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LN-25 IRONWORKER

Operator’s Manual

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Date Purchased

Code:

(ex: 10859)

Serial:

(ex: U1060512345)

IM10084

| Issue D ate 11-Apr

For use with machines having Code Numbers:

11752

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Содержание LN-25 IRONWORKER

Страница 1: ...ode ex 10859 Serial ex U1060512345 IM10084 Issue D ate 11 Apr Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 11752 Register your machine www lincolnelectric com register Authorized Service and Distributor Locator www lincolnelectric com locator ...

Страница 2: ...AKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR bEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is ava...

Страница 3: ...or cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Страница 4: ...s to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Страница 5: ...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...

Страница 6: ...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...

Страница 7: ...ding 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 touching these...

Страница 8: ...lly important when identifying the correct replacement parts CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their u...

Страница 9: ...Case Front Controls B 3 B 4 WFS Calibration with Digital Meters B 5 B 6 Internal Controls B 7 B 8 Rear Controls B 9 Gas Purge Pushbutton B 9 ________________________________________________________________________________ Accessories Section C Factory Installed Equipment C 1 Drive Roll Kits used C 1 Accessories Used C 2 thru C 3 _____________________________________________________________________...

Страница 10: ...17 2 kg Handle folded down PHYSICAL DIMENSIONS INPUT VOLTAGE 10 15 110 VDC INPUT AMPERES 4A RATED OUTPUT 104 F 40 C DUTY CYCLE 60 rating INPUT AMPERES 450 GEARING WIRE FEED SPEED RANGE WIRE SIzE WFS RANGE 50 700 ipm 1 3 17 7m min WFS RANGE 50 700 ipm 1 3 17 7m min WIRE SIzES 023 1 16 0 6 1 6mm WIRE SIzES 030 5 64 0 8 2 0mm GEARING Standard Speed K2614 5 GMAW FCAW Thermal tests have been performed ...

Страница 11: ...r 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 IRONWORKER work clip when the welding power source is on Do not attach the work clip to the wire feeder Connect the work clip directly to the work as close as possi...

Страница 12: ... 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 adapter between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seated for connection t...

Страница 13: ...the thumb screw hole aligns with the thumb screw hole in the feed plate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned 10 Tighten the socket head cap screw 11 Insert the welding gun into the gun bushing and tighten the thumb screw GUN RECEIVER BUSHING LOOSEN TIGHTEN THUMB SCREW OUTER WIRE GUIDE SOCKET HEAD CAP SCREW CONNECTOR BLOCK WARNING PROCEDURE...

Страница 14: ... the spindle 2 Place the spindle adapter on the spindle aligning the spindle brake pin with the hole in the adapter 3 Place the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool An indicator mark on the end of the spindle shows the orientation of the brake tab Be certain the wire feeds off of the spool in the proper direction 4 Re install the ...

Страница 15: ...Place CV CC switch in the feeder in the CV position Work clip Work Electrode Across the Arc 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 LN 25 IRONWORKER FIGURE A 6 POWER SOURCE TO LN 25 IRONWORKER CAbLE CONNECTION DIAGRAMS K K2614 9 KP1695 XX KP1696 XX KP1697 XX See magnum Literature K1803 1 Description LN 25 IRONWOR...

Страница 16: ...841 Description LN 25 IRONWORKER Drive Roll Kit Welding Gun CV power Source Welding Cables CV Power Source with Twist Mate Connectors and no Remote Local Switch See Figure A 9 Place CV CC switch in the feeder in the CV position Work clip Work Electrode Jumper CV 250 CV 300 LN 25 IRONWORKER FIGURE A 9 K K2614 9 KP1695 XX KP1696 XX KP1697 XX See Magnum Literature K1841 K852 95 K484 Description LN 25...

Страница 17: ...s Keep 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...

Страница 18: ...5 IRONWORKER 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 set up menu on meters with digi tal displays RECOMMENDED PROCESSES GMAW FCAW PROCESS LIMITATIONS GMAW P procedures must be qualified by t...

Страница 19: ... activated For example if the original wfs 200 in min the feed er 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 b 3 OPERATION b 3 See Customer Assistance Policy in the front of this Instruction Manual CASE FRONT CONTROLS See Figure b 1 ITEM DES...

Страница 20: ...ay 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 speeds The right display shows the arc voltage If the wire feeder is connected for electrode negative welding then the voltage display shows a minus sig...

Страница 21: ... 9 or 1 2mm solid steel wires at high wire feed speeds To change the Run in setting Rotate the WFS knob to the left to turn Run In OFF US V A O O O O WFS LN 25 IRONWORKER U o r E V A O O O O WFS LN 25 IRONWORKER Rotate the WFS knob to the right to turn Run In ON Then rotate the WFS knob to the 12 o clock position Press the set up button again to enter the WFS cali bration menu WFS CALIbRATION Meas...

Страница 22: ...n AMPERAGE CALIbRATION Measurements for adjusting the Amperage calibration must be made before entering the set up menu When first entering Amperage Calibration the calibra tion factor displayed is the value in memory If the knob is rotated the calibration factor changes based upon the position of the knob If no changes are being made to the calibration then press the set up button to enter Displa...

Страница 23: ...ment Arm 3 Optional Timer Kit See Accessories Section 4 Spool Retainer 5 Spindle Brake 6 Gun Bushing ITEM DESCRIPTION 1 9 8 7 6 3 2 7 Thumb Screw for securing the welding Gun 8 Socket Head Cap Screw for securing the Gun Bushing 4 5 9 Drive Hubs 11 Cold Feed Pushbutton 10 Inlet Wire Guide 11 10 FIGURE b 2 ...

Страница 24: ...terlock operation provides for operator com fort 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 feed i...

Страница 25: ...otor 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 b 9 OPERATION b 9 REAR CONTROLS LN 25 IRONWORKER 1 Gas Purge Pushbutton 2 Shielding Gas Inlet 3 Electrode Lead ITEM DESCRIPTION 1 2 3 ...

Страница 26: ...o Lug 2 0 Cable 9 2 7m long 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 Lug to Lug 4 0 Cable of length xx for lengths greater than 60 18 3m K484 Jumper Plug Kit Includes 14 pin circular con nector with jumper for leads 2 4 For use in power sources for turning the weld terminals ON at all times K2330 2 K2596 2 Timer Kit Pla...

Страница 27: ... connectors Magnum 200 300 400 guns and compatible with Tweco 2 4 Gun Receiver Bushing for guns with K613 7 Lincoln gun connec tors Magnum 550 guns and com patible with Tweco 5 Includes One 300 Amp Ground Clamp Includes One 500 Amp Ground Clamp Includes Gun receiver bush ing set screw and hex key wrench Includes Gun receiver bush ing with hose nipple set screw and hex key wrench Includes Gun recei...

Страница 28: ...er spools on 2 in 51 mm spindles Deluxe Adjustable Gas Regulator Wire Feed Speed Meter Includes Gun receiver bush ing with hose nipple set screw and hex key wrench Includes Gun receiver bushing with hose nipple 4 guide tubes set screw and hex key 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 w...

Страница 29: ...n energized several seconds after the gun trigger is released Do not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work D 1 MAINTENANCE D 1 LN 25 IRONWORKER WARNING SAFETY PRECAUTIONS ROUTINE MAINTENANCE Check weld cables control cables and gas hoses for cuts Clean and tighten all weld terminals PERIODIC MAINTENANCE Clean drive rolls and ...

Страница 30: ...ervice 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 a...

Страница 31: ...1 Motor overload long term Err 82 Motor overload short term 1 The wire drive motor has over heated 1 The wire drive motor current draw has exceeded limits usually because the motor is in a locked rotor state 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...

Страница 32: ... solenoid 5 There is a loose solenoid connec tion 6 The solenoid has failed 1 The gun cable is kinked and or twisted 2 The wire is jammed in the gun and cable 3 The gun liner is dirty or worn 4 The electrode is rusty or dirty 5 The contact tip is partially melted or has spatter 6 Improper gun liner tip drive rolls and or inner wire guide 1 Connect the work sense lead to the work in a location free...

Страница 33: ...achometer is connected improperly 2 The tachometer has failed 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 The Run In switch is ON 1 Improper procedures or tech niques 7 Adjust the tension arm per the Instruct...

Страница 34: ... 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 ...

Страница 35: ...F 2 DIMENSION PRINT F 2 LN 25 IRONWORKER 16 CIRCLE 12 x 18 ELLIPSE 23 17 14 81 8 65 17 19 ...

Страница 36: ...NOTES LN 25 IRONWORKER ...

Страница 37: ...NOTES LN 25 IRONWORKER ...

Страница 38: ... electrically live parts or 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 moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

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

Страница 40: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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