IM677-A
RED-D-ARC February, 2005
LN-25 PORTABLE CV/CC
SEMIAUTOMATIC WIRE FEEDER
10731
For use with machines having Code Numbers:
RETURN TO MAIN INDEX
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.
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.
1-800-245-3660
North America’s Largest Fleet of Welding Equipment
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER 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 available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland,
Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY
QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to 2.a. Electric current flowing through any conductor causes
prevent spilled fuel from vaporizing on contact localized Electric and Magnetic Fields (EMF). Welding
with hot engine parts and igniting. Do not spill current creates EMF fields around welding cables and
fuel when filling tank. If fuel is spilled, wipe it up welding machines
and do not start engine until fumes have been
eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in position before welding.
and in good repair.Keep hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts when starting, 2.c. Exposure to EMF fields in welding may have other health
operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do
2.d.3. Do not place your body between the electrode and
not attempt to override the governor or idler by
pushing on the throttle control rods while the work cables. If the electrode cable is on your right
engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free-
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your
full area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings
or scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable
or accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) fumes and gases.When welding, keep
Welder. your head out of the fume. Use enough
� DC Manual (Stick) Welder. ventilation and/or exhaust at the arc to keep
� AC Welder with Reduced Voltage Control. fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic instructions on container or MSDS) or on lead or
welding gun are also electrically “hot�. cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical also required when welding on galvanized steel.
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.f. Maintain the electrode holder, work clamp, welding cable
The heat and rays of the arc can react with solvent vapors to
and welding machine in good, safe operating condition.
form phosgene, a highly toxic gas, and other irritating
Replace damaged insulation.
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
3.h. Never simultaneously touch electrically “hot� parts of
especially in confined areas, to insure breathing air is safe.
electrode holders connected to two welders because volt-
age between the two can be the total of the open circuit volt-
5.d. Read and understand the manufacturer’s instructions for this
age of both welders.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.i. When working above floor level, use a safety belt to protect
employer’s safety practices. MSDS forms are available from
yourself from a fall should you get a shock.
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
8.b. Install equipment in accordance with the U.S. National
create fire hazards or overheat lifting chains or cables until
Electrical Code, all local codes and the manufacturer’s
they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
7. Quand on ne soude pas, poser la pince à une endroit isolé de
et les précautions de sûreté specifiques qui parraissent dans ce
la masse. Un court-circuit accidental peut provoquer un échauf-
manuel aussi bien que les précautions de sûreté générales suiv-
fement et un risque d’incendie.
antes:
8. S’assurer que la masse est connectée le plus prés possible de
Sûreté Pour Soudage A L’Arc
la zone de travail qu’il est pratique de le faire. Si on place la
1. Protegez-vous contre la secousse électrique:
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
a. Les circuits à l’électrode et à la piéce sont sous tension
passer le courant de soudage par les chaines de levage,
quand la machine à souder est en marche. Eviter toujours
câbles de grue, ou autres circuits. Cela peut provoquer des
tout contact entre les parties sous tension et la peau nue
risques d’incendie ou d’echauffement des chaines et des
ou les vétements mouillés. Porter des gants secs et sans
câbles jusqu’� ce qu’ils se rompent.
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
9. Assurer une ventilation suffisante dans la zone de soudage.
soude dans des endroits humides, ou sur un plancher met-
Ceci est particuliérement important pour le soudage de tôles
allique ou des grilles metalliques, principalement dans
galvanisées plombées, ou cadmiées ou tout autre métal qui
les positions assis ou couché pour lesquelles une grande
produit des fumeés toxiques.
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
10. Ne pas souder en présence de vapeurs de chlore provenant
soudage et la machine à souder en bon et sûr état defonc-
d’opérations de dégraissage, nettoyage ou pistolage. La
tionnement.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
d.Ne jamais plonger le porte-électrode dans l’eau pour le
du solvant pour produire du phosgéne (gas fortement toxique)
refroidir.
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
parce que la tension entre les deux pinces peut être le total
le code “Code for safety in welding and cutting� CSA Standard
de la tension à vide des deux machines.
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
LES MACHINES À SOUDER À
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
TRANSFORMATEUR ET À
du corps.
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi 1. Relier à la terre le chassis du poste conformement au code de
qu’un verre blanc afin de se protéger les yeux du rayon- l’électricité et aux recommendations du fabricant. Le dispositif
nement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une bonne
quand on regarde l’arc. mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debrancher
4. Des gouttes de laitier en fusion sont émises de l’arc de à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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.
Mar. �93
v v
for selecting a QUALITY product. We want you to take pride in
Thank You operating this product •â?¢â?? as much pride as we have in bring-
ing 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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and
keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for
your protection. The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury
or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or dam-
age to this equipment.
TABLE OF CONTENTS
SAFETY ...............................................................................................................................................i-iv
INSTALLATION .......................................................................................................................SECTION A
Technical Specifications.....................................................................................................................A-1
Safety Precautions .............................................................................................................................A-2
Power Source Connections ................................................................................................................A-2
Gun Cable Connection to Feeder ......................................................................................................A-3
Weld Cable Connection......................................................................................................................A-4
Electrode Cable Connection ..........................................................................................................A-4
Work Cable Connection .................................................................................................................A-4
Wire Feed Drive Roll and Guide Tube Kits ........................................................................................A-4
OPERATION ............................................................................................................................SECTION B
Safety Precautions .............................................................................................................................B-1
General Description............................................................................................................................B-1
Recommended Processes and Equipment ........................................................................................B-1
Welding Capability .............................................................................................................................B-1
Controls and Settings.........................................................................................................................B-2
Sequence of Operation ......................................................................................................................B-4
Loading Electrode ..........................................................................................................................B-4
Loading Wire Drive ........................................................................................................................B-5
Idle Roll Pressure Setting ..............................................................................................................B-5
Presetting Wire Feed Speed ..........................................................................................................B-6
Making a Weld ...............................................................................................................................B-7
Procedure at End of Coil....................................................................................................................B-8
Automatic Protection Shutdown .........................................................................................................B-9
ACCESSORIES........................................................................................................................SECTION C
LN-25 Option Chart............................................................................................................................C-1
Options and Accessories ...................................................................................................................C-1
K430-2 Gas Solenoid Kit ...............................................................................................................C-1
K443-2 LN-25 Contactor Kit...........................................................................................................C-1
K557-1 Rear Handle Kit.................................................................................................................C-1
Gun Cable Connector Requirements .............................................................................................C-2
MAINTENANCE .......................................................................................................................SECTION D
Safety Precautions .............................................................................................................................D-1
Routine Maintenance .........................................................................................................................D-1
Circuit Protection and Automatic Shutdown .......................................................................................D-1
Adjusting Speed Sensor Module........................................................................................................D-1
Calibration of the LN-25 Wire Speed Dial ..........................................................................................D-2
TROUBLESHOOTING GUIDE .................................................................................................SECTION E
How to Use the Troubleshooting Guide .............................................................................................E-1
Troubleshooting Guide .......................................................................................................................E-2
WIRING DIAGRAM ..........................................................................................................SECTION F1,F-2
PHYSICAL DIMENSIONS ......................................................................................................SECTION F3
PARTS MANUAL ..................................................................................................................P374 SERIES
INSTALLATION
A-1 A-1
TECHNICAL SPECIFICATIONS � LN-25
V O LTA G E
OPERATING ARC VOLTAGE
Constant Voltage (CV)
or 15-40 VDC (110VDC Maximum OCV)
Constant Current (CC)
R RATED C U R R E N T
AT E D CURRENT
Rated current without contactor 500 Amps 60% Duty Cycle
Rated current with contactor 300 Amps 60% Duty Cycle
W I R E SPEED RANGE
WIRE F E E D S P E E D
50 � 700 Inches Per Minute (IPM)
WIRE DIAMETERS
RECOMMENDED ELECTRODE WIRE SIZES
â?16â€?
1
.023� to SOLID STEEL WIRE
.045â€? to â?64â€?
5
CORED WIRE
.035â€? to 1â?16â€? ALUMINUM WIRE
PHYSICAL DIMENSIONS
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
(Handle Down) w/o Options
14 Inches 7.4 Inches 21 Inches 28 lbs
(354 mm) (187 mm) (531 mm) (13 kg)
TEMPERATURE RANGE
OPERATION: - 40o C to +40o C (- 40o F to +104o F)
STORAGE: - 40o C to +85o C (- 40o F to +185o F)
E N V I R O N M E N TA L R AT I N G
IP23 (IEC529)
LN-25
INSTALLATION A-2
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
� Turn off power source before
welding power source is on.
installing or servicing.
� Unless an optional output control or contactor
� Do not touch electrically
is used with the LN-25, the electrode circuit
hot parts.
(including welding wire, wire drive and welding
gun) is electrically hot when the welding power � Turn the input power to the
source is on. The gun trigger controls wire feed welding power source off at the
only. fuse box before working on the
� Disconnect or shut off welding power source terminal strip.
before making connections or installations to the
LN-25. � Only qualified personnel should
� Welding gun should be stored in the install, use or service this
insulated gun holder, located near the rear on equipment.
the top of the LN-25 case, to avoid accidental ----------------------------------------------------------------------
DC-250
arcing.
� The LN-25 should be positioned upright on a
a. Connect a jumper from 2 to 4 on the power source
horizontal surface.
terminal strip so the output will be energized when
----------------------------------------------------------------------
POWER SOURCE CONNECTION the DC-250 is turned on.
b. Connect electrode cable to the “Innershield/ GMAW�
The LN-25 can be used with most DC welding power
output terminal of polarity required by electrode.
source. A constant voltage power source is
Connect work lead to other “Innershield/GMAW�
recommended; however, the LN-25 can also be used
output terminal.
with a constant current power source as long as the
open circuit voltage is less than 110V DC.
c. Place “Set to CV Electrode Cable Polarity� switch
at appropriate position.
CAUTION d. Place power source toggle switch in “Output
Control at DC-250� position, unless a Remote
Do not use LN-25 models below Code 9200 with
Control is connected to 75, 76 and 77 on the DC-
any TIG or Square Wave welding power sources.
250 terminal strip.
Do not use LN-25 models equipped with internal
contactors with non- Lincoln TIG or Square Wave e. Place mode switch in “Innershield GMAW (CV)�
welding power sources. Damage to the LN-25 position. Set CV arc control to �2� (or “NORMAL�
circuit can occur as a result of the high output on some machines). Initially set the output control
inductance typically associated with these power on �7�.
sources. TIG high frequency power should never be
applied to the LN-25.
DC-400 AND CV-400
If not using an LN-25 Remote Output Control
a. Connect a jumper from 2 to 4 on the power source
option (See Remote Output Control Options and
terminal strip so the output will be energized when
Cable Assemblies Section), the power source
the power source is turned on.
output must be electrically “hot� at all times when
the power source is turned on. NOTE: DC-400 machines above Code 9200 have an
output toggle switch to perform this function.
----------------------------------------------------------------------
b. Connect the electrode cable to the output terminal
See the power source instruction manual for proper of polarity required by electrode. Connect work
power source connections and setting required. lead to other output terminal.
LN-25
INSTALLATION
A-3 A-3
c. Place “Set to Same Polarity As Electrode Cable c. Set ELECTRODE POLARITY switch to constant
Connection� switch at appropriate position. voltage polarity required by electrode.
d. Place power source toggle switch in “Output d. Set toggle switch to “Constant Voltage� and set
Control at DC(CV) -400� position, unless a remote the Constant Voltage Control on welder and the
control is connected to 75, 76 and 77 on the portable field control on #5 for initial start.
power source terminal strip.
SA-200, �250 OR SAE-300, �400 (WITH
e. If power source has a mode switch, set switch to
CV ADAPTER)
Constant Voltage Innershield. Initially set the
output control on �6�.
a. For electrode negative welding, connect the
electrode lead from the LN-25 to the output
DC-600 terminal on the CV Adapter, and the work lead to
the power source output terminal labeled
a. Connect a jumper from 2 to 4 on the power source
“POSITIVE�. For electrode positive welding,
terminal strip so the output will be energized when
interchange the above lead connections so the
the DC-600 is turned on. (For DC-600 below Code
LN-25 electrode lead is then connected to the
8200, also jumper N to S.)
positive power source terminal.
b. Connect the electrode cable to the output terminal
b. Place both switches on the CV Adapter to the CV
of polarity required by electrode. Connect work
INNERSHIELD position and make appropriate
lead to other output terminal.
power source settings per the CV Adapter instruc-
c. Place “Set to Same Polarity As Electrode Cable tions provided for the power source being used.
Connection� switch at appropriate position.
c. The output voltage is set with the voltage control
d. Place power source toggle switch in “Output on the CV Adapter.
Control at DC-600� position, unless a remote
NOTE: Refer to the Instruction Manual provided with
control is connected to 75, 76 and 77 on the DC-
the machine for details on connection and operation
600 terminal strip.
of the LN-25 with the power source.
e. Set mode switch to Constant Voltage Innershield.
Initially set output control on �4�.
INVERTEC, CV300 AND OTHER NEWER
LINCOLN POWER SOURCES
R3S-325
Refer to the instruction manual provided with the
a. Connect a jumper from 4 to 32 on the power
power source for details on connection and operation
source terminal strip so that the output will be
of the LN-25 with these newer machines.
energized when the R3S-325 is turned on.
b. Connect the electrode cable to the output terminal GUN CABLE CONNECTION
of polarity required by electrode. Connect work
TO FEEDER
lead to other output terminal.
c. Set power source per its instruction manual.
Lay the cable out straight. Insert the connector on the
welding conductor cable into the brass conductor block
NOTE: Use of the optional Line Voltage
on the front of the wire drive unit. Make sure it is all the
Compensator available for the R3S-325 is
way in and tighten the hand wheel clamp. Keep this
recommended if input line voltage variation
connection clean and bright. Connect the control cable
exceeds ±3%.
polarized amphenol plug into the mating 5-cavity
receptacle on the front panel of the wire feeder case.
SAM-400, �650
FOR GMA GUN AND CABLES:
a. Connect a jumper from 2 to C4 on the power
source terminal strip so the output will be
Requires installation of K430-1 Gas Solenoid Kit
energized when the SAM power source is on.
(factory installed on K446 and K449 models).
b. Connect work lead to WORK stud. Connect
See K430-1 Gas Solenoid Kit Section (in Accessories
electrode to AUTO EQUIPMENT stud. Connect
Section) for gas solenoid operation and gas supply
SAM-650 “Tap� lead to the Innershield stud
connection.
desired.
LN-25
INSTALLATION
A-4 A-4
Install the barbed fitting and union nut to the 5â?8-18 WIRE FEED DRIVE ROLL AND
female inert gas fitting on the front panel of the LN-
GUIDE TUBE KITS
25 case. Connect the 3â?16â€? I.D. gas hose from the gun
cable to the barbed fitting.
WARNING
When the gun is to be removed, this fitting can be
easily detached by loosening the union nut.
Turn off welding power source before installing
or changing drive roll and/or guide tubes.
WELD CABLE CONNECTION
--------------------------------------------------------------------
The size of the electrode cable and work cable must
NOTE: The maximum wire sizes the LN-25 will
be sufficient for the maximum weld current and total
satisfactorily feed are 5â?64â€? cored and 1â?16â€? solid
cable length to be used. Refer to table A.1.
electrodes.
TABLE A.1
The electrode sizes that can be fed with each roll and
guide tube are stencilled(1) on each part. Check the kit
Total Cable Length
Weld Current for proper components. See the instructions, included
60% Duty Cycle 50�-100� 100�-150� 150�-200� 200�-250�
with the drive roll kit, to install these parts on new
machines or replace them on used machines. Refer
200Amps 2 AWG 2 AWG 1 AWG 1/0
300Amps 1 AWG 1 AWG 1/0 2/0 to table A.2.
400Amps 2/0 2/0 3/0 3/0
500Amps 2/0 3/0 3/0 4/0
TABLE A.2
ELECTRODE CABLE CONNECTION Kit Instructions
Route the electrode cable through the oval hole in the Steel Wire Sizes:
lower portion of the LN-25 rear panel. Connect the .068-5â?64 Cored KP653-3â?32 L9932
â?16 (.062) Cored or Solid -1â?16
1
electrode cable to the LN-25 input stud using the 1â?2â€? Steel
nut provided. (Can also be used for .052)
.045 and .052 Solid Steel -.052
.045 and .052 Cored -.052C
Secure the cable with the strain relief clamp provided.
.035 Solid Steel -.035S
All units are supplied with an optional pigtail for .035 Cored -.035C
customers that prefer to make a taped and bolted .030 Solid Steel -.030S
.025 Solid Steel -.025S
connection externally.
WORK CABLE CONNECTION Aluminum Wire Sizes:
KP654-1â?16A
â?16 L9932
1
â?64 -3â?64A
3
Connect a work lead of sufficient size between the .035 -.035A
proper output stud on the power source and the
Drive rolls for only cored electrode sizes are stencilled with a
(1)
work. Be sure the connection to the work makes
“C� suffix to the wire sizes.
t i g h t m e t a l - t o - m e t a l e l e c t r i c a l c o n t a c t . Poor
work lead connections can result in poor welding Drive rolls for only solid electrode sizes are stencilled with an
“S� suffix to the wire sizes.
performance.
Drive rolls for aluminum wire sizes are stencilled with an “A� suffix
to the wire sizes.
LN-25
OPERATION B-1
B-1
SAFETY PRECAUTIONS GENERAL DESCRIPTION
The LN-25 is a lightweight portable semiautomatic
READ AND UNDERSTAND ENTIRE SECTION
wire feeder designed for “across-the-arc� operation
BEFORE OPERATING MACHINE without a control cable on most any DC welding power
source. Simply connect the LN-25 to the electrode
cable, clip it to Work and it is ready to weld, using up
to 30 lb. coils or spools.
WARNING The wire drive, controls and wire reel are fully
enclosed in a rugged molded plastic case providing a
ELECTRIC SHOCK can kill.
compact and versatile welding package ideally suited
to “on-the-go� field welding applications in virtually any
� Do not touch electrically live
environment.
part or electrode with skin or
wet clothing.
� Insulate yourself from work
RECOMMENDED PROCESSES
and ground.
AND EQUIPMENT
� Always wear dry insulating
gloves.
When combined with the quality drive roll kits and
accessories available for use with the LN-25, a
FUMES AND GASSES can be
versatile portable welding system can be provided to
dangerous.
meet the specific needs of Innershield, submerged arc
or gas metal arc welding applications within the wire
� Keep your head out of fumes.
feed capabilities of the LN-25.
� Use enough ventilation or
The LN-25 provides constant wire feed speed for use
exhaust at the arc, or both, to
with constant voltage (CV) power sources, and arc-
remove fumes from your
sensing wire feed speed for use with constant current
breathing zone and general
(CC) (formerly variable voltage) power sources. Wire
area.
speed is presettable on a dual-range calibrated dial.
WELDING SPARKS can cause The power sources recommended for use with the LN-
fire or explosion. 25 include the DC-250, -400, -600, CV-400 and R3S
type transformer machines, and the SAM-400, -650
� Keep flammable material
engine welders, as well as the SA-200, -250 or SAE-
away.
300, -400 with CV Adapter and Pulse Power 500 with
K460-1 LN-25 Kit.
� Do not weld on containers
which have held flammable
WELDING CAPABILITY
material.
The LN-25 will handle up to 500 Amp 60% duty cycle
ARC RAYS can burn.
welding currents. However, when equipped with a
� Wear eye, ear and body pro- K443-2 Contactor, the LN-25 will handle up to 300
tection. Amp 60% duty cycle.
LN-25
OPERATION B-2
B-2
NOTE:
LN-25 INSTRUMENTS AND
CONTROLS 1. The Voltmeter will read zero if the LN-25 work clip
lead is not connected to work, even if the elec-
trode is electrically “hot� to work.
Refer to Figure B.1 for control locations.
2. The Voltmeter will read below zero if the LN-25
REMOTE WIRE SPEED
polarity switch is not set to the same polarity as
ARC VOLTAGE DIAL RANGE
CONTROL SWITCH the electrode.
(OPTIONAL)
3. The Voltmeter will read power source open circuit
WIRE
voltage when the gun trigger is open, even if the
SPEED
LN-25 is equipped with the internal contactor.
DIAL
“ELECTRODE POLARITY� SWITCH
VOLT
GAS POST/ METER
The polarity switch is located on the front panel of the
PRE FLOW
LN-25 case.
TIMERS
(OPTIONAL)
Set the switch to the same polarity as the electrode
lead connection to the power source. If the switch is
ELECTRODE
POLARITY not set for the correct polarity, the wire feeder will not
WORK CLIP
SWITCH
LEAD operate.
GAS
FITTING GUN
WIRE FEED MODE SWITCH
(OPTIONAL) CONNECTION
BLOCK
GUN
The CV-VV (CC) Wire Feed Mode switch is located
TRIGGER
inside the LN-25 case. The toggle switch extends from
AMPHENOL
beneath the control box just above the wire drive.
CONNECTOR
The forward “CV� position provides constant wire feed
speed mode for use with constant voltage (CV)
welding power sources.
The backward “VV (CC)� position provides arc-sensing
wire feed speed mode for use with constant current
OPTIONAL
GAS INPUT
(formerly variable voltage) welding power sources.
FITTING
WIRE SPEED DIAL AND RANGE SWITCH
GAS PURGE
The Wire Speed control dial on the front panel of the
BUTTON
LN-25 has two calibrated dial ranges selected by the
HI-LO Dial Range switch.
When switched to the LO range position, the constant
wire feed speed (CV Wire Feed Mode) is set on the
ELECTRODE
inside (white) dial range calibrated for 50 to 350
CABLE
in/min.
When switched to the HI range position, the constant
FIGURE B.1 CONTROL LOCATIONS
wire feed speed (CV Wire Feed Mode) is set on the
outside (black) dial range calibrated for 50 to
VOLTMETER
700 in/min.
(Factory installed on model Codes above 9218)
The volts marks around the HI range calibrated dial
indicate the minimum arc volts required to obtain the
The 40V DC analog voltmeter is mounted to the front
indicated HI range wire feed speeds. For example; if
control panel of the LN-25 and is connected to read
wire speed is set to 400 in/min., a welding procedure
the arc voltage between the LN-25 electrode cable
arc voltage of at least 17V would be required to obtain
connection and the work clip lead.
the 400 in/min. wire feed speed.
LN-25
OPERATION B-3
B-3
WORK CLIP LEAD AWG Maximum Length
#14 25 Ft(7.6m)
WARNING #12 50 Ft(15.2m)
#10 100 Ft(30.5m)
ELECTRIC SHOCK can kill. #6 200 Ft(61m)
� Do not touch metal por-
GAS FITTING (OPTIONAL)
tions of the LN-25 lead
clip when welding power
Provides gas output connection to the welding gun for
source is on.
the GMAW process. Refer to K430-2 Gas Solenoid Kit
in the Accessories Section.
IMPORTANT SAFETY NOTE: To avoid possible
electrical shock, do not touch the metal portions of
the LN-25 work lead clip if the power source output is
on. The clip will be electrically “HOT� to work if the
input electrode cable to the LN-25 is electrically “HOT�
even if the gun trigger is off and even if an internal
contactor is used. Care should be taken to only handle
the LN-25 work clip by its non-metal insulated portions
and/or the welding power source should be turned off
before handling the work clip.
The 15 ft. (4.6m) work clip lead attached to the front
panel of the LN-25 case must be connected directly
to the work using the spring clip on the end of the lead.
If not connected, the LN-25 will not operate even if a
K431-1 or K624-1 (42V) Remote Output Control option
(refer to Accessories Section) is used. However, the
electrode will still be electrically “HOT� when the clip
lead is disconnected, if K431-1 or K624-1 (42V)
Remote Output Control Option, or Internal Contactor
(K443-2), is not used.
When used with a K460-1 Pulse Power Adapter Kit,
the LN-25 does not need a clip lead.
NOTE: The clip lead also serves as a work sensing
lead for the LN-25 Voltmeter (if installed). If the clip
lead is extended by the user beyond the standard 15
ft. length, the voltmeter reading will be lower than the
actual arc volts due to the LN-25 motor control cur-
rent flowing through the resistance of the extended
lead. To minimize this voltmeter error, the following
minimum lead size is recommended for the maximum
extended lengths shown:
LN-25
OPERATION B-4
B-4
SEQUENCE OF OPERATION g. To remove Readi-Reel from Adapter, depress re-
taining spring tab with thumb while pulling the
LOADING ELECTRODE Readi-Reel cage from the molded adapter with
both hands. It is not necessary to remove
WARNING adapter from spindle.
ELECTRIC SHOCK can kill. h. Load wire into wire drive per Loading Wire Drive
Section.
� Unless an optional output
control or internal contac- MOUNTING 10 TO 30 LB SPOOLS
tor is used with the LN-25,
the electrode circuit is For 12� Diameter Spools:
electrically “Hot� when
a. Remove the locking collar and the Readi-Reel
the power source is on.
adapter (if so equipped) on the 2� diameter
� Turn off the Welding spindle (adapter is not required).
power source while
b. Place the spool on the spindle so the brake
mounting electrode coils.
holding pin enters one of the holes in the back
side of the spool. Be sure the wire comes off the
MOUNTING 22 TO 30 LB READI-REEL® COILS spool in a clockwise direction when dereeled
from the bottom of the coil.
The LN-25 will require an optional K363-P Readi-
c. Replace and tighten the locking collar.
Reel® Adapter which is required to load Lincoln 22 to
30 lb Readi-Reel coils.
d. See Loading Wire Drive section for loading
instructions.
a. Make certain that the threaded locking collar is
tight and securely locks the adapter on the
For 8� Diameter Spools (Requires optional K468
spindle (see figure B.2).
Spindle Adapter for 8� Spools):
b. Rotate the spindle and adapter so the retaining
a. Remove the locking collar and the Readi-Reel
spring is at the 12 o’clock position.
adapter (if so equipped) on the 2� diameter
c. Position the Readi-Reel so that it will rotate in a spindle (adapter is not required).
clockwise direction when feeding (wire is to be
b. Slide S18221 Spindle Adapter onto the 2�
dereeled from bottom of the coil).
spindle so the brake holding pin enters the
d. Set one of the Readi-Reel inside cage wires on adapter pin hole.
the slot in the retaining spring tab.
c. Place the spool on the spindle so the adapter tab
e. Lower the Readi-Reel to depress the retaining enters one of the holes in the back side of the
spring and align the other inside cage wires with spool. Be sure the wire comes off the spool in a
the grooves in the molded adapter. clockwise direction when dereeled from the
bottom of the coil.
f. Slide cage all the way onto the adapter until the
retaining spring “pops up� fully. d. Replace and tighten the Locking Collar.
e. Load wire into wire drive per Loading Wire Drive
Section.
CAUTION
MOUNTING 13 OR 14 LB INNERSHIELD COILS
(Requires Optional K435 Spindle Adapter for 14 lb
Check to be sure the retaining spring has fully
Coils.)
returned to the locking position and has securely
locked the Readi-Reel cage in place. Retaining
a. Remove the locking collar and the Readi-Reel
spring must rest on the cage, not the welding
adapter (if so equipped) on the 2� diameter
electrode.
spindle (adapter is not required).
-------------------------------------------------------------------- b. Mount K435 Spindle Adapter and Innershield coil
per the Instructions (S18256) included with the
K435.
LN-25
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
THREAD LOCKING COLLAR
a. Turn the reel or spool until the free end of the
f. Inch the electrode through the gun.
electrode is accessible.
g. Adjust the brake tension with the thumbscrew on
b. While tightly holding the electrode, cut off the
the spindle hub until the reel turns freely, but
bent end and straighten the first six inches. Cut
with little or no overrun when wire feeding is
off the first inch. (If the electrode is not properly
stopped. Do not over tighten.
straightened, it may not feed or may not go into
the outgoing guide tube causing a “bird nest�.)
CAUTION
c. Insert the free end through the incoming guide
tube to the drive roll. Keep gun in LN-25 gun holder when not feeding
wire to prevent accidental arcing.
d. Turn on the welding power source.
--------------------------------------------------------------------
WARNING IDLE ROLL PRESSURE SETTING
The idle roll pressure is set at the factory backed out
� Unless an optional output control or internal
two turns from full pressure. This is an approximate
contactor is used with the LN-25, the electrode
setting. For small wire sizes and aluminum wire, the
circuit is electrically “hot� when the power
optimum idle roll pressure varies with type of wire,
source is on.
surface condition, lubrication and hardness. The op-
timum idle roll setting can be determined as follows:
� When inching with gun trigger, the electrode
and drive mechanism are always “hot� to work
1. Press end of gun against a solid object that is
and ground. Use the “cold� inch switch on
electrically isolated from the welder output.
models with internal contactor.
Press the gun trigger for several seconds.
--------------------------------------------------------------------
2. If the wire “bird nests,� jams or breaks at the
drive roll, the idle roll pressure is too great. Back
e. Press the gun trigger and push the electrode
the pressure setting out 1â?2 turn, run new wire
until it just enters the drive roll.
through gun, and repeat above steps.
LN-25
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 1â?4 turn, lock the gun cable in place and
repeat the above steps.
PRESETTING WIRE FEED SPEED
The LN-25 permits accurate presetting of the desired
wire feed speed, before welding, in both CV and CC
wire feed modes.
SETTING CONSTANT WIRE FEED SPEED
(CV MODE)
a. Set Wire Feed Mode switch to CV position.
b. Set Dial Range switch to LO position for wire
feed speeds up to 350 in/min., or HI position for
wire feed speeds over 350 in/min.
FIGURE B.3 CC WIRE SPEED SETTING
c. Set Wire Feed dial to the desired wire feed
(Hl or LO Range)
speed on the selected calibrated dial range.
The wire speed will remain constant at the value set,
independent of arc voltage changes, as long as the b. Referring to the graph located above the Mode
arc voltage does not drop below the value per the switch (also shown in Figure B.3):
chart below for the max. wire feed speed shown: 1. Select the horizontal line representing the DE-
SIRED IN/MIN. for the welding procedure.
Maximum Speed Minimum Arc Volts (See example arrow line for 375 in/min.)
2. Select the diagonal line representing the ARC
350 IPM 15V
VOLTS to be used for the welding procedure.
400 IPM 17V
(See example arrow line for 29 volts.)
500 IPM 21V
600 IPM 24V 3. Determine the vertical line representing the
700 IPM 27V CC WIRE SPEED SETTING where the above
two lines cross. (See example arrow line for
SETTING ARC SENSING WIRE FEED SPEED 450.)
(VV [CC] MODE)
c. Set the Wire Speed dial to the value determined
in Step (3) above (450 for example used). Use
When using a constant current (formerly variable
HI Dial Range if value to be set is over 350.
voltage) power source, welding performance is im-
proved using arc sensing wire feed speed (VV [CC]
The wire will feed at the DESIRED IN/MIN speed
mode). In this wire feed mode the wire speed
when the welding power source is set to the arc
increases if arc voltage increases, and decreases if
voltage to be used for the weld procedure (375
arc voltage decreases, but remains constant at any
in/min. at 29V for example used).
specific voltage level.
A chart representation of the VV (CC) wire speed
The LN-25 permits accurate VV (CC) mode
setting graph is shown in Figure B.4, giving the Wire
presetting of the desired wire feed speed, for the
Speed dial setting required for the DESIRED IN/MIN
desired arc voltage to be used, by setting the Wire
and ARC VOLTS used for the welding procedures:
Speed dial in the following manner before welding:
a. Set Wire Feed Mode switch to VV (CC) position.
LN-25
OPERATION
B-7 B-7
MAKING A WELD
Arc Volts Used
Desired SETUP
In/Min 16 18 20 22 24 26 28 30 32 34
a. Connect work cable to metal to be welded. Work
50 109 97 88 80 73 67 63 58 55 51
cable must make good electrical contact to the
60 131 117 105 95 88 81 75 70 66 62
work. The work must also be grounded as stated
70 153 136 123 111 102 94 88 82 77 72
80 175 156 140 127 117 108 100 93 88 82 in “Arc Welding Safety Precautions.�
90 197 175 158 143 131 121 113 105 98 93
b. Check that the LN-25 is properly connected to
100 219 194 175 159 146 135 125 117 109 103
the power source for the polarity and process to
110 241 214 193 175 160 148 138 128 120 113
be used, and appropriate power source settings
120 263 233 210 191 175 162 150 140 131 124
are made for the procedure to be used. (Refer to
130 284 253 228 207 190 175 163 152 142 134
140 306 272 245 223 204 188 175 163 153 144 power source operating and connection
instructions.)
150 328 292 263 239 219 202 188 175 164 154
160 350 311 280 255 233 215 200 187 175 165
NOTE: If the K431-1 Remote Output Control Kit or
170 372 331 298 270 248 229 213 198 186 175
K624-1 42V Remote Control Module is installed but
180 394 350 315 286 263 242 225 210 197 185
190 416 369 333 302 277 256 238 222 208 196 the LN-25 is to be used without the K432 Remote
Control Cable Assembly, then the Remote Board
200 438 389 350 318 292 269 250 233 219 206
harness plug must be removed from the 16-pin
210 459 408 368 334 306 283 263 245 230 216
receptacle on the Control Board and the jumper plug
220 481 428 385 350 321 296 275 257 241 226
230 503 447 403 366 335 310 288 268 252 237 (T13498-21) reinstalled.
240 525 467 420 382 350 323 300 280 263 247
NOTE: If the K460-1 Pulse Power Adapter Kit is
250 547 486 438 398 365 337 313 292 273 257
installed but the LN-25 is to be used without the K461
260 569 506 455 414 379 350 325 303 284 268
Pulse Power Control Cable Assembly, then the
270 591 525 473 430 394 365 338 315 295 278
280 613 544 490 445 408 377 350 327 306 288 instructions for returning the unit to across the arc
290 634 564 508 461 423 390 363 338 317 299
operation included with the Installation Instructions
(L9636) must be followed.
300 656 583 525 477 438 404 375 350 328 309
310 678 603 543 493 452 417 388 362 339 319
c. Place the LN-25 conveniently near the work area
320 700 622 560 509 467 431 400 373 350 329
330 642 578 525 481 444 413 385 361 340 in a location to minimize exposure to weld spatter
340 661 595 541 496 458 425 397 372 350
and to avoid sharp bends in the gun cable.
350 681 613 557 510 471 438 408 383 360
d. Connect the LN-25 Clip Lead to work and set Po-
360 700 630 572 526 484 450 420 394 370
larity Switch to same polarity as electrode.
380 666 604 554 512 472 444 416 392
400 700 636 584 538 500 466 438 412
e. Set WIRE FEED MODE switch to CV or CC, as
420 668 612 566 526 490 460 432
appropriate for the power source, then set the
440 700 642 592 550 514 482 452 proper DIAL RANGE and WIRE SPEED dial set-
460 670 620 576 536 504 472
ting for the proper wire feed speed per the
480 700 646 600 560 526 494
welding procedure:
500 674 626 584 546 514
For CV: Set dial to the calibrated IN/MIN
520 700 650 606 568 536
desired. (Refer to Setting Constant Wire Feed
540 676 630 590 556
560 700 654 612 576 Speed Section.)
580 676 634 598
For CC: Set dial to value determined from the
600 700 656 618
CC Wire Speed Graph for the DESIRED IN/
620 678 638
MIN and ARC VOLTS to be used. (Refer to
640 700 658
Setting Arc Sensing Wire Feed Speed
660 680
Section.
680 700
700
NOTE: If procedure permits a range of acceptable
arc voltage, use the middle of the range to
VV (CC) Speed Setting = Desired IPM X 35
determine proper WIRE SPEED setting.
Arc Volts
f. If using the optional Gas Flow Timer, set the de-
FIGURE B.4 VV(CC) WIRE SPEED SETTING sired PREFLOW TIME and POSTFLOW TIME.
LN-25
OPERATION B-8
B-8
g. Be sure the proper contact tip for the wire size c. Lower welding helmet, close gun trigger, and
being used is in the gun, and the gun is safe begin welding. Hold the gun so the contact tip to
from work contact. (Use the LN-25 insulated work distance gives the correct electrical stick
gun holder.) out as required for the procedure being used.
NOTE: If the arc voltage is not within the proper
h. Turn on the welding power source, as well as the procedure range adjust the power source output
shielding gas supply (if used). control. (The CC mode WIRE SPEED setting should
not be changed from the preset procedure value for
WARNING the proper arc voltage.)
d. To stop welding, release the gun trigger and
� Unless an optional output control or then pull the gun away from the work. Store the
internal contactor is used, the gun in the LN-25 insulated gun holder when
electrode is electrically “hot� when the not welding.
power source is on. The gun trigger
controls wire feed only.
PROCEDURE AT END OF COIL
WARNING
When the wire on the reel is used up, the following
CYLINDER may explode if
procedure is to be followed for removing the old wire
damaged.
from the gun cable and loading a new reel.
� Keep cylinder upright and
a. Shut off power source if a Remote Output
chained to support.
Control Option or internal contactor is not used.
� Keep cylinder away from
b. Cut the end of the electrode off at the gun end.
areas where it may be dam-
Do not break it off by hand since this puts a slight
aged.
bend in the wire and makes it difficult or
impossible to pull it back through the nozzle.
� Never lift welder with cylin-
der attached
c. U n c o u p l e t h e g u n c o n d u c t o r c a b l e f r o m
the LN-25.
� Never allow welding elec-
trode to touch cylinder.
d. Lay the cable out straight.
� Keep cylinder away from
e. Using pliers to grip the wire, pull it out of the
welding or other live electri-
cable from the connector end. Do not pull it from
cal circuits.
the gun end.
f. Put the conductor cable back on wire drive unit
WELDING
after the electrode has been removed.
g. Load a new coil of wire and feed it through the
WARNING
cable as described in Loading Electrode Section.
ARC RAYS can burn.
OPEN ARC WELDING WITH A
� Do not touch metal por-
CONSTANT CURRENT POWER
tions of the LN-25 lead
SOURCE
Clip when welding power
source is on.
WARNING
a. Cut the electrode within approximately 3â?8â€? of the The LN-25 should be used with a constant current
end of the contact tip for solid wire and within machine only upon non-critical weldments and after
approximately 3â?4â€? of the extension guide for cored testing is done to assure quality is adequate for the
wire. application.
b. Position electrode over joint. End of electrode
should be slightly off the work.
LN-25
OPERATION B-9
B-9
Arc shorting is more difficult to avoid when using
CAUTION a CC power source, and requires a more refined
operator technique than when using a CV power
source. Improved performance can be obtained
Do not use LN-25 models below Code 9200 with
on CC power source applications within the
any TIG or Square Wave welding power sources.
following guidelines:
Do not use LN-25 models equipped with internal
contactors with non-Lincoln TIG or Square Wave 1. Flatter slope power sources with higher arc
welding power sources. Damage to the LN-25 circuit force (short circuit current) will improve
can occur as a result of the high output inductance performance over steep slope machines. The
typically associated with these power sources. TIG steeper the slope, the more critical it is to hold
high frequency power should never be applied to proper electrode stick out to maintain arc
the LN-25. stability. Welding techniques, such as weaving,
will be more difficult to control. Use the highest
output current tap or setting capable of providing
While welding with a continuously fed electrode, the voltage adjustment required for the
weld current variations are continuously taking place. procedure.
There are many causes for these variations, but
predominantly they occur due to changes in 2. Use spray or non-shorting small ball type
electrical stick out (operator hand movements, transfer processes at higher procedure voltage
nozzle tip contact variations, etc.) and the dynamic levels. Generally, open arc processes with
metal transfer characteristics of the process or procedure voltage levels over 22 volts perform
procedure being used (short arc, globular transfer, satisfactorily. Arc stability at procedure voltage
etc.). levels below 22 volts may be more difficult to
control, with the general exception of fine (.023�
When using a CV power source, these current .035) solid steel electrodes with Argon-rich
variations have essentially no effect on the welding shielding gas or NR-152 and NR-211 Innershield.
arc stability since CV power sources can provide a
wide range of weld current levels with virtually no
change in average arc voltage. These “flat slope� CV
AUTOMATIC PROTECTION
power sources, therefore, provide the arc power
SHUTDOWN
required to produce the best welding characteristics
and ease of operation for most open arc, constant
wire feed speed, welding processes. The LN-25 control provides automatic electronic
protection circuits which shut down the LN-25 for
CC (formerly VV) power sources, on the other hand, excessively high power source open circuit voltage
permit the arc voltage to decrease with increases in or excessive motor overload.
welding current. The output characteristics of these
power sources can range from a “drooping slope,�
OVERVOLTAGE SHUTDOWN
which provide minor arc voltage changes with weld
current variations, to “steep slope� which provide
If the power source open circuit voltage exceeds
broad voltage changes with only minor current
about 110-120 volts, the LN-25 will not operate until
variations. The steeper the slope the more difficult it
the power source voltage drops below about 102-
becomes to maintain arc voltage stability with a
110 volts.
constant wire speed open arc process.
MOTOR OVERLOAD SHUTDOWN
To aid in stabilizing the arc voltage when welding on
CC power sources the LN-25 is provided with a VV
If excessive motor overload occurs (due to prolonged
(CC) wire feed mode. This arc voltage sensing feed
excessive feeding force, jammed drive rolls or
mode decreases (or increases) the wire speed when
shorted motor leads), the LN-25 will shut down within
the arc voltage decreases (or increases). However,
a few seconds after the overload occurs.
if the electrode shorts to the work, the arc voltage
will essentially drop to zero and the short circuit
The shutdown will reset automatically when the gun
current supplied by the CC power source may not
trigger is released, but will reoccur if the overload
provide enough power to re-establish the arc
situation is not remedied.
(especially with steeper slope machines). Under this
condition the LN-25 feeder will stop, as if the trigger
was released, and not restart until the short has
been opened.
LN-25
ACCESSORIES
C-1 C-1
LN-25 MODELS-K449-2 WARNING
KIT NO. K430-2: Solenoid Kit
CYLINDER may explode if
damaged.
OPTIONAL ACCESSORIES
� Keep cylinder upright and
chained to support.
WARNING � Keep cylinder away from areas where it may be
damaged.
ELECTRIC SHOCK can kill.
� Never lift welder with cylinder attached.
� Do not operate with covers
removed. � Never allow welding electrode to touch cylinder.
� Keep cylinder away from welding or other live
� Turn Welding power source
electrical circuits.
off before installing or servic-
� See American National Standard Z-49.1, “Safety in Welding
ing.
and Cutting� published by the American Welding Society.
� Do not touch electrically hot
parts. See GMA Gun Cable Gas Connection.
Installation instructions (M19154) are included with the
� Turn the input power to the
kit.
welding power source off at
the fuse box before working
K577-1 REAR HANDLE KIT
in the terminal strip.
(For LN-25 model codes above 9383)
� Only qualified personnel
should install, use or ser-
The fold-down handle mounts to the rear of the LN25
vice this equipment.
case per the Installation Instructions (M16567)
shipped with the kit.
K430-2 GAS SOLENOID KIT
This handle provides a means to also carry the LN25
(For Codes above 10500 only) in the vertical position, especially convenient for pass-
ing the unit through a manhole.
(Factory Installed on K446 and K449 Models)
K363P READI-REEL ADAPTER KIT
The kit permits the LN-25 to be used for Gas
Adapts Lincoln Redi-Reel coils of electrode 30 lb. (14
Metal Arc Welding (GMAW) processes with a
kg) and 22 lb. (10 kg) to a 2� (51mm) spindle. Durable
GMA gun cable. molded plastic one piece construction. Designed for
easy loading; adapter remains on spindle for quick
The kit can be used with or without a Remote Output changeover.
Control option installed in the LN-25 and provides
flow of shielding gas:
1. With wire feed, when the gun trigger is closed.
2. Without wire feed, when the kit’s Purge button
(located beneath the gas inlet fitting) is pressed.
NOTE: Always shut off the valve at the gas cylinder
before making any gas connections to the LN-25.
User must provide a supply of shielding gas, a pres-
sure regulator, a flow control valve and a hose from
the flow valve to the gas inlet fitting of the LN-25.
Install by connecting a supply hose from the gas flow
valve outlet to the 5â?8-18 female inert gas fitting on the
back panel of the LN-25 case.
The LN-25 can be used with any shielding gas
recommended in the electrode’s product literature at
a maximum pressure of 60 psi (4.1 bar). This may
include gases such as Argon, Helium, Nitrogen and
blended gasses such as Ar-He, Ar-N2, Ar-O2, Ar-
CO2, CO2, Ar-CO2-O2.
LN-25
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
SWITCH REQUIREMENTS
should be made from brass if it is to be part of the
â?2 Amp AC 24 Volts â€? Inductive
1
welding current carrying circuit.
â?2 Amp DC 24 Volts â€? Inductive
1
“A Dia. Hole�
To be Concentric to .749/.747
Wire Size Dia. Within .008 F.I.M.
.068 thru 5â?64 .125 (1â?8 Drill)
â?16 (.062) .078 (5â?64 Drill)
1
.045 & .052 .062 (1â?16 Drill)
.023 thru .035 .055 (#54 Drill)
Drive Roll & Guide Tube Wire Sizes Used
Kit No.
T-13355-3â?32 â?64, .072 & .068
5
S12024-1 (L.E. Part No.)
T-13355-1â?16 â?16, .062
(1) 1
Amphenol AN3057-10 (or equiv.)
S12020-6 (L.E. Part No.)
T-13355-.052C .045, .052 Cored
Amphenol MS-3106A-18-11P (or equiv.)
T-13355-.052 .045, .052 Solid
T-15010.-.035S .023 thru .035 Solid
Can also be used for .052� wire
(1)
FIGURE C.2 SWITCH REQUIREMENTS
LN-25
MAINTENANCE D-1
D-1
CONTROL BOX
SAFETY PRECAUTIONS
Every six months open and inspect the control sec-
WARNING tion. The accumulated dirt should be gently blown off
all of the electrical components. Be sure the air that
ELECTRIC SHOCK can kill. is being used is dry. Check that lead plugs are secure
in their receptacles.
� Do not operate with covers
removed.
WIRE DRIVE MOTOR AND GEAR BOX
� Turn off power source before
Every year examine the gear box. Paint the gear teeth
installing or servicing.
with molydisulfide filled grease. Lincoln specification
� Do not touch electrically hot E2322. Do not use a graphite grease.
parts.
Check the motor brushes. Replace if they are worn
â€? Turn the input power to the down to 1â?4’â?? or less. When ordering feed motor
welding power source off at b r u s h e s , g i v e a l l i n f o r m a t i o n f r o m t h e motor
the fuse box before working nameplate.
in the terminal strip.
GUN AND CABLE MAINTENANCE
� Only qualified personnel
should install, use or ser-
See IM manual provided with the gun and cable as-
vice this equipment.
sembly.
CIRCUIT PROTECTION AND
ROUTINE MAINTENANCE AUTOMATIC SHUTDOWN
DRIVE ROLLS AND GUIDE TUBES
CONTROL PC BOARD
After feeding every coil of wire, inspect the drive roll
The Control P.C. Board has electronic protection for
section. Clean it as necessary. Do not use a solvent
trigger circuit faults to the electrode circuit.
for cleaning the idle roll because it may wash the lu-
bricant out of the bearing. The drive roll, idle roll and
AUTOMATIC PROTECTION SHUTDOWN
guide tubes are stamped with the wire sizes they will
feed. If a wire size other than that stamped on the rolls
is to be used, the rolls and guide tubes must be (See Automatic Protection Shutdown Section.)
changed.
ADJUSTING SPEED
The drive rolls for .035 through .052 cored electrode
SENSOR MODULE
and 1â?16 through 5â?64 electrode have a double set of teeth
so they can be reversed for additional life. Drive rolls
for .023 through .052 solid electrode and aluminum The LN-25 Speed Sensor Module is a three lead Hall
sizes have no teeth but use two grooves so they also Effect switch device encased in an externally threaded
can be reversed for additional life. housing which is screwed into a mounting plate on the
motor side of the wire drive gearbox.
See Wire Feed Drive Roll and Guide Tube Kits Sec-
tion for roll changing instructions. Proper positioning of this module is critical to proper
operation of the LN-25 wire feed speed control. If the
WIRE REEL SPINDLE device is not screwed in far enough, the LN-25 motor
speed could be unstable or run at full speed with no
No routine maintenance required. Do not lubricate control. If screwed in too far, it will rub a moving part
spindle. inside the gearbox.
LN-25
MAINTENANCE D-2
D-2
The module is properly mounted to the gearbox
WARNING
as shipped from the factory. If the device is ever
removed or replaced, proper mounting technique is
as follows: Electrode will be electrically “hot�. Do not allow
fed wire to touch your body or contact any metal
1. Be sure all power to the LN-25 is shut off at the
common with welding work.
power source.
--------------------------------------------------------------------
2. Check that the module mounting plate is screwed
securely to the side of the gearbox.
An alternate means to measure wire feed speed
is as follows:
3. Gently screw the module into the mounting plate
until it just touches and stops against the a. Cut wire off at the end of the gun tip.
rotating part inside the gearbox.
b. Press trigger to feed wire for exactly 30 seconds.
4. Back the module out 1â?2 turn, then snug the
c. Cut fed wire off at the end of the gun tip and
module lock nut without rotating the module
accurately measure its length.
position. Do not over tighten lock nut.
d. Multiply the measured length by 2 to obtain
the wire speed (IN/MIN).
CALIBRATION OF LN-25 WIRE
SPEED DIAL e. Repeat above steps to assure repeatable
accuracy.
Calibration of the LN-25 Wire Speed dial is achieved
4. Carefully slip speed knob onto potentiometer
by proper mounting of the dial knob to the speed
shaft so it points precisely to the wire speed
potentiometer shaft. Whenever the knob is removed,
measured in step 3, then secure the knob set
the dial is recalibrated as follows:
screw without disturbing the position. Recheck by
repeating step 3.
NOTE: Knob set screw does not seat on shaft flat.
1. Be sure the Wire Speed potentiometer mounting
nut is securely tightened, then rotate the
potentiometer shaft so its flat faces about to the
100 mark on the LO range calibrated dial.
2. Set DIAL RANGE switch to LO and WIRE FEED
MODE switch to CV position.
3. Press gun trigger to feed wire and measure
the wire feed speed (IN/MIN) using a Portable
Digital Wire Feed Speed Meter (Lincoln K283).
Take at least two readings to assure repeat-
able accuracy.
Feed Speed Meter (Lincoln K283). Take at least
two readings to assure repeatable accuracy.
LN-25
E-1 E-1
TROUBLESHOOTING
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform
TOMS)�. This column describes possible symptoms the Recommended Course of Action safely, contact
that the machine may exhibit. Find the listing that your local Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE�
lists the obvious external possibilities that may con-
tribute to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
LN-25
TROUBLESHOOTING E-2
E-2
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
FEEDING PROBLEMS
No wire feed when gun trigger is 1. Power source must be on
pulled 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
If all recommended possible areas
or missing.
of misadjustment have been
checked and the problem persists,
5. The power source O.C.V.
Contact your local Authorized
must be above 15 VDC. But
Field Service Facility.
not more than 110 VDC.
6. The gun trigger may be
faulty.- Replace gun.
Wire feeds for a short time but 1. The drive motor may be
stops feeding. When gun trigger overloaded. Check the wire
is released and retriggered wire feeding system. EX. Drive
feeding starts but stops again. roll tension, reel brake and
gun cable liner.
Wire feeds OK, but stubs or 1. If the power source is a
stops while welding. constant current type
supply the arc voltage may
be “dipping� below 15 VDC
causing the LN-25 to stop
or hesitate.
2. Connect a constant voltage
type power supply to the
LN-25.
3. Make sure wire-feed mode
switch (S3) is in the proper
position.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local authorized field service facility for technical troubleshooting assistance before you proceed.
LN-25
TROUBLESHOOTING E-3
E-3
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
FEEDING PROBLEMS
Rough wire feeding or wire not 1. Gun cable kinked and/or
feeding but drive rolls turning. twisted.
2. Wire jammed in gun and cable.
If all recommended possible areas
3. Incorrect size or installation
of misadjustment have been
of drive roll and guide tubes.
checked and the problem persists,
4. Drive roll loose. Contact your local Authorized
Field Service Facility.
5. Gun cable dirty.
6. Worn drive roll.
7. Electrode rusty and/or dirty.
8. Worn nozzle or cable liner.
9. Partially flashed or melted
contact tip.
10. Incorrect idle roll pressure.
11. Wire reel brake tension set
too high.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local authorized field service facility for technical troubleshooting assistance before you proceed.
LN-25
TROUBLESHOOTING E-4
E-4
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Solenoid does not close when 1. Make certain that plugs J2
trigger is pulled or purge button and J3 are connected to the
is pressed. Wire feeds properly. control board securely.
WELD PROBLEMS
Variable or “hunting� arc. 1. Worn and/or melted contact
tip -Replace. If all recommended possible
areas of misadjustment have
2. Worn work cable or poor
been checked and the problem
work connection.
persists, Contact your local
Authorized Field Service
3. Loose electrode connect-
Facility.
ions. -Check for loose or
faulty connections.
4. Wrong electrode polarity for
process being used.
Weld porosity, narrow and ropey 1. Contaminated weld joint or
bead, or electrode stubbing into improper procedures. -
plate when welding. Clean joint and check
procedure (wire speed and
all voltage).
Motor feeds but there is no wire 1. Make sure all molex plugs
feed speed control. and leads are securely
connected to the control
board.
2. Check speed sensor - see
maintenance section.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local authorized field service facility for technical troubleshooting assistance before you proceed.
LN-25
WIRING DIAGRAM - LN-25 FOR CODE 10731
F-1
TO REMOTE
S2 OR CONTACTOR
TIMER P.C.
WIRE SPEED DIAL 11 P.C. BOARD
BOARD
530
1
RANGE SWITCH 667 1 3
621 OPTIONAL REMOTE 530A
2
N.D.,N.E.
500 9 500A KIT PLUG
2 3 607
J1 N.A.
HI LO J10*
*
530 3 667 1 4 512
621 2 4
622A 5 500
J9 *
N.L. 607 8
523 606
6
500A
500
7 7
606 6
N.B. CONTACTOR
522
500
15 15
512 5 1
621
P C BOARD
607
607
9 9
530A 7 4
608
OPTIONAL TIMER KIT
622A
622
16 16
624 4 5 *
J2 512
512
13 13
13 2
632
ARC VOLTS
530A
530A
12 12
14 690 3
633 R3
667
10 10
12 691 6
75
624
624
14 14 A
10 75
R1 631 77
* 76 B
J3 500A
500A
8 8 76
10K SOLENOID P.C. 77 C
530
530
11 11
530A 2
BOARD PLUG
WIRE SPEED D
606
606
1 1
512 4
E
CONTROL RHEOSTAT
621
621
6 6
606 6 F
J6
N.B. * 622A
622A
5 5
607 3 N.D.
3 3
530 1 OPTIONAL REMOTE VOLTAGE CONTROL
2
2
500 5
CONTROL
4
4
ARC
J7 P.C. BOARD
* 2
1
VOLTMETER
41
2
+ 42
3
VM
4
4
* 41 A
2
1
OPTIONAL J12
OPTIONAL
* REMOTE
J4 5 42 B
621
667 TIMER CONTACTOR P.C. BOARD 6 2 C
PLUG P.C. BOARD PLUG D
7 4
E
8
500
530
N.G. F
75
G
76
622A
1
3 6 1 4 10 8 11 2 9 13 14 7 12 5
H
77
621
2
J6 *
500A
3
530A
4
509
632
523
522
633
523
524
631
539
541
500
555
512
76
530
5
621 75
77
624
6
N.G. *
1234 5 6 J8
667 606
7 R3
530 622
8
ARC VOLTS
RED
607
9
S3
500
BLUE
WHITE
BLACK
BLACK
512
621 10
N.B. WIRE FEED GAS
11
530
607
512
500
606
MODE SWITCH
TO WORK CLIP SOLENOID
530A
500
12
N.B., N.D., VALVE TO CONTROL BOARD
S4 VV
BLACK CV
690
N.H.
COLD INCH
TO TIMER P.C. BOARD
PUSHBUTTON
NEG
POS
524
S1 OPTIONAL 42 VOLT REMOTE OUTPUT CONTROL
523
509
SWITCH
POLARITY
691
SWITCH
75 A
N.B. REMOTE 701
1 76 B
667
N.L.
P.C. BOARD 700
2 77 C
*
S2 J13
LN-25
D
3 700
S1 N.D.
67 701
702 E
4
608
F
702
N.F. PURGE 622A
1
76
621
PUSHBUTTON 2 75
77
J6 *
S1 S5
N.F. 500A
3
S5
R3
530A
4
A 622A ARC VOLTS
530
5
N.L.
J5
RED
BLUE
BLACK
624
B 6
N.G. *
J13 1234 5 6 J8
* ESD SNUBBER
TRIGGER 606
7
C 500A
WIRING DIAGRAM
CONNECTOR 622
8
D 3 1 2 4
N.J.,N.K 607
9
E
512
10
NOTES 11
530
607
512
500
606
BLACK
WHITE
530A
500
12
U B R N.A. WHEN A CONTACTOR IS NOT USED THE JUMPER PLUG MUST BE
TO CONTROL BOARD
N.F.
INSTALLED UNLESS OPTIONAL REMOTE KIT IS BEING USED.
67 1 2
HALL TO TIMER P.C. BOARD
EFFECT CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT AND SWITCHES.
N.B.
OPTIONAL REMOTE OUTPUT CONTROL
INPUT SWITCH
N.D. ITEM FACTORY INSTALLED ON SOME MODELS AND OPTIONAL EQUIPMENT
CABLE
ON SOME MODELS.
CONTACTOR 667 A
66
7
REMOTE 1 34 4 B
N.E. CONTACTOR CAN BE INSTALLED IN UNITS WITH A G1757-3 (OR HIGHER 621
P.C. BOARD 2 33 33 C
*
J13
PART NO.) CONTROL PC BOARD.
CONTACTOR 3 D
34
21
GUN CABLE
COIL 4 E
4 21
541
539
N.F. WHEN A CONTACTOR IS NOT USED, THE '67' LEAD TO THE POLARITY
WHITE
BLACK
F
75
SWITCH COMES FROM THE CONDUCTOR BLOCK AND THE INPUT CABLE G
1 76
622A 76
CONNECTS DIRECTLY TO THE CONDUCTOR BLOCK.
N.F. H
2 77
621 77 75
J6 *
N.D.,N.E.
I
3 621
500A
N.G. JUMPER PLUG MUST BE INSTALLED UNLESS OPTIONAL TIMER IS USED. R3
4 530A
5 ARC VOLTS
530
N.H. TOGGLE SWITCH USED ON EARLIER UNITS.
N.G. 6 624
*
1234 5 6 TO
J8
N.J. PROVIDES AN ESD PATHWAY FROM EXPOSED METAL SURFACES TO THE WORK. 7 606
POLARITY
8 622
N.K. PRESENT ON EUROPEAN MODELS ONLY. SWITCH
9 607
LEGEND
10
N.L. CONNECTS TO THE BUSHING OF THE COMPONENT. 512
S1 POLARITY SWITCH 11
530
607
512
500
606
530A
12 500
S2 WIRE SPEED DIAL RANGE SWITCH CONNECTOR CAVITY NUMBER
*
S3 WIRE FEED MODE SWITCH TO CONTROL BOARD
S4 COLD INCH SWITCH TO TIMER P.C. BOARD
S5 PURGE PUSHBUTTON
OPTIONAL PULSE POWER ADAPTOR KIT
2-20-98A
F-1
L10925
NOTE: This diagram is for reference only. 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.
F-2
WIRING DIAGRAM - LN-25 FOR CODE 11146
N.B., N.D.,
OPTIONAL REMOTE N.H.
TIMER P.C.
S4 J7 KIT PLUG BOARD
COLD INCH CONTROL 530
1
1 6
530C 530B P.C. BOARD
PUSHBUTTON 530A
2
N.A.
500C 500B 7
SWITCH 2 3 607
J10
9 4 512
1 5 500
6
2 500
530A 7
5
530A 606
6
7 J14
4
512 4 15
512
9
6 607
606 9
606 8
1
622
16
607 3
3
5 OPTIONAL TIMER KIT
N.M. 530 512
13
1 530 10
4
530A
500 12
500
5 2
8
ARC VOLTS
10
3
R3
624
14
10 OPTIONAL J11
75
J3 A
500A
8
ARC 2 75
J14 77
TIMER PLUG 76 B
76
530
11
N.G.
VOLTMETER N.H. 77 C
3
621 621 606
1
D
+ 667 621
6
667 1 E
J1
VM
622A
500A 5
2 F
621 3
622A 4
667
2 OPTIONAL REMOTE VOLTAGE CONTROL
4
A 622A
J5
2
1
B
TRIGGER
N.B. 41
1
621 2
C 500A
CONNECTOR
42
3
TO 4
608
D
S1 S1 J4 4
4 41 A
BLACK 5
E J12
621 POLARITY J2 REMOTE 5 42 B
2
SWITCH
WORK CLIP P.C. BOARD 6 2 C
690 3 D
7 4
S5
NEG 691 6
POS E
8
PURGE
621 F
75
8 1 9 10 4 3 11 2 6 12 7 5 13 14
PUSHBUTTON
G
76
1 622A
SOLENOID P.C.
608 H
77
621
2
BOARD PLUG N.D. J6
N.L. 667 S5 500A
3
S1
539
523A
541
509
524
633
631
632
522
523B
512
500
555
530A
4
N.D.
N.L. 76
530
5
690
75
77
67 624
6
N.G.
GAS 1234 5 6 J8
606
7 R3
SOLENOID
RED
622
8
VALVE
BLUE
ARC VOLTS
WHITE
BLACK
BLACK
9 607
691 N.H. 512
10
11
530
607
512
500
606
530A
500
12
TO J3 ON
CONTROL BOARD
S1
TO TIMER P.C. BOARD
OPTIONAL 42 VOLT REMOTE OUTPUT CONTROL
N.F.
632
75 A
N.B. REMOTE 701
1 76 B
RED
BLUE
BLACK
522
523B
N.F.
523A
509
524
J16
631
P.C. BOARD
633
700
CW 2 77 C
J13
LN-25
ESD SNUBBER 3 D
700
R1 N.L. LO 3 1 2 4
HI
N.J.,N.K 701
702 E
4
VV
CV
67 10K W F
702
INPUT WIRE SPEED
N.B. 622A
1
S2 76
S3
BLACK
WHITE
CABLE CONTROL RHEOSTAT 2 621 75
WIRE SPEED DIAL 77
J6
UB R
WIRE FEED 500A
3
RANGE SWITCH R3
N.B. MODE SWITCH 2 1 530A
4
J15
HALL
CONTACTOR S2 ARC VOLTS
530
S1 5
COIL EFFECT 624
6
N.G.
S5 1234 5 6 J8
606
7
SWITCH
WIRING DIAGRAM
622
8
607
9
N.H. 10 512
11
530
607
512
500
606
530A
500
12
CONTACTOR TO J3 ON
GUN CABLE
541
539
CONTROL BOARD
N.F.
WHITE
BLACK
***
OPTIONAL REMOTE OUTPUT CONTROL
N.D.,N.E.
NOTES
N.A. JUMPER PLUG MUST BE INSTALLED IF REMOTE KIT IS NOT PRESENT. 667 A
66
7
REMOTE 1 34 4 B
CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT AND SWITCHES.
N.B. 621
P.C. BOARD 2 33 33 C
J13
N.D. ITEM FACTORY INSTALLED ON SOME MODELS AND OPTIONAL EQUIPMENT ON SOME MODELS. 3 D
34
21
1 1 2 N.E. CONTACTOR CAN BE INSTALLED IN UNITS WITH AN L12253-1 CONTROL PC BOARD.
1 3 4 E
4
1 5 21
F
75
N.F. WHEN A CONTACTOR IS NOT USED, THE �67� LEAD TO THE POLARITY SWITCH COMES FROM THE CONDUCTOR
G
1 622A 76
76
BLOCK AND THE INPUT CABLE CONNECTS DIRECTLY TO THE CONDUCTOR BLOCK.
E H
2 621 77
77 75
J6
4 6
3 4 10
6 D N.G. IF TIMER KIT IS NOT INSTALLED:
A
2 I
3 500A 621
J7,J15 J1,J16 J2,J11 R3
J14 -ON UNITS WITHOUT REMOTE PC BOARD, JUMPER MUST BE INSTALLED IN J11. 4 530A
C B
5 ARC VOLTS
530
-ON UNITS WITH REMOTE PC BOARD, JUMPER MUST BE INSTALLED IN J6 OF REMOTE PC BOARD.
1 7 1 8 N.G. 6 624
1234 5 6 TO
N.H. TIMER KIT HARNESS INSTALLATION: J8
7 606 POLARITY
- ON UNITS WITH REMOTE PC BOARD, TIMER HARNESS MUST PLUG INTO J6 OF REMOTE PC BOARD. 8 622
J5 SWITCH
- ON UNITS WITHOUT REMOTE PC BOARD, TIMER HARNESS MUST PLUG INTO J11. N.H.
14
8 9 9
16 607
N.J. PROVIDES AN ESD PATHWAY FROM EXPOSED METAL SURFACES TO WORK. 10 512
J4 J3 11
530
607
512
500
606
N.K. PRESENT ON EUROPEAN MODELS ONLY.
530A
12 500 TO J3 ON
N.L. CONNECTS TO BUSHING OF COMPONENT.
ELECTRICAL SYMBOLS PER E1537 CONTROL BOARD
N.M. J14 JUMPER PLUG USED ON K428 ONLY.
CONNECTORS VIEWED FROM INSERTION END TO TIMER P.C. BOARD
OPTIONAL PULSE POWER ADAPTOR KIT B
G4679
F-2
NOTE: This diagram is for reference only. 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.
DIMENSIONS F-3
F-3
LN-25 PHYSICAL DIMENSIONS
16.60
14.00
.25 21.00
7.40
LN-25
G Keep flammable materials away. G Wear eye, ear and body protec-
G Do not touch electrically live parts or tion.
electrode with skin or wet clothing.
WARNING G Insulate yourself from work and
ground.
G Mantenga el material com-
Spanish
G No toque las partes o los electrodos bustible fuera del área de tra- G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa bajo. cuerpo.
mojada.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête-G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la
terre.
G Berühren Sie keine stromführenden
German
G Entfernen Sie brennbarres G Tragen Sie Augen-, Ohren- und
Teile oder Elektroden mit Ihrem
Material! Kör-perschutz!
Körper oder feuchter Kleidung!
WARNUNG G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese G Não toque partes elétricas e elec-
G Use proteção para a vista, ouvido
trodos com a pele ou roupa mol-
G Mantenha inflamáveis bem e corpo.
ATENÇÃO hada.
guardados.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES
TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y
LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRO-
DUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES
HERSTELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Turn power off before servicing.
G Do not operate with panel open
G Keep your head out of fumes.
WARNING
or guards off.
G Use ventilation or exhaust to
remove fumes from breathing zone.
G Desconectar el cable de ali- Spanish
G Los humos fuera de la zona de res- G No operar con panel abierto o
AVISO DE
mentación de poder de la
piración. guardas quitadas.
máquina antes de iniciar
G Mantenga la cabeza fuera de los
PRECAUCION
cualquier servicio.
humos. Utilice ventilación o
aspiración para gases.
French
G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées. G Débranchez le courant avant l’en-
ouverts ou avec les dispositifs de
G Utilisez un ventilateur ou un aspira-
ATTENTION
tretien.
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von G Strom vor Wartungsarbeiten
oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
abschalten! (Netzstrom völlig öff-
Betrieb setzen!
G Sorgen Sie für gute Be- und nen; Maschine anhalten!)
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer moventes.
G Use ventilação e exhaustão para
ATENÇÃO
G Não opere com os paineis aber-
serviço.
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. tos ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E
SIGA AS PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
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