Red-D-Arc LN-25x Operator'S Manual Download

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RED-D-ARC

LN-25x

IM10297

Dec, 2015

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.

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.

For use with machines having Code Numbers:

12504

North America’s Largest Fleet of Welding Equipment

OPERATOR’S MANUAL

(

Summary of Contents for LN-25x

Page 1: ...lt 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 For use with machines having Code Numbers 12504 North America s Largest Fleet of Welding E...

Page 2: ...the general area IN 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 helm...

Page 3: ...afety 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 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 comple...

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: ...ough 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 thawing CYLIND...

Page 6: ...TRIGGER 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 8 REAR CONTROLS B 10 OPTIONS ACCESSORIES C 1 MAINTENANCE D 1 ROUTINE MAINTENANCE D 1 ...

Page 7: ...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 limitations Not recommended for stitch or spot welding equiPment limitations The duty cycle of the wire feeder is 325A 100 and 450A 60 Duty cycle is based upon the amount of welding performed in a 10 minute period The maximum spool size is 45 lb...

Page 8: ...PHYSICAL DIMENSIONS Model Height Width Depth Weight K4267 1 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 AGENCY APPROVALS Model Market Conformity Mark Standard K4267 1 US AND CANADA CSAC UL C22 2 NO 60 UL551 EUROPE CE EN 60974 5 EN 60974 10 CHINA CCC GB T15579 ...

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: ... 2 KP1695 xx KP1696 xx KP1697 xx Drive Roll Kit 3 See Magnum PRO Literature Welding Gun 4 CV power source 5 K1841 xx Welding Cables 6 K852 95 Twist Mate Cable Plug Item K Description 1 K4267 1 LN 25x 2 KP1695 xx KP1696 xx KP1697 xx Drive Roll Kit 3 See Magnum PRO Literature Welding Gun 4 CV power source 5 K1803 1 Welding Cables 1 1 3 3 5 5 6 4 4 2 2 CV 400 CV 600 DC 400 DC 600 DC 655 V450 PRO SAE ...

Page 11: ...5 K1841 xx Welding Cables 6 K852 95 Twist Mate Cable Plug Item K Description 1 K4267 1 LN 25x 2 KP1695 xx KP1696 xx KP1697 xx Drive Roll Kit 3 See Magnum PRO Literature Welding Gun 4 CV power source 5 K1803 1 Welding Cables 6 K484 Jumper Plug Kit 1 1 3 3 5 5 6 6 4 4 2 2 Ranger 250 Ranger 250 LPG Ranger 305G Ranger 305D Ranger 10 000 Ranger 3 Phase Ranger 225 Ranger 225 GXT Commander 300 Vantage 30...

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: ...e small leads combine together to form the work lead one end attached to the power source and the other end to the work piece See Figure A 5 To install 1 Turn the input power off at the welding power source 2 Connect one end of the center lead to the power source electrode connection and the other end to the wire feeder electrode connection 3 Connect the outer lead bundle to the power source work ...

Page 14: ... 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 15: ...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 16: ...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 17: ...Welding 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 c...

Page 18: ...nd 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 is and must be solely respons...

Page 19: ...l set value when activated For example if the original 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 ther...

Page 20: ...e 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 workpoint with a CrossLinc connection Five Pin Gun Trigger Connector The 5 Pin Gun Trigger Connector is where the trigger that is attached to the welding gun is connected This will actuate the welding current when the ...

Page 21: ...rossLinc When connected to a power source with CrossLinc When connected to a power source without CrossLinc or switched to local 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 hig...

Page 22: ...eed during the time from when the trigger is pulled to when an arc is struck When Run in is ON the wire feed speed is reduced until an arc is struck Factory setting is Run In OFF When Run in is OFF the wire feed speed is the same as the welding wire feed speed Turn Run In OFF for fast crisp starts especially when running with 035 or 045 0 9 or 1 2mm solid steel wires at high wire feed speeds To ch...

Page 23: ...splay Selection 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 To change the left display reading Rotate the WFS knob to the left to display ...

Page 24: ... button to enter the hold display menu Hold Display The LN 25x will display the actual wire feed speed or amperage and voltage after welding has stopped The hold display option will hold these values for either 10 seconds or 300 seconds To change setting Rotate the WFS knob to the left for 10 second hold Rotate the WFS knob to the right for 300 second hold Press the set up button to exit the set u...

Page 25: ...erlock Switch not present on K2613 3 and K2613 4 2 Pressure Adjustment Knob 3 Optional Timer Kit 4 Spool Retainer 5 Spindle Brake 6 Gun Bushing 7 Thumb Screw 8 Socket Head Cap Screw for Gun Bushing 9 Drive Hubs 10 Inlet Wire Guide 11 Cold Feed Pushbutton 1 7 6 8 10 11 9 2 3 4 5 ...

Page 26: ...ire drive will feed electrode but neither the power source nor the gas solenoid will be energized Adjust the speed of cold feeding by rotating the WFS knob Cold feeding or cold inching the electrode is useful for threading the electrode through the gun Preflow Burnback and Postflow Timer Kit The Preflow Burnback and Postflow Timer Kit gives control over the shielding gas at the beginning and end o...

Page 27: ...urce 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 28: ...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 29: ...f 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 G...

Page 30: ... 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 31: ...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 32: ...e obvious 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 F...

Page 33: ... 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 34: ...1 Properly connect the normal speed extra torque jumper 2 Install the proper pinion gear in the wire drive 3 Replace the motor gearbox assembly The wire feed speed 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 moto...

Page 35: ...06 607 608 7 6 5 4 3 2 1 610 1 2 3 4 5 6 7 8 9 10 J1 TO P60 ON HARNESS GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 LEAD COLOR CODING B BLACK W WHITE 507 578 CONTACTOR COIL 1 2 3 4 J15 CURRENT TRANSDUCER 509B 509A 509 8 7 6 5 4 3 2 1 601 509B 605 606 607 608 550 551 CONNECTS TO J8 ON PRESET P C BD FLEX EXTRA TORQUE 5 6 7 8 TO OPTIONAL TIMER KIT 667 67A 821B 621 708 BRIDGE RECTIFIER AC AC A P14...

Page 36: ...F 2 DIAGRAMS LN 25X 17 22 12 X 18 ELLIPSE 16 CIRCLE 14 81 23 15 ...

Page 37: ...Red D Arc LN 25X 12504 ...

Page 38: ...laneous Items AR 1 P 979 C Front Panel Assembly AR 2 P 979 D Control Box Assembly AR 3 P 979 E Spindle Mast Assembly AR 4 P 979 F Wire Drive Assembly AR 5 P 979 G Case Assembly AR Index of Sub Assemblies 12504 Red D Arc LN 25X 12504 1 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 39: ...P 979 A jpg Index of Sub Assemblies 12504 2 Red D Arc LN 25X 12504 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 40: ...KEY PART NUMBER DESCRIPTION QTY 9SG8565 WIRING DIAGRAM 1 Miscellaneous Items Red D Arc LN 25X 12504 3 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 41: ...No Image Miscellaneous Items 4 Red D Arc LN 25X 12504 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 42: ...REW 2 5 9SM22778 2 KNOB 1 5 2 6A 9ST13637 5 DIODE BRIDGE35A800VF W1 PH 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 7 9SS18581 2 BOOT 1 8A 9SM25728 RECESSED BRACKET 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 9 9ST14530 2 RECEPTACLE 1 10A 9SS24287 STRAIN RELIEF CLAMP 1 10B 9ST10082 29 SEMS SCREW 2 9SS17211 7 GROUND LEAD ASBLY 1 9SS18250 1100 PLUG LEAD ASBLY 1 9SS9225 4 THREAD FORMING SCREW ROLLING ...

Page 43: ...P 979 C jpg Front Panel Assembly 6 Red D Arc LN 25X 12504 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 44: ...PPING SCREW 4 9SCF000027 1 2 13HN 1 8B 9SS9262 80 PLAIN WASHER 1 8C 9SE106A 15 LOCKWASHER 1 8D 9SCF000052 1 2 13X1 50HHCS 1 9SL12936 1 CONTACTOR ASBLY 1 9A 9SM15308 9 CONTACTOR 1 9B 9SM21094 1 CONTACTOR BRACKET 1 9ST14731 67 METRIC PAN HEAD SCREW 2 9SE106A 1 LOCKWASHER 2 9E 9SM21010 BUS BAR ASBLY 1 9F 9SM21005 BUS BAR ASBLY 1 9G 9ST9860 4 LOCKWASHER 2 9ST15088 INSULATED FASTENER 1 9SS9262 98 PLAIN...

Page 45: ...DECAL FLOWMETER 1 17A 9SS27028 FAN ASBLY 1 9SS8025 15 SELF TAPPING SCREW 2 9SM22570 1 DECAL MAST 1 18A 9SS18504 6 CURRENT TRANSDUCER 1 18B 9ST7028 181 INSULATING TUBE 2 18C 9SCF000122 10 24X1 50RHS 2 18D 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 19 9SS28863 FILTER 1 20A 9SM21011 2 CONTROL BOX COVER 1 9SS9225 99 SELF TAPPING SCREW 4 9ST12250 5 HOLE PLUG 1 Control Box Assembly 8 Red D Arc LN 25X 125...

Page 46: ...P 979 D jpg Control Box Assembly Red D Arc LN 25X 12504 9 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 47: ... 4 9ST9860 6 LOCKWASHER 2 5 9SS9262 23 PLAIN WASHER 2 6 9ST12380 1 BUSHING 3 7 9SL10560 2 SPINDLE 1 8 9SS17435 3 FRICTION WASHER 2 9 9ST12965 2 KEYED WASHER 1 10 9ST11862 14 SPRING 1 11 9ST14813 A THUMB SCREW 1 12 9SS23811 RETAINING COLLAR ASBLY 1 13 9SS9262 192 PLAIN WASHER 1 Spindle Mast Assembly 10 Red D Arc LN 25X 12504 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 48: ...P 979 E jpg Spindle Mast Assembly Red D Arc LN 25X 12504 11 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 49: ...9SS9225 102 SELF TAPPING SCREW 1 3 9SL12081 1 MOTOR GEARBOX 1 9SS24018 8 CONNECTORMOLEXMINILDS8 PIN 1 9SS24019 8 CONNECTORLOCKING POSTFOR 8 CAVITY 1 3C 9SS24170 1 WOODRUFF KEY METRIC 1 3D 9SS9776 27 RETAINING RING 1 9SS28460 MOTOR BRUSH KIT 1 9SE106A 2 LOCKWASHER 3 9ST14731 18 METRIC PAN HEAD SCREW 3 4A 9SM19870 DRIVE GEAR 1 4B 9SS25414 COLLAR 1 4C 9ST4291 A LOCKWASHER 1 4D 9ST14731 47 METRIC PAN ...

Page 50: ...1C 9SE106A 15 LOCKWASHER 1 11D 9SS9262 80 PLAIN WASHER 1 12 9SM22571 6 DECAL 1 13 9SM22571 4 DECAL 1 14 9SM22571 2 DECAL 1 15 9ST10800 38 SWITCH TOGGLE 2 9SS26310 DECAL 1 17 9SS22905 2 GUN ADAPTER ASBLY 1 18 9ST13858 SCREW HANDLE ASBLY 1 9SL13057 PLUG AND LEAD ASBLY 1 20 9SS25890 1 DECAL 1 9ST13086 130 CONFORMITY DECAL 1 Wire Drive Assembly Red D Arc LN 25X 12504 13 Printed 01 05 2016 at 15 59 05 ...

Page 51: ...P 979 F jpg Wire Drive Assembly 14 Red D Arc LN 25X 12504 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 52: ... 9SS11893 8 DOOR LOGO DECAL 1 9ST13086 201 DECAL CROSSED OUT WHEELED BIN 1 8 9ST10397 6 PLUG BUTTON 2 9 9ST10397 19 PLUG BUTTON 2 9SS26924 GASKET 1 11 9ST15088 2 INSULATED FASTENER 7 12 9SS9225 102 SELF TAPPING SCREW 1 13A 9SS18170 HANDLE ASBLY 1 13B 9SS9262 98 PLAIN WASHER 2 9SS9262 113 PLAIN WASHER 1 9SE106A 2 LOCKWASHER 2 9SCF000013 1 4 20X 625HHCS 2 Case Assembly Red D Arc LN 25X 12504 15 Prin...

Page 53: ...P 979 G jpg Case Assembly 16 Red D Arc LN 25X 12504 Printed 01 05 2016 at 15 59 05 Produced by Enigma ...

Page 54: ...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 55: ... 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 56: ...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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