the postflow timer expires The range for Postflow gas time is Off 1 10sec Use postflow to protect the weld while the weld cools Display ...

Page 23: ...o calibrate the voltage meter To calibrate the arc voltage display before entering the setup menu Determine the ratio of the actual arc voltage and the arc voltage displayed While in the setup menu adjust the calibration factor as follows Actual arc voltage displayed arc voltage calibration factor Example 20 0 20 5 0 97 Arc current display calibration Cur CAL 0 90 1 10 1 This is used to calibrate ...

Page 24: ...Figure B 4 for 29 volts 4 Determine the vertical line representing the CC Wire Feed Speed setting where the above two lines cross See Figure B 4 arrow line for 450 Set the LN 25X wire feed speed knob to this value CC WFS dial setting desired WFS x 35 Arc Volts Example 375 in min Horizontal Line x 35 29 Arc Volts Diagonal Line 452 5 Vertical Line See Figure B 4 Actual wire feed speed 50 100 150 200...

Page 25: ...power sources are used Lowering the wire feed speed raises the voltage raising the wire feed speed lowers the voltage Lengthening the contact tip to work distance raises the voltage shortening the contact tip to work distance lowers the voltage If the contact tip to work distance is properly maintained a satis factory operating voltage range may be achieved and a sound weld may result However when...

Page 26: ...p Trigger Interlock Switch not present on K2613 3 and K2613 4 2 Pressure Adjustment Knob 3 Spool Retainer 4 Spindle Brake 5 Gun Bushing 6 Thumb Screw 7 Socket Head Cap Screw for Gun Bushing 8 Drive Hubs 9 Inlet Wire Guide 10 Cold Feed Pushbutton 1 6 5 7 9 10 8 2 3 4 ...

Page 27: ...operation provides for operator comfort when making long welds When the gun trigger is first pulled the welding power source energizes the output and the wire feeder feeds wire for welding The gun trigger is then released while the weld is made To stop welding the gun trigger is pulled again and when it is released the welding power source output turns off and the wire feeder stops feeding wire Ca...

Page 28: ... 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 LN 25X Item Description 1 Gas Purge Pushbutton 2 Shielding Gas Inlet 3 Electrode Lead 4 Gas Flowmeter 1 2 3 4 ...

Page 29: ...4MM KP1696 1 16S 1 16 1 6MM KP1696 1 035 045 0 9 1 2MM KP1696 2 040 1 0MM Cored Wire Drive Roll Kits KP1697 035C 030 035 0 8 0 9MM INCLUDES 2 KNURLED DRIVE ROLLS AND INNER WIRE GUIDE KP1697 045C 040 045 1 0 1 2MM KP1697 052C 052 1 4MM KP1697 1 16C 1 16 1 6MM KP1697 068 068 072 1 7 1 8MM KP1697 5 64 5 64 2 0MM KP1697 3 32 EXTRA TORQUE MODELS 3 32 2 4MM Aluminum Wire Drive Roll Kits KP1695 035A 035 ...

Page 30: ... of length xx for lengths up to 60 18 3m Lug to Lug 4 0 Cable of length xx for lengths greater than 60 18 3m K910 1 K910 2 Work Clamp Jaws open full 2 1 2 inches 63 mm Welding cable lug bolts directly to the work clamp 60 duty cycle Select K910 1 for 300 Amp applications K910 2 for 500 Amp K1500 1 Gun Receiver Bushing for guns with K466 1 Lincoln gun connectors Innershield and Subarc guns Includes...

Page 31: ... Adapter made from 2 coil retainers Electrode not included K468 Spindle Adapter for mounting 8in 203mm diameter spools on 2 in 51 mm spindles Includes 2 Spindle Adapters one for 2 wide spools and the other for 3 wide spools K586 1 Deluxe Adjustable Gas Regulator Includes Deluxe Gas Regulator for Mixed Gases Adapter for CO2 and 10 3 0m Hose K283 Wire Feed Speed Meter Includes A wire feed speed mete...

Page 32: ...e DC welding power source DC 400 V 350 CV 400 or equivalent To verify the flow meter accuracy 1 Turn power OFF 2 Connect the LN 25X to the constant voltage DC welding power source The work lead of the LN 25X must be connected to the work terminal of the power source 3 Connect a supply of CO2 to the wire feeder Do not exceed the maximum inlet pressure of the wire feeder 4 Disconnect the shielding g...

Page 33: ...vious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact you local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facil...

Page 34: ... free of dirt rust and paint 2 Turn ON the power source The wire feeder power up but there is no output when the trigger is pulled The shielding gas is flowing and the drive rolls turn 1 The contactor coil connections are loose 2 The contactor has failed 1 Verify the contactor coil connections 2 Replace the contactor No shielding gas 1 The gas supply is OFF or empty 2 The gas hose is cut or crushe...

Page 35: ...ed stuck at 200 300 in min and there is no change when the wire feed speed knob is adjusted 1 The tachometer is connected improperly 2 The tachometer has failed 1 Verify all of the tachometer leads are properly connected 2 Replace the motor and tachometer assembly Variable or hunting arc 1 Wrong size worn and or melted contact tip 2 Worn work cable or poor work connection 3 Wrong polarity 4 The ga...

Page 36: ...BOLS PER E1537 LEAD COLOR CODING B BLACK W WHITE 507 578 CONTACTOR COIL 1 2 3 4 J62 CURRENT TRANSDUCER 550 551 5 6 7 8 667 67A 821B 621 708 BRIDGE RECTIFIER AC AC A P14 622A TRIGGER CONNECTOR B C D E N O N O SHOWN IN 2 STEP D1 621A INPUT ELECTRODE CABLE CONNECTION 1 2 3 4 5 6 P51 J51 J1 J2 CAVITY NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF P C BOARD 6 5 10 1 J6 9 8 16 1 4 6 1 3 J5 J50 J52 J53...

Page 37: ...F 2 DIAGRAMS LN 25X 23 17 14 81 ...

Page 38: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführenden Teile oder Elektroden mit ...

Page 39: ... und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para remover fumo da zona respiratória l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l entre tien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten l Não o...

Page 40: ...tion or advice As a matter of practical consideration we also cannot assume any respon sibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold ...

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