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Lincoln LN-25 PRO, Operator'S Manual

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Lincoln LN-25 PRO Operator'S Manual Download Page 30

C-3

ACCESSORIES

C-3

LN-25™ PRO

K910-1

K910-2

K1500-1

Ground Clamp

Ground Clamp

Gun Receiver Bushing (for guns

with K466-1 Lincoln gun connec-

tors; Innershield and Subarc guns)

Includes:  One 300 Amp

Ground Clamp.

Includes:  One 500 Amp

Ground Clamp.

Includes:  Gun receiver bush-

ing, set screw and hex key

wrench.

K484

Jumper Plug Kit

Includes:     14 pin circular

connector with jumper for

leads 2-4.  For use in power

sources for turning the weld

terminals "ON" at all times.

Summary of Contents for LN-25 PRO

Page 1: ...s having Code Numbers 11746 11747 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for future reference Date P...

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: ...ers 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 may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use th...

Page 4: ...m 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 an...

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: ...riés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Elo...

Page 7: ...the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where the...

Page 8: ...ons Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touchin...

Page 9: ...ols B 3 thru B 6 Constant Current Wire Welding B 4 B 5 Case Front Controls Description B 6 Internal Controls B 7 Internal Controls Decription B 8 Rear Controls B 9 ________________________________________________________________________________ Accessories Section C Factory Installed Equipment C 1 Drive Roll Kits used C 1 Accessories Used C 2 thru C 4 ______________________________________________...

Page 10: ...uTPuT 104 F 40 C DuTY CYCLE 60 rating INPuT AMPERES 450 GEARING WIRE FEED SPEED RANGE WIRE SIzE WFS RANGE 50 400 ipm 1 3 10 1m min 50 700 ipm 1 3 17 7m min WFS RANGE 50 400 ipm 1 3 10 1m min 50 700 ipm 1 3 17 7m min WIRE SIzES 023 1 16 0 6 1 6mm 023 1 16 0 6 1 6mm WIRE SIzES 030 3 32 0 8 2 4mm 030 5 64 0 8 2 0mm GEARING Extra torque K2613 7 Standard Speed K2613 5 GMAW FCAW Thermal tests have been ...

Page 11: ...PRECAuTIONS 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 out put cables or control cables Only qualified personnel should perform this installation Do not touch metal portions of the LN 25 PRO work clip when the welding power source is on Do not attach the work clip to the wire feeder Connect the ...

Page 12: ...tion Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve out let 4 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench Note if connecting to 100 CO2 cylinder insert regulator adapte...

Page 13: ...ng power source 2 Remove the welding wire from the wire drive 3 Remove the thumb screw 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 bushing Important Do not attempt to completely remove the socket head cap screw 6 Remove the outer wire guide and push the gun bushing out of the wire drive Because of ...

Page 14: ...e roll pressure arm 3 Remove the outer wire guide by turning the knurled thumbscrews counter clockwise to unscrew them from the feed plate 4 Rotate the triangular lock and remove the drive rolls 5 Remove the inner wire guide 6 Insert the new inner wire guide groove side out over the two locating pins in the feed plate WARNING 7 Install a drive roll on each hub assembly secure with the triangular l...

Page 15: ...se of the thumb screw FIGuRE A 4 WARNING PRESSuRE ARM and ADJuSTMENT ELECTRIC ShOCK can kill Turn the input power OFF at the welding power source before instal lation 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 sec onds after the gun trigger i...

Page 16: ...Feed module SAE s Without CV Adapter SAE 400 with CV adapter Engine Driven welder with Wire Feed Module Across the Arc Work clip Work Electrode Jumper LN 25 PRO CV 400 CV 655 DC 400 DC 600 DC 655 V450 Pro SAE 400 with CV adapter Engine Driven welder with Wire Feed Module Ranger 250 GXT Across the Arc FIGuRE A 5 FIGuRE A 6 K K2613 5 K2613 7 KP1695 xx KP1696 xx KP1697 xx See Magnum Literature K1803 ...

Page 17: ...Ranger 250 250 LPG Ranger 305G 305D Ranger 10 000 Ranger 3 Phase Ranger 225 225GXT Commander 300 Vantage 300 400 500 Air Vantage 500 Work clip Work Electrode LN 25 PRO V350 Pro CV 305 Across the Arc FIGuRE A 7 FIGuRE A 8 K K2613 5 K2613 7 KP1695 XX KP1696 XX KP1697 XX See Magnum Literature K1803 XX Description LN 25 PRO LN 25 PRO Extra Torque Drive Roll Kit Welding Gun CC power Source Welding Cabl...

Page 18: ...e feeder in the CV position Work clip Work Electrode Jumper LN 25 PRO Across the Arc CV 250 CV 300 FIGuRE A 9 K K2613 5 K2613 7 KP1695 XX KP1696 XX KP1697 XX See Magnum Literature K1841 XX K852 95 K484 Description LN 25 PRO LN 25 PRO Extra Torque Drive Roll Kit Welding Gun CV power Source Welding Cables Twist Mate Cable plug Jumper Plug kit ...

Page 19: ...eep your head out of fumes use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away ARC RAYS can burn Wear eye ear and body protec tion SEE ADDITIONAL WARNING INFORMATION uNDER ARC WELDING SAFETY PRECAuTIONS AND IN ThE FRONT OF ThIS OPERATING MAN uAL WARNING SAFETY PRECAuTIONS READ AND uNDERSTAND ENTIRE SECTION bEFORE OP...

Page 20: ...ing without slippage With a 450 amp 60 duty cycle rating these feeders are ready for heavy duty welding General Functional Description All LN 25 PRO s 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 by a rocker switch or through the...

Page 21: ...welding See Customer Assistance Policy in the front of this Instruction Manual CASE FRONT CONTROLS See Figure b 1 ITEM DESCRIPTION 1 Analog Voltmeter 2 Wire Feed Speed Knob 3 Wire Feed Speed Range Switch 4 5 pin gun trigger connector 5 Work sense lead 6 Thermal LED Motor Overload 7 Polarity LED LN 25 PRO 1 6 5 2 7 3 4 FIGuRE b 1 ...

Page 22: ...l 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 1a LN 25 PRO 50 100 150 in min 200 250 300 350 375 400 450 500 550 600 650 700 50 100 150 200 250 300 350 400 450 500 550 650 700 35 31 29 27 25 23 21 19 17 15 33 600 ARC VOLTS CC FIGuRE b 1a CV OPERATION A constant voltage CV power source is recommended for flux...

Page 23: ... 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 short ening the contact tip to work distance lowers the volt age If the contact tip to work distance is properly main tained a satisfactory operating voltage range may be achieved and a sound weld may result However when a welder uses a lon...

Page 24: ...b Note selecting the low range does not increase the torque of the wire drive 4 5 PIN GuN TRIGGER CONNECTOR There is one circular connector for the gun trigger on the front of the LN 25 PRO 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 5 WORK SENSE LEAD Always turn power off at the wel...

Page 25: ...p Trigger Interlock Switch 2 CV CC Switch 3 Pressure Adjustment Arm 4 Optional Timer Kit 5 Spool Retainer 6 Spindle Brake 7 Gun Bushing Thumb Screw and Socket Head Cap Screw ITEM DESCRIPTION 1 9 8 7 6 3 2 8 Drive Hubs 9 Cold Feed Pushbutton 4 5 FIGuRE b 2 ...

Page 26: ...m the welding power source remains energized and the wire feeder will continue to feed wire until the gun trigger is again pulled and then released 2 CV CC SWITCh The CV CC switch sets the wire feed speed control method for the wire feeder 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 In the...

Page 27: ...trode Lead ITEM DESCRIPTION 1 3 2 1 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 ...

Page 28: ... 1 0mm 3 64 1 2mm 1 16 1 6mm KP KIT KP1696 030S KP1696 035S KP1696 045S KP1696 052S KP1696 1 16S KP1696 1 KP1696 2 KP1697 035C KP1697 045C KP1697 052C KP1697 1 16C KP1697 068 KP1697 5 64 KP1697 3 32 KP1695 035A KP1695 040A KP1695 3 64A KP1695 1 16A FACTORY INSTALLED EQuIPMENT K1500 2 Gun Receiver Bushing Includes 2 V groove drive rolls and inner wire guide Includes 2 Knurled drive rolls and inner ...

Page 29: ... weld cable of length xx Ends of the weld cable have lug connections Use for Pulse or STT welding Includes Twist Mate to Lug 2 0 cable 14 1 2m long with Ground Clamp and Twist Mate to Lug 2 0 Cable 9 2 7m long Includes Twist Mate to Lug 1 0 cable of length xx IIncludes Lug to Lug 3 0 Cable 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 K...

Page 30: ...n gun connec tors Innershield and Subarc guns Includes One 300 Amp Ground Clamp Includes One 500 Amp Ground Clamp Includes Gun receiver bush ing set screw and hex key wrench K484 Jumper Plug Kit Includes 14 pin circular connector with jumper for leads 2 4 For use in power sources for turning the weld terminals ON at all times ...

Page 31: ...y wrench Includes Spindle Adapter made from 2 coil retainers Electrode not included Includes 2 Spindle Adapters one for 2 wide spools and the other for 3 wide spools Includes 2 hoses with female quick connectors at each end 2 male connectors for 3 16 ID hose 2 male connectors for _ ID hose and mounting hardware Includes Deluxe Gas Regulator for Mixed Gases Adapter for CO2 and 10 3 0m Hose Includes...

Page 32: ...E Clean drive rolls and inner wire guide and replace if worn Blow out or vacuum the inside of the feeder Inspect the motor brushes every 6 months Replace if shorter than 0 5 12 7mm CALIbRATION SPECIFICATION VOLTMETER VALIDATION See Figure D 1 To verify the analog voltmeter accuracy 1 Turn power OFF 2 Connect the LN 25 PRO to the constant voltage DC power supply capable of supply at least 4 amps Co...

Page 33: ...e switch in the high setting Set the WFS knob to 50 ipm for K2613 5 25 ipm for K2613 7 4 Trigger the LN 25 PRO and measure the rpm of the motor gear Adjust the WFS knob as required until the rpm measures 8 9 to 9 2 rpm 5 Insert the shorting plug into the control board for 1 second and then remove the shorting plug The shorting plug shorts pins 4 and 7 of J3 6 Set the WFS knob to 800 ipm for K2613 ...

Page 34: ...ice Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility hOW TO uSE TROubLEShOOTING GuIDE 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 ...

Page 35: ...The gas supply is OFF or empty 2 The gas hose is cut or crushed 3 The flow meter valve is closed 4 Dirt or debris is in the solenoid 5 There is a loose solenoid connec tion 6 The solenoid has failed 1 Check that the electrode slides easily through the gun and cable 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...

Page 36: ...operly 2 The wrong gear is installed in the wire drive 3 The brushes on the motor are worn 1 The tachometer is connected improperly 2 The tachometer has failed 1 Keep the gun cable as straight as possible Avoid sharp corners or bends in the cable 2 Remove the gun from the wire feeder and pull the jammed wire out of the gun and cable 3 Blow dirt out of the liner with low pressure 40psi or less Repl...

Page 37: ...ow and ropy looking bead 1 Wrong size worn and or melted contact tip 2 Worn work cable or poor work connection 3 Wrong polarity 4 The gas nozzle is extended beyond the contact tip or the wire stickout is too long 5 Poor gas shielding on processes requiring gas 1 Improper procedures or tech niques 1 Replace the contact tip 2 Verify all work and electrode con nections are tight and that the cables a...

Page 38: ...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 ...

Page 39: ...F 2 DIMENSION PRINT F 2 LN 25 PRO 17 19 8 65 16 CIRCLE 12 x 18 ELLIPSE 23 17 14 81 ...

Page 40: ...NOTES LN 25 PRO ...

Page 41: ...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 42: ... 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 43: ...stomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility 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 manufactur...

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