Home

Lincoln Electric LN-25 SVM114-C User's Manual

1. _ 99200 ENGINEERING CONTROLLED CHANGE DETAIL NEW MANUFACTURER CAVITY NUMBERING SEQUENCE GENERAL INFORMATION E COMPONENT SIDE BOARD nput rower ELECTRICAL SWEOLS PER E1537 Al 5 20 4 882 gt gt 3 4 4 9 6 6 10 WHITE R RED 1 7 1 8 U BLUE CODES 11144 11145 11146 ati MONITOR LN 25 FEEDHEAD BOARD ARC SchematrG4616 D VOLTAGE 2 FEEDBACK 35V NOTE OLDER OPTION BOARDS MAY BE LEFT 4 5 A PEAK m IN CIRCUIT OR REMOVED IF REMOVED SENSE cn CURRENT A PROPER JUMPER PLUG NEEDS TO BE WW LIMIT INSTALLED VM DU Vin POWER COM COM SUPPLY 667 J1 1 0 Gas Solenoid 05 415V ISO CONTACTOR BD m Wire Drive Circuit 20 7 T to Timer Bd 1 COM 1 a ISO 933 101667
2. R9 881 R83 R 10 R52 R64 2 2 2 OJO lt lt N N a N wo N R13 R14 14648 11 4700 OHM 5W RESISTOR R15 R20 R21 R29 R30 R34 19400 2212 22 1K 1 4W R39 R40 R49 R67 R68 R71 140 R79 R80 R82 R89 90 R16 R61 S 19400 1003 R 18 R 19 R24 R26 R60 R63 5 19400 1002 516296 2 R23 S 19400 68 12 R25 R32 519400 3321 S 19400 1004 0 R28 R36 R58 S 19400 5621 R33 R62 R66 S 19400 1503 R35 R56 R59 R70 R75 S 19400 2672 R38 T14648 18 R41 S 19400 3922 R42 R88 519400 2431 2 43K 1 4W 5 19400 3921 5 19400 6811 519400 1501 5 19400 4752 T 12300 77 519400 4422 519400 1652 5 19400 1023 519400 2801 5 19400 2670 5 19400 1502 5 19400 3322 519400 7681 519400 1301
3. nn n wee me ae s me e n amos om e s a O B FET DRIVER WHEN A CONTACTOR IS NOT USED A JUMPER PLUG MUST BE INSTALLED UNLESS OPTIONAL REMOTE OUTPUT KIT IS BEING USED CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT AND SWITCHES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER ON 61757 2 THRU G1757 5 P C BOARDS 1 8 AMP FUSE INTERRUPTS THE 500A LEAD ON THE G1757 1 P C BOARD 5 AMP SLOW BLOW FUSE WAS USED TO INTERRUPT THE 667 LEAD R72 WAS 1 5K AND THERE WAS NO R86 ACTUAL CIRCUIT OF X3 ITEM FACTORY INSTALLED ON SOME MODELS AND OPTIONAL EQUIPMENT ON OTHER MODELS CONTACTOR CAN BE USED WITH C1757 3 OR HIGHER PART NO CONTROL P C BOARD WHEN CONTACTOR IS NOT USED THE G7T LEAD TO THE POLARITY SWITCH COMES FROM THE CONDUCTOR BLOCK AND THE INPUT CABLE CONNECTS DIRECTLY TO THE CONDUCTOR BLOCK JUMPER PLUG MUST BE INSTALLED UNLESS OPTIONAL TIMER IS USED R25 WAS ON 1757 30 OR LOWER PART NO P C BOARDS TOGGLE SWITCH USED ON EARLIER UNITS NOTE This diagram is for reference only It may not be accurate for
4. OPTIONAL ACCESSORIES ELECTRIC SHOCK can kill not operate with covers removed Turn off power source before installing or servicing Do not touch electrically hot parts e Turn the input power to the welding power source off at the fuse box before working in the terminal strip qualified personnel should install use or service this equipment GAS SOLENOID KIT 2 copEs ABOVE 10500 OR K430 1 FOR CODES BELOW 10500 Factory Installed on K446 and K449 Models The kit permits the LN 25 to be used for Gas Metal Arc Welding GMAW processes with a GMA gun cable The kit can be used with or without a Remote Output 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 M Install by connecting a supply hose from the gas flow valve outlet to the 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
5. ELECTRICAL DIAGRAMS 52 WIRE SPEED DIAL m liye mam 1 p RANGE SWITCH 661 r 6 1 HE 621K 3 e OPTIONAL REMOTE EN ucro 5004 9 5 NDSN E 500A 2 Che ET 1 mu 22 6674011 EE KIT PLUG BE Nit 523 aye se 09 622A 1 4 iam 522 806 1 4 6 CONTACTOR Hel TH i 500 7 SODA 530 lt 7 e 60611 519 11607 1 9 gt 607 624 1 l 46 52 3 te 5916 622 16 6224 632 bok 13 M 6244 4 64 13 502 13 512 633 4 1 12 16 530A 112 530A 2122 it TN 1110 6674 1 RI e 631 E SOLENOID P C li Ty 624 i 14 624 ioko Ee pese 1 BOARD PLUG 3 4 9 8 i 500A 8 gt 500A CONTROL RAEOSTAY E M SSUES BE ob NB E I reza beo CEP 3 1 L ARC ho E Bleu 221 VOLTMETER ed hassi 4 1 BOARD es mm ss w u M 9 igo o Nh fea i 2 2 J4 CONTACTOR N G ibiibilibiii i BATEE A
6. KI 500 512 Contactor 690 LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lt Return to Section Return to Master TOC o 0 F 38 TROUBLESHOOTING AND REPAIR F 38 CONTROL PC BOARD REPLACEMENT continued FIGURE 24 CONTROL BOARD REPLACEMENT 7 Remove the screws holding the control PC 10 board to the inside of the case Carefully remove the control board See Figure F 24 8 Place the new control PC board in position inside the case Secure the control PC board by installing the screws from the outside of the case 11 9 For codes 10148 and above install the four Molex type plugs J1 J2 J3 and J4 onto the 11 control PC board See Figure F 20 NOTE For Codes above 10148 with a newer 12 Control Board L12253 and a contactor install plug J14 See Figure F 22 LN 25 LINCOLN 2 6 8 24 2 gni Z 2 X aA BALA 22 22 PC BOARD For codes 9812 and below install the four Molex type plugs J1 J2 J3 and J4 Also connect the five individual leads to the control PC board If necessary refer to the wiring diagrams in the Electrical Diagrams Section See Figure 21 Re install the Contactor PC
7. LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O Fie 9 0 9 53 4 cc Cc Return to Section TOC Return to Master TOC A 2 INSTALLATION TECHNICAL SPECIFICATIONS LN 25 Constant Voltage CV Constant Current CC VOLTAGE 15 40 VDC 110VDC Maximum OCV RATED CURRENT A 2 Rated current without contactor 500 Amps 60 Duty Cycle 300 Amps 60 Duty Cycle WIRE FEED SPEED 50 700 Inches Per Minute IPM WIRE DIAMETERS Rated current with contactor 023 to SOLID STEEL WIRE 045 to 264 CORED WIRE 035 to ALUMINUM WIRE HEIGHT Handle Down 14 Inches 354 mm OPERATION STORAGE PHYSICAL DIMENSIONS WEIGHT w o Options 7 4 Inches 21 Inches 28 Ibs 187 mm 531 mm 13 kg TEMPERATURE RANGE 40 to 40 40 F to 104 F 40 C to 70 C 40 F to 158 F ENVIRONMENTAL RATING IP23 529 LN 25 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 SAFETY PRECAUTIONS WARNING Unless an optional output contro
8. BME THE LINCOLN ELECTRIC CO 530 ON 3 DECIMALS 00 pr CLEVELAND OHIO USA 20171 5 one am weass 21964 17 rr In Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 13 G 14 ELECTRICAL DIAGRAMS vl PC BOARD ASSEMBLY CONTROL BELOW CODE 9900 G1757 6 T13157 15 TAB TERMINAL T13157 14 TAB TERMINAL T11577 46 05 600V S 13490 106 470 350V C3 C6 C 12 C20 C28 C33 C34 C35 C38 C37 C38 C39 C40 T11577 40 022 MFD 25 VDC CAPACI TOR C41 C42 C43 C47 C4 C23 13490 8 5 13490 92 13490 19 13490 73 13490 77 T11577 51 813490 39 5 16668 5 5 13490 62 5 13490 95 5 13490 76 5 13490 12 11577 57 5 13490 25 513490 42 12 199 4 T12199 1 0 25 3300 50 1 8 20 20 50 00227400 100p f 1000 187 15 022 50 0033 200 33 50 001 400 10725 0 1 400 4 7 35 1
9. 4 K433 Power Source Remote Box 4 K432 Remote Control Cable Assembly C 4 K439 Remote Extension Cable 5 K624 1 42V Remote Output Control Module 5 K625 K626 K627 Remote Control Cable Assembly C 5 K444 K444 1 or K444 2 Remote Voltage Control Kit C 5 KS63P Readi Reel Adapter Kit 4 Gun Cable Connector Requirements Permit Proper Connection To LN 25 Wire Feeder C 6 LN 25 LINCOLN Section C 2 ACCESSORIES 2 How to use Table 1 9 5 Determine which Kit No is to be used Locate that Kit No in the left hand vertical column m a Scan horizontally to determine which LN 25 model is required and what additional kits may be required 25 TABLE C 1 Ale N 25 OPTION CHART tle CANNOT BE USED WITH X REQUIRED REQUIRES ONE OF THESE INCLUDED WITH 5 SEE TEXT cc LN 25 MODELS LN 25 KITS E E DA N N ea CN 242424 EH oolenoid K430 1 2 Kit 2 Remote Control Cable 115VAC K433 Power Source Remote Box Gas Flow 50 Ft KS 1 Contactor Kit 0 Kit K432 Return to Section TOC Return to Master TOC EL Kit K443 2 Codes 10500 10558 K443 3 Contactor Kit Co
10. Return to Section Return to Master TOC 81 5 024 4 16V IW a at o _e _ C4 25 js Y NEGATIVE 20v SUPPLY 5 62K Qs Q v S 6 48v A 14 C22 e 1 4 e 2 o Bu oa an 23 Cu 4 58 7 n eae 4 0 Y 621 wate 4 2 T 10 OSCILLATOR i 1 2222 2 E ll ae ei ee CLOCK 2 EN RESET 2 52 ds pul gt 1 th 18 18 d ra lt 3 t5 15v 158K ds 0 e 4 140138 LM2907 __ 1 41 _ m d BE T F V CONVERTER J ee ACTUAL SPEED 8 die CONI c EET 5 dQe gus _ BUFFER 19K Baza 4 C 1 TACH INPUT NC NC GNO 18145 TACH INPUT 5 ISOURCE C20 V E NR E Le Mei e FET DRIVER 08 4 29 COMPARATOR RR 227 8 54 512 14 100 500 Gt Blas 100V 9 9 T T Return to Master TOC 26 7 8 8 1521 9 en 263
11. 4 Gas SOlENOIG sies E 4 Protective Devices amp Circuits E 5 Overvoltage Shutdown E 5 Motor Overload Shutdown E 5 Control Board Fuses E 5 FIGURE E 1 THEORY OF OPERATION BLOCK DIAGRAM OPTIONAL CONTACTOR 771 CONDUCTOR GUN CABLE BLOCK L zou COLD es al M GUN D Op TRIGGER INCH OPTIONAL Y SWITCH CONTACTOR EFFECT BOARD _ R FT MODULE ELECTRODE INPUT CABLE ARMATURE VOLTAGE TO WORK 4 SENSING LEAD CONTROL RPM FEEDBACK BOARD RANGE WIRE FEED SWITCH MODE SWITCH pu xS 352 Lo SOLENOID GAS PC BOARD SOLENOID EARLY MODELS ONLY LATER MODELS HAVE CIRCUITRY INCLUDED ON CONTROL BOARD LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O Fie 9 9 g 2 0912 gt cc Cc Return to Section TOC Return to Master TOC THEORY OF OPERATION E 2 voltage It is designed for maximum versatility in a variety of field applications It can be used with most constant voltage or constant current DC power sources without the need of a control cable GENERAL DESCRIPTION The LN 25 is a portable semiautomatic wire feeder designed to operate from
12. 109 600v 92 lt lt 1 Baas 023 e BE Gu e ucc a lcs se ee LE 2 400v l 500p 8E 1 usce A ee SED SPEED SCALER BUFFER ACCELERATION B b ud 89 C28 4 44 2K mle Sese 8 4 75K K H e 3 3 7 poe eE eei 2 257 06 3 5 82K lt 214 500p 267 2 WIRE FEE ans 21 V n C lt M GNE C MN MEE 27 523 lt amp WIRE SPEED 3 2 lt e e 5 9 E Fc olo O DIAL RANGE mw Eo y WITCH 523 4 lt _ _ i rt Ras C RR 21101112 0 0 21201010 1 4 02 ZEE TEN NIME _ i e 63 lt et a es hay al cen i E 2246 i ere 2 TRIGGER SENSING _ i M 512 p 512 RK lt h 23 gw 1 t LI 1 3 amp T cni T gj 8 be um 6 au m ea E 22 1K 512 x 4 s
13. 2 953 5 x Return to Section TOC Return to Master TOC LN 25 LINCOLN 5 E 6 LN 25 LINCOLN amp E 6 JO Je1se N NOL Je1se N uinjeH NOL Je1se N 0 NOL 4 18 0 DOL uonoes uunjeg DOL uonoes DOL uonoes DOL uonoes Section TABLE OF CONTENTS Section F TROUBLESHOOTING AND REPAIR SECTION 5 o Troubleshooting and Repair Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures F 3 3 Troubleshooting Guide F 4 Test Procedures Gas Solenoid Valve and Solenoid PC Board Test F 7 Gas Solenoid Valve and Control PC Board Test F 13 Hall Effect Module Test F 19 Wire Drive Motor Test F 23 Contactor amp Contactor PC Board F 25 Component Replacement Procedures Contactor PC Board Replacement F 31 Control PC Board Replacement F 35 5 Contactor Replacement codes below 10500 F 39 Contactor Replacement codes above 10500 F 41 Gas Solenoid Valve and or Solenoid PC Board If
14. CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING N C WRAP LEADS WITH TWO TURNS OF ITEM 4 a ANCHOR CAPACITORS TO BOARD WITH 25 WIDE 50 LONG FOR PARTS ORDERS BEAD OF ITEM 5 2 PLACES SEND 110863 11 518250 323 518250 310 518250 589 113498 22 521416 amp T14477PRINT 2 4816 1 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the 2 machine O o Fle JE 9 2 8 8 JE cic
15. N OCI 1 03 04 05 G6 010 012 013 014 07 011 12704 69 518397 2 5 18395 6 520630 1 14648 25 14648 5 5 19400 1000 5 19400 10RO 5 19400 1822 19400 4751 19400 2671 519400 1001 5 19400 1372 516296 3 2N4403 TRANSISTOR amp HEAT SINK ASBLY SS TRANSISTOR amp HEAT SINK ASBLY SS SBS 10 5w 3 3K 5W 100 1 4W 10 1 4W 18 2 1 4W 4 75K 2 67K 1 4W 1 4W 13 7K 1 4W 500 1 2W TRIMMER 015 Return to Section Return to Master TOC R2 R72 R86 R3 RS R 17 R37 R73 R6 R31 R7 R12 R84 R85 R94
16. 4 E 2 on o o 530A lt 834 We p e ws 05A lt 4 10 0 025 33K a 2 E 267K i 80 00 i EE O O i 5 jm HONEC TEES M E 512 E 2 5 14 K 22 510 d E eee 15 224K B 221 OPTIONAL OPTIONAL JUMPER 3 REMOTE PLUG PCB PLUG PCB PLUG 021 ee T 09 ZR 022 460 i ay E x10 7 28 4007 50 013 a 1 SEES 400V dst e box T 20 OVER VOL TAGE 1 SHUT DOWN 621 ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE IFIED LABELS DIODES 1A400V UNLESS OTHERWISE SPECIFIED SUPPLY POWER SUPPLY SOURCE POINT V COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION LAST NO USED 19 X 13 0 18 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANU mmm TRAN T ton 4 UNLESS OTHERWISE SPECIFIED TOLERANCE 5 ON 2 PLACE DECHSALS 15 1 O 05mm 2 NONE EQUIPMENT TYPE LN 25 1 OF 2 ON 3 PLACE DECIMALS IS 00 in
17. 9 953 cc Cc Return to Section TOC Return to Master TOC LN 25 LINCOLN 26 TROUBLESHOOTING REPAIR F 26 9 amp CONTACTOR PC BOARD TEST continued 5 5 FIGURE F 13 CONTACTOR LEAD IN LINE CONNECTORS 8 8 IN LINE CONNECTORS clic Return to Section TOC Return to Master TOC o 0 T CONTACTOR TEST PROCEDURE 1 Open the case door Remove the wire reel 3 Separate the two in line connectors located behind removing the retaining collar See Figure 5 the reel stand assembly See Figure F 13 For codes 9812 and below remove the two 2 Remove the screws holding the control box contactor coil leads from the contactor PC cover in place and remove the control box board See Figure F 14 cover See Figure F 5 Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC LI 9 T Return to Section Return to Master TOC lt o 0 A 27 TROUBLESHOOTING AND REPAIR F 27 CONTACTOR amp CONTACTOR PC BOARD TEST continued
18. RETURN TO MAIN MENU 9 SVM114 C LN 25 PORTABLE CV CC vos 227 dE SEMIAUTOMATIC WIRE FEEDER 5 For use with machines having Code Numbers 9218 10556 11144 9219 10557 11145 9220 10558 11282 9383 11144 11283 9810 11145 Safety Depends on You 11204 Lincoln arc welding and cutting equip ment 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 Return to Master TOC View Safety Info SERVICE MANUAL 0 5 gt 0 E D Return to Master TOC View Safety Info NCOLN Copyright Lincoln Global Inc e World s Leader in Welding and Cutting Products Sales 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 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproducti
19. SOV 35 6 e X5 621 7 GENERAL INFORMATION e LAST NO USED ELECTRICAL SYMBOLS PER E1537 R 37 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED C M CO C6 X3 C7 4 Oil 5 V RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS D 11 3300 pum 18 621 DIODES _ 1A 400V UNLESS OTHERWISE SPECIFIED BV LM2901 MC14538B 20V 1 2001 SUPPLY VOLTAGE NET NOTES C POWER SUPPLY SOURCE POINT 12 8 12 O o N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 77 7 FRAME CONNECTION e m oon THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 2 I ROUND 5 FILE 19065 1 Ch ge Sht No 621 ge EQUIP V 2 20 98A THE LINCOLN ELECTRIC CO TYPE LN 25 9 8 10 23 98E CLEVELAND OHIO U S A CONTACTOR SCHEMATIC SHT DR SUP S D G vo M19065 c tr NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual x G 16 ELECTRICAL DIAGRAMS G 16 olo SCHEMATIC CONTACTOR PC BD CODE 10100 THRU 10500 M17621 IES ME gt 19 0 2 7 2 667 456 0 3 R38 al 144005 Ja 3 600V 56 02 624 C4 a 14 CONTAC TOR J9 i 2 2 82
20. 2 13614108112913147 125 1 18 BDESBRSSSS SN 4 LULA BE BB N D WIRE FEED zz gm GAS 0 WORK CLIP COLD INCH MODE SWITCH SOLENOID BLACK PUSH VALVE ON d t GAS SOLENOID n iddu S1 BOARD 1 SWITCH NH 530 M Eu nem N L R TI F wem ww 606 512 1 608 4 N D pr 621 608 l ee PUSHBUTTON Wi doo ee d soos 55 45 aS N L TRIGGER 1139 m ESD SNUBBER CONNECTOR gt N J N K NOTES TO 5 OR CONTACTOR P C BOARD MER PC _ 1 530 2 p o EI 512 5 L500 OPTIONAL TIMER KIT ARC VOLTS TONJO I gt TO CONTROL BOARD OUTPUT CONTROL ice pus 701 mE 700 sp 1 WHITE O o FE JE 9 ejg 5 cic f ewe ee eee m x DT WHEN CONTACTOR IS NOT USED THE JUMPER PLUG MUST BE m INSTALLED UNLESS OPTIONAL REMOTE KIT IS BEING USED m EFFECT CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT AND SWITCHES SWITCH N D ITEM FACTORY INSTALLED ON SOME MODELS AND OPTIONAL EQUIPMENT CONTACTOR ON SOME MODELS I z CONTACTOR CAN BE INSTALLED IN UNITS WITH A 61757 3 OR HIGHER BOARD 1 CONTAC
21. LN 25 LINCOLN Return to Section TOC Return to Master TOC F 5 TROUBLESHOOTING AND REPAIR F 5 Troubleshooting Guide see Wiring Diagrams for location of specified components See Wiring Diagrams for troubleshooting of specific circuits PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FEEDING PROBLEMS Continued 1 The drive motor may be Observe Safety Guidelines detailed in the beginning of this manual The wire feeds for a short period of 1 Check the motor armature Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O O Fie 9 953 cc Cc time but then stops feeding When the gun trigger is released and then retriggered the wire resumes feeding but soon stops again The wire stops or stubs while welding NOTE On codes above 10100 the motor leads 541 amp 539 are in Control Board Connector J4 pins 13 amp 14 Check for overloaded Check the wire feeding path for mechanical restrictions While welding make certain the power source arc voltage is staying above 15 VDC The feeder will not function properly on less than 15 VDC If the LN 25 is connected to a constant current power source the arc voltage may be dipping below the 15 VDC threshold that is essential for proper LN 25 operation Try connecting the LN 25 to a constant voltage p
22. O18 PUSHBUTTON 2222 8 19 104 3112 612 7 5 13 14 0 SOLENOID Yy Telex FF FFT HF QD S5 26 MAK 00 5 ONDE gt x NL Le 0000 1 HHH 6 10 DP D I id 690 we GAS n X 5 SOLENOID D VALVE mz 7 ARC VOLTS Tc 691 m m J3 CONTROL BOARD B gt TO TIMER BOARD LLI tc N B REMOTE P C BOARD e 9 N LO V N LO ESD SNUBBER NL 1 1 N J N K e 0 go 633 1 631 522 509 523 10KW hs N B WIRE SPEED S2 53 25 622A 76 olo CONTROL RHEOSTAT WIRE SPEED DIAL 1 m 621 77 75 RANGE SWITCH v 500A N B MODE SWITCH 2 1 J15 530A R3 1 530 ARC VOLTS c EFFECT 624 012 SWITCH 606 AE 2 0 0 2 512 9 712 gt 500 TO J3 ON cle CONTROL BOARD 02 07 2005 EA E OPTIONAL REMOTE OUTPUT CONTROL o 2 NOTES Qc E amp N A JUMPER PLUG MUST BE INSTALLED IF REMOTE KIT IS NOT PRESENT 667 gt N B CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT SWITCHES eer mat 2 ke N D ITEM FACTORY INSTALLED ON SOME MODELS AND OPTIONAL EQUIPMENT ON SOME MODELS J34 5 ne 1 2 1 483 1 5 CONTACTOR CAN BE INSTALLED IN UNI
23. 41 1 11270471 d Ri 5 2 i 1 14648 5 daxo ___ E 8 519400 3382 332 OHM 1 4 9 s a Pw 5 MAKES 10 BOARDS 519400 1502 914 NOTE FOR BLANK SHEARING TOLERANCE SEE Ro 1 619400 1821 182K 1 4 c E P C BOARD ASSEMBLY DRAWING BLANK PART L9185 B R6 R7 R9 R13 R25 R26 R28 19400 2212 22 1K 1 4W 5 818 R17 R27 cc 812 835 519408 3321 3 32K 1 44 R14 619400 1003 100K 1 4 519400 2211 2222211 12300 79 11 w t om 519400 1503 150K 1 4W 519400 2801 2 8 1 49 T13165 11 2 7 OHM 5 515128 10 VOLTAGE REF T N B KA 515018 9 CMOS 5388 SS O o ITEM NO DESCRIPTION mEO D c ETE E ea Hu 1 91858 ______ CONTACTOR BOARD BLANK 1 EN 8895 2 T13498 19 ______ JUMPER PLUG aa E 5 MANUFACTURED AS N A 3 _ 514165 424 ______ RECEPTACLE amp LEAD AS BLY 1 9 TEL ole 9185 2B0 nb Bes 2 3 INDUCTANCE HENRYS EE 882 T IDENTIFICATION CODE CAPACITORS MFD VOLTS cic MAKE PER E1911 ENCAPSULATE WITH E1844 TEST PER 2741 0 THE LINCOLN ELECTRIC CO THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF NOTES N A DO NOT COAT WITH ENCAPSULATION MATERIAL
24. 88 a y ems dee 2 aah cca Sah R45 215 Go id uto 8602 Imi 95A sal 221K 5 porarity 92 lt 10 51 ee a SET SPEED is 7 2 TRIGGER K e UB SCALER BUFFER T dud 512 ps 1 les 4 0 CONNECTOR 6274 lt n t RN V V SCALER EG 2 9 9i p 224N sea 8 5 ETR 5 ACCELERATION 1 ae run 21100 1 2 Ven 2 e 4 i 5v Lase eT ee p Es ATSK 60 T5K aem T 2 sir ou 34 a aR WIRE FEED 328 ___ 512 203K 215 820pF MODE SWITCH is p i 523 4 4 WIRE D 522 4 EN M SWITCH 521 621 1633 sc M 2 2 2 MEL 2 632 lt 463 215555 5 TOOK def 1506 CONTROL bl lt M ix CURRENT sl gs mam V LIMITING iS 35v V 62 momo gt Vez i i B 606 10 606 lt 7 gt m n 542 22 3 K P K 1 00K 40668 512 2 N x V i 621 IE kb gt 667 40 e 00V 624 4 lt 6 SHOOT THRU A S 27 1K D i 530 lt 530 K PROTECTION o 9
25. 9 RANGE 2 2 WIRE FEED SWITCH olo MODE SWITCH J 3E 2 5 5 L 51 WIRE SPEED c CONTROL SOLENOID GAS PC BOARD SOLENOID EARLY MODELS ONLY LATER MODELS HAVE CIRCUITRY OPTIONAL CIRCUITS CONTACTOR The contactor contactor PC board and cold inch switch are commonly incorporated in the LN 25 This feature enables the user to have an electrically COLD gun even though the power sources output terminals are electrically HOT Upon receiving a command from the control board the contactor PC board sends a current signal to activate the contactor The signal closes the welding current path from the cable to the conductor block making the gun electrically HOT The cold inch switch allows the user to feed wire without closing the contactor In this manner the electrode wire can be fed through the gun with the gun electrically COLD See Figure 4 LATER MODELS Codes above 11144 have the Contactor circuitry added to the Control Board and the Contactor PC Board has been eliminated Older codes that have been upgraded to the newew PControl Board may have had the Contactor PC Board removed INCLUDED ON CONTROL BOARD GAS SOLENOID Early Models Only Below 10500 The gas solenoid feature permits the LN 25 to be used for gas metal arc welding GMAW processes When the gun trigger circuit is activated the control board signals the solenoid PC board to activate the gas s
26. Observe the static electricity precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section Open the case door Remove the wire reel b removing the retaining collar See Figure F 5 Remove the screws holding the control box LN 25 4 LINCOLN amp cover in place and remove the control box cover See Figure F 5 For codes 10148 and above remove plug J9 and plug J7 from the contactor PC board See Figure F 17 33 TROUBLESHOOTING AND REPAIR F 33 CONTACTOR PC BOARD REPLACEMENT continued FIGURE F 18 CONTROL PC BOARD PLUG LOCATIONS CODES 9812 AND BELOW Return to Section TOC Return to Master TOC O Pg 515 ETS o 2 818 5 5 For codes 9812 and below remove the codes 9812 and below remove plug J3 from the contactor coil leads and plug 47 from the control PC board See Figure F 18 contactor PC board See Figure F 17 Also for O O e 515 ETS o gt 2 5 5 e O O ate 515 o gt 2 5 5 e LN 25 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC o Fle 9 8 5 cc Cc Return to Section TOC Return to Master TOC Return to Master TOC F 34 TROUBLESHOOTING AND REPAIR F 34 CONTACTOR PC BOARD REPLACEMENT contin
27. gt DRIVE MOTOR i MOUNTING SCREW Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lo 5 oO gt 818 cc CC Return to Section TOC Return to Master TOC F 51 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR If a failed test indicates that any mechanical part that could affect the machine s electrical characteristics must be replaced or if any electrical components are repaired or replaced the machine must be retested and meet the following standards Wire Feed Speed 50 through 700 Inches Per Minute VOMMGICN TP Must be operative from 0 through 40 VDC Gas Solenoid optional Must operate when gun trigger is activated Contactor optional Must operate when gun trigger is activated LN 25 LINCOLN F 51 52 Y 1 5 E N 2 LL NOL 4 18 NOL 4 18 uinjeH NOL 4 18 NOL 491se N DOL uonoes uinjeg DOL uonoes uinjeg DOL uonoes uinjeg DOL uonoes uinjeg Return to Master TOC Return to Master TOC 4 o 0 Return to Master TOC G 1 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS
28. iibiiiiiiiiici ONON na EA 2 13614108112 913147 125 Y F 04 O uu 0 TO CJ lO QN CJ IO O m L8 900280902 885 21201 111 r4 E S3 pm 54 lt gt N B i WIRE FEED 0 GAS WORK 777777 MODE SWITCH SOLENOID BLACK 54 NUS wl lev COLD INCH 4111 69 S1 Pos PUSHBUTTON POLARITY SWITCH SWITCH 691 N L m N D 67 608 PURGE PUSHBUTTON 55 15 622 BLACK ESD SNUBBER gt E BLUE B TRIGGER 1 5003 i is ede SUNBEEISR 13 1 2 4 1 EY Y 5 pg mno 2 T NOTES aa U B R Iii WHEN A CONTACTOR IS NOT USED THE JUMPER PLUG MUST 2l INSTALLED UNLESS OPTIONAL REMOTE KIT IS BEING USED mene EFFECT v N B CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT AND SWITCHES CABLE ay N D ITEM FACTORY INSTALLED ON SOME MODELS AND OPTIONAL EQUIPMENT ON SOME MODELS LI CONTACTOR CAN BE INSTALLED IN UNITS WITH A 61757 3 OR HIGHER CONTACTOR E 9 PART NO CONTROL PC BOARD 1 i N F WHEN A CONTACTOR IS NOT USED THE 67 LEAD TO THE POLARITY NC 5 SWITCH COMES FROM THE CONDUCTOR BLOCK AND THE INPUT CABLE N D N E N F CO
29. 13640 11 515128 10 515018 4 13552 2 515128 4 515128 11 515018 10 515018 6 92K 1 4 81K 1 4W 1 5K 1 4 47 5K 1 4W 0 1 OHMS 7WATT WIRE WOUND 44 2K 1 4W 16 1 74W 102K 1 4W 2 8K 1 4W 267 1 4 15K 1 4 33 2 1 4W 7 68K 1 4W 1 1 4W 45 VOLTAGE REF MC 14584 SS FREQ TO VOLTAGE CONVERTER LM224 14 PIN QUAD COMPARATOR 14 PIN I C SS DIGITAL INTEGRATED CIRCUIT 55 R44 R95 R45 0 11 00 04 846 847 850 R53 865 R54 R55 R57 R69 R74 R77 o Fle 9 gt 8 5 cc Cc R91 TP1 X1 X2 X5 X6 X7 X8 X9 X10 X11 gt lt gt lt 2 D D D 0 N NIN 0 NO Oo 1 21 02 CLEVELAND OHIO U S A oe CONTROL BOARD a 3 1 1 aec E wars NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine CAPACITORS
30. 9 953 cc Cc Return to Section TOC Return to Master TOC F 46 10 TROUBLESHOOTING AND REPAIR F 46 GAS SOLENOID VALVE AND OR SOLENOID PC BOARD IF PRESENT REPLACEMENT continued FIGURE F 31 GAS SOLENOID ASSEMBLY FOR EARLIER CODES GAS SOLENOID VALVE GAS SOLENOID NIPPLE GAS HOSE GAS SOLENOID ASSEMBLY BRACKET PC BOARD MOUNTING SCREW For codes 9812 and below remove the two solenoid leads from the solenoid PC board and disconnect the purge switch leads See Figure F 31 Also remove plug J2 from the control board Remove the gas hose from the gas solenoid nipple Remove the brass fitting connected to the gas solenoid valve from the outside of the case See Figure F 31 Remove the two screws mounting the gas solenoid and assembly bracket to the case Carefully remove the assembly Remove the two screws mounting the gas solenoid valve to the assembly bracket Remove the gas solenoid valve Remove the two screws mounting the solenoid PC board to the assembly bracket Remove the solenoid PC board Install the replacement solenoid PC board onto the assembly bracket and secure with the two mounting screws BRASS FITTING ow Pa m GAS SOLENOID ASSEMBLY MOUNTING SCREW PC BOARD 11 12 13 14 Install the replacement gas solenoid valve onto the assembly bracket and secure with the two
31. DC Voltage Source 25 to 100 VDC O10 O O Fie 9 953 4 cc Cc Return to Section TOC Return to Master TOC LN 25 LINCOLN F 20 TROUBLESHOOTING AND REPAIR F 20 HALL EFFECT MODULE TEST continued FIGURE F 9 CONTROL PC BOARD CODES 10148 THRU 10500 Return to Master TOC 0 5 500 512 FIGURE 10 CONTROL BOARD CODES 9812 AND BELOW 539 541 al o 4 9 500 555 512 TEST PROCEDURE 3 Locate the three hall effect leads 500 512 and 555 incorporated in plug J4 on the Control 1 Open the case door Remove the wire reel by Board for codes 9812 and below the leads removing the retaining collar See Figure F 5 connect directly to the Control Board Do not disconnect the leads from the board See Figure F 9 or F 10 See Figure F 11 for codes above 10500 2 Remove the screws holding the control box cover in place and remove the control box cover See Figure F 5 Return to Master TOC LN 25 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O O Fie 9 913 cc CC Return to Section TOC Return to Master TOC F 21 TROUBLESHOOTING
32. FIGURE F 14 CONTACTOR PC BOARDS CODES 9812 AND BELOW CODES BELOW 10500 520963 J6 7 V J7 CONTACTOR COIL LEADS COIL LEADS 4 Apply 12 VDC to the contactor coil leads 7 the resistance is high or open between the two large terminal studs when the contactor is A CAUTION activated the contactor is faulty Replace Do not leave the 12 VDC applied to the contactor 8 If the contactor activates and the resistance coil for a prolonged period of time 15 seconds between the terminals is low when the 12 VDC maximum Damage to contactor may result is applied the contactor is good 5 f the contactor does not activate when the 12 VDC is applied the contactor is faulty Replace NOTE When the contactor is not activated the resistance between the terminals should be very high 6 If the contactor activates when the 12 VDC is infinite If the resistance is always low the contacts applied check the resistance between the two stuck and the contactor is faulty Replace large terminal studs with the contactor activated The resistance should be very low 0 to 1 ohm LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 O O Fie 9 0 913 4 cc Cc Return to Se
33. au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier SAFETY 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sen
34. 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 gases such as 2 Ar CO CO 02 02 A WARNING See American National Standard Z 49 1 Safety in Welding and Cutting published by the American Welding Society C 3 ACCESSORIES C 3 WARNING CYLINDER may explode if damaged B cylinder upright and chained to support e Keep cylinder away from areas where it may be dam aged e Never lift welder with cylinder attached e Never allow welding electrode to touch cylinder e Keep cylinder away from weld ing or other live electrical cir cuits See GMA Gun Cable Gas Connection Installation instructions are included with the kit K434 1 GAS FLOW TIMER KIT Requires either a K431 1 Remote Output Control Kit K624 1 42V Remote Output Control Kit or internal contactor K443 1 K443 2 installed in LN 25 The K434 1 Gas Flow Timer Kit is used with the LN 25 Gas Solenoid when the LN 25 is equipped with any of the Remote Output Control Options or internal contactor This kit provides the following gas flow timer functions 1 Preflow Control Provides flow of shielding gas to the work before the arc is established The solenoid valve is energized immediately when the gun trigger is closed but the time delay before the wire feeder and welding o
35. mounting screws Install the gas solenoid assembly bracket into the case and secure with the two mounting Screws Install the gas hose onto the gas solenoid nipple Install the brass fitting into the solenoid valve from the outside of the case For codes 10148 thru 10500 install plug 411 onto the solenoid PC board Connect the leads to the gas solenoid valve and purge switch 15 For codes 9812 and below install the two leads 16 17 LN 25 LINCOLN from the gas solenoid valve onto the solenoid PC board and connect the purge switch leads Also install plug J2 onto the control board Install the control box cover and secure by installing the three screws previously removed Install the wire reel and retaining collar and close the case door 47 TROUBLESHOOTING REPAIR F 47 DRIVE MOTOR AND GEARBOX REPLACEMENT AND ACCESS TO HALL EFFECT MODULE WARNING Service and repair should performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electri
36. 008 ES Q3 20KmA R18 BN 20 50V 50 284128 TAM REF 35V T B2K 2 8K 2 621 621 7 al 224 cx 4 R13 04 CURRENT LIMIT ae 621 7 GENERAL INFORMATION 1 ELECTRICAL SYMBOLS PER E1537 V CAPACITORS MFD 022 80V UNLESS OTHERWISE SPECIFIED x5 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 1777 DIODES 1 400 UNLESS OTHERWISE SPECIFIED A BUR Voce Nel NOTES T POWER SUPPLY SOURCE POINT 12 3 2 1 2 1 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 4 3 45 6 5 COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MA 6 5 4 789 7 1 FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 2L NUMBER CONNECTOR CAVITY NUMOERING 18 1 12 EARTH GROUND CONNECTION CANADA naon SEQUENCE COMPONENT SIDE OF BOARD THE LINCOLN ELECTRIC CLEVELAND OHIO 0 S A 1 24 SCALE NONE ae DR MODI TAN BREITES EAE D as _ PIE Th d a Die ma SUNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER 2056 ON 2 PLACE DECIMALS IS _02 ON 3 PLACE DECIMALS IS 002 LN 25 CONTACTOR ge ShtNo 5 6 88 SCHEMATIC NO M15428 N ALL
37. 1 815018 9 CMOS MC14538B SS 0912 0 A MANUFACTURED AS ITEM PART NO DESCRIPTION REQD 20 3 25 SEE BLANK INFORMATION CONTACTOR P C BOARD BLANK 1 a 0 3 50 204 86 2 N A 2 13498 22 JUMPER PLUG 1 3 E2861 ADHESIVE 03 02 IDENTIFICATION CODE INDUCTANCE HENRYS CAPACITORS MFD VOLTS MAKE PER E1911 ENCAPSULATE WITH E1844 ee NOTES TEST PER 2747 FOR PARTS ORDERS SCHEMATIC REFERENCE 19065 1 0 DO NOT COAT WITH ENCAPSULATION MATERIAL INCLUDE 1 T14477PRINT S o N B CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC 5 p a THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED 0 PROPRIETARY amp CONFIDENTIAL i TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC ANCHOR CAPACITORS BOARD WITH 25 WIDE 50 LONG TALES OT ERTISE SPECT ED TOLERANCE ESIGN INFORMATION REFERENCE EQUIPMENT TYPE IN 25 17 PLACES ON ALL ANGLES IS 5 OF A DEGREE m SUBJECT CONTACTOR P C BOARD ASSEMBLY Oe 1 AGREE ENGINEER SCALE a 5 2 wb a CR02207 10863 1 12 J cc NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your fa
38. AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE 7 7 FRAME CONNECTION EARTH GROUND CONNECTION UNLESS OTHERWISE SPECIFIED TOLERANCE e an E nV PURE ected s a THE LINCOLN ELECTRIC CO TWE 04 PLACE DECIMALS IS e 402 d CLEVELAND OHIO U S A suBJecr SCHEMATIC MATERIAL TOLERANCE TO AGREE _ SCALE ___ __ _ Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual x Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O O o FE JE 9 ejg 5 cic Return to Section TOC Return to Master TOC G 17 ELECTRICAL DIAGRAMS G 17 CONTACTOR BELOW CODE 9900 H CONTACTOR 9 CONTROL BOARD j 667 OF 01 624 7 621 5884 O 508 O 1 512 or TIMER BOARD J6 o 5304 46 86 2 216 52 2 2 508 2 226 530 gs COLD INCH SWITCH ee 7 17 538 32447 PE J7 c5 C6 3300 58V LM29301 621 AUSTRALIA x y 06 BACK UP COIL SUPPLY gl TO CONTACTOR 6 Bl 5124 9 D3 14 1
39. ANGLES IS 5 OF A DEGREE dici TOLERANCE 7 TO AGREE 4 99 FRANCE 2 21 27 PUBLISHED STANDARDS NOTE This is ior only not be accurate 0 by this nena Return to Section TOC Return to Section TOC 9 9 Return to Section Return to Master TOC Return to Master TOC Return to Master TOC o 0 G 18 ELECTRICAL DIAGRAMS SCHEMATIC CONTACTOR PC BD BELOW CODE 9900 16 COMAG TOR M171 bs 1667 1624 Cy 621 530 O 622 d 5204 Di 590 512 606 S 5384 687 TIMER BOARD 687 J6 3 530A 226 88 gis 52 2 KE 500 1 CONTROL BOARD CA 530 2 76 COLD INCH an 2 J7 7 one 47 C5 3300 LM2961 621 x 2 BACK UP COIL SUPPLY R38 B 4 i i 144005 amp 02 18 600v 512 2 7 OW 244401 2 8K G 18 TO CONTACTOR 5124 B 1 03 1000 5 o 5 62 K Bun 621 7 621 tw e 72 215 iN 838 D4 3 32K 3 32 12 08 2500 f 2708pf p P 50 E 50v 9 14 7 621 621 145388 2901 NOTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
40. BOARDS 8 c TRIGGER 1 8 AMP FUSE INTERRUPTS THE 5004 pees CONNECTOR LEAD TO THE TRIGGER SWITCH THE 01757 1 HIE E gt P C BOARD 5 AMP FUSE WAS USED TO INTERRUPT coi THE 667 LEAD EHE a ITEM FACTORY INSTALLED ON SOME MODELS AND 8788 OPTIONAL EQUIPMENT ON SOME MODELS I CONTACTOR BE INSTALLED IN UNITS WITH A 223 1757 3 OR HIGHER PART NO CONTROL BOARD CONNECTOR CAVITY NUMBER WHEN A CONTACTOR IS NOT USED THE 67 LEAD uj 211 po TO THE POLARITY SWITCH COMES FROM THE 2 d 22111646 CONDUCTOR BLOCK AND THE INPUT CABLE 4 987 CONNECTS DIRECTLY TO THE CONDUCTOR BLOCK 3 42042706 N G JUMPER PLUG MUST BE INSTALLED UNLESS OPTIONAL TIMER IS USED CAVITE NUMBERING SEUDEINSE N H TOGGLE SWITCH USED ON EARLIER UNITS avo NOTE This diagram 15 for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code 15 pasted inside one of the enclosure panels of your machine G 6 SCHEMATIC COMPLETE MACHINE CODES ABOVE 11140 G5366 ELECTRICAL DIAGRAMS
41. Connection switch at appropriate position d Place power source toggle switch in Output Control at DC 600 V position unless a remote control is connected to 75 76 and 77 on the DC 600 terminal strip e Set mode switch to Constant Voltage Innershield Initially set output control on 4 SAM 400 650 a Connect a jumper from 2 to C4 on the power source terminal strip so the output will be energized when the SAM power source is on b Connect work lead to WORK stud Connect electrode to AUTO EQUIPMENT stud Connect SAM 650 Tap lead to the Innershield stud desired c Set ELECTRODE POLARITY switch to constant voltage polarity required by electrode d Set toggle switch to Constant Voltage and set the Constant Voltage Control on welder and the portable field control on 5 for initial start SA 200 250 OR SAE 300 400 WITH CV ADAPTER a For electrode negative welding connect the electrode lead from the LN 25 to the output terminal on the CV Adapter and the work lead to the power source output terminal labeled INSTALLATION A 4 POSITIVE For electrode positive welding interchange the above lead connections so the LN 25 electrode lead is then connected to the positive power source terminal b Place both switches on the CV Adapter to the CV INNERSHIELD position and make appropriate power source settings per the CV Adapter instruc tions provided for t
42. Constant Wire Feed Speed CV Mode B 7 Setting Arc Sensing Wire Feed Speed CC Mode B 7 Making a Weld OT B 8 E 9 Procedure at End of Coil B 9 Open Arc Welding with a Constant Current Power Source B 9 Automatic Protection Shutdown B 10 Overvoltage Shutdown B 10 Motor Overload Shutdown B 10 LN 25 LINCOLN Section B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 2 B 2 SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE A WARNING e ELECTRIC SHOCK can kill Do not touch electrically live part or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASSES can be dangerous e Keep your head out of fumes Use ventilation or exhaust to remove fumes from breath ing zone WELDING SPARKS can cause fire or explosion Keep flammable material away ARC RAYS can burn Wear eye ear and bo
43. HEX 4584 SS 4 1 13552 2 IC CONVERTER F V 2907 X5 X6 2 515128 4 OP AMP QUAD GEN PURPOSE 224N TS ORDER OL 7 8 9 12 4 815128 11 IC COMPARATOR QUAD 2901N X10 1 515018 10 IC CMOS FLIP FLOP D DUAL 4013 SS NB CAUTDN THB SUBJECT TO DAMAGE BY STATT FOR PAR 06 53 CONTR D xi SWITCH ANALOG OUAD 4086188 ELECTRICITY SEE E2454 BEFORE HANDLING ND WENT K 1 515018 9 IC CMOS MULTIVBRTR DUAL 4538 SS X13 S p REPLACE ND ANCHOR ITEMS C2 C5 C8 AND C9 TO BOARD W IH 25W DE 50 LONG BEAD OF ITEM 8 PROPRIETARY amp CONFIDENTIAL 15 DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC EQUIPMENT TYPE LN 25 AN PIN UNLESS OTHERWISE SPECIFIED TOLERANCE DESIGN INFORMATION 2 PLACE DECIMALS IS 02 in 0 5 mm ON 3 PLACE DECIMALS IS 002 in 0 05 mm 1 1 DRAWN bwilliam DRAWN BY DOCUMENT E mom SUBJECT CONTROL P C BOARD NUMBER WITH PUBLISHED STANDARDS UNITS MATERIAL APPROVAL PROJECT REFEREN SONOTSCAE emees UF uet 272005 Rus 9 5 08425 3 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoo
44. INPUT CABLE sso M 530 1 X2 TL431IP PRECISION REFERENCE 53044 1 1 530 4 1 X3 20022222 MC14584B HEX SCHMITT TRIGGER 6224 i i 6224 4 LM2907 FREQUENCY TO VOLTAGE CONVERTER i 5 X6 LM324 QUAD OP AMP il i THRU LM2901 QUAD COMPARATOR 622 4401 __________ MCI4013B D TYPE FLIP FLOP Xi MC14066B QUAD ANALOG SWITCH 500 4N35 OPTO COUPLER Eleg pel do 512 l 667 D 6674 69244 624 q 621 e 621 5607 4411 607 lt LL uae kem 34 eee COLOR LEGEND 2 BLACK ene 1 N F N G N J U BLUE 606 BROWN 2 0 PT ets q pi h 530 R RED 5304x Ds CONTACTOR G GREEN i l P C BD W WHITE eee 500 1 60724411 ne b da 76 L512 22 01 9 ise 667 621 j 995 i iee 31 606 0 A E d Locus SEE CONTACTOR 624 AC 5 KIT SCHEMATIC OPTIONAL TIMER PLUG i i i i MEG NR NM 75 7 1 cato del N B x PUSH BUTTON SWITCH Gi Oo bha uU c 2022 2724 Lu ELECTRICAL DIAGRAMS DG 20 600V DYNAMIC BRAKING 512 12VDC C9 4100 aes 223 350v T 350 EF 50 F D7 470 3 621 9 50VDC 80 512 TO HALL EFFECT 512 F V CONV
45. J9 JC 9 rcu It 43 141624 c 0 MOTOR SUPPLY JR VOLTAGE MONITOR RECT BD MOTOR FETS VM J8 6 621 e BOTH OFF WHEN INPUT AVERAGE 815 500 sis Positive VOLTAGE DROPS 2 are BELOW 20V MOTOR E pr J2 BRAKE PULSE BY PULSE gt lta e 26 PEAK CURRENT amp 2 w z 22 m o E LIMIT 5 5 gt 31359 MD TURIS 6 724 1 lt o Z optional 05 5 98 558 ive 512 toU 6012 6 a J14 8 606 JT TMER O 9 130Hz 502411 4 25 VDC when gas TM SOLENOID De 500 ____ W B 185kHz 700mfnn Coilmeasures 21 dams C M OLD E PWM antola EWM REMOTE BD 553 SOL_DRV aie m OLD CONTACTOR BD optional s 5 SOLENOID Located under the cover 135VDC Ah Sumy _ PRN gt gt 12 45 J3 13 512 19VDCO 505001 TORODD at the rear of the feeder 5 THER 10K p 1 C TOROID 201 700 hmi RAH 284 Sigal 44 ACTIVATE J3 11 530 2 E C IOGT Located behind the insulating 22271898 01 19 mu FEEDER i wire dive panel Remove the oe ux SERM TIMER BD im tE software set 6 COM 530 optional 1 wire
46. PC boards the amp fuse interrupts the 500A lead to the trigger switch On G1757 1 PC boards a 5 amp fuse was used to interrupt the 667 lead The LN 25 will not operate if the fuse is blown AUTOMATIC PROTECTION SHUTDOWN See Automatic Protection Shutdown Section ADJUSTING SPEED SENSOR MODULE The LN 25 Speed Sensor Module is a three lead Hall Effect switch device encased in an externally threaded housing which is screwed into a mounting plate on the motor side of the wire drive gearbox LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 Proper positioning of this module is critical to proper operation of the LN 25 wire feed speed control If the device is not screwed in far enough the LN 25 motor speed could be unstable or run at full speed with no control If screwed in too far it will rub a moving part inside the gearbox The module is properly mounted to the gearbox as shipped from the factory If the device is ever removed or replaced proper mounting technique is as follows 1 Be sure all power to the LN 25 is shut off at the power source 2 Check that the module mounting plate is screwed securely to the side of the gearbox Refer to Dr
47. Present Replacement F 43 Drive Motor And Gearbox Replacement and B Access to Hall Effect Module F 47 Retest After Repair F 51 2 WARNING ELECTRIC SHOCK can kill Never work on the inside of the machine without removing the input power You can receive a life threatening electrical shock if you fail to do this Only qualified technicians should perform installation maintenance and troubleshooting work on the machine 4 o 0 Return to Master LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC L 4 Return to Section Return to Master TOC 4 o 0 TROUBLESHOOTING REPAIR HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and 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 locate an
48. The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims LN 25 LINCOLN F 4 TROUBLESHOOTING AND REPAIR F 4 Troubleshooting Guide see Wiring Diagrams for location of specified components See Wiring Diagrams for troubleshootin
49. The Module includes a 42V Remote PC board and control cable receptacle which mount and connect inside the LN 25 control box per the Installation Instructions included with the kit NOTE If the K624 1 42V Remote Output Control Module is installed but the LN 25 is to be used without the K625 K626 or K627 Remote Control Cable Assembly then the Remote Board harness plug must be removed from the 16 pin receptacle on the Control Board and the jumper plug T13498 21 reinstalled K625 K626 K627 REMOTE CONTROL CABLE ASSEMBLY Requires K624 1 Remote Output Control Module installed LN 25 The K625 K626 K627 control cable assemblies include an electrode cable and a 8 conductor control cable C 5 ACCESSORIES 5 60 DUTY RATING POWER SOURCE ELECTRODE CONNECTION Stud Terminal Stud Terminal Twist Mate 500 Amps 350 Amps 400 Amps The cable assembly end with the socket pin connector connects to the LN 25 per the Instructions included with the K624 1 Kit The cable assembly end with the male pin connector connects to the power source per the Instructions included with the K624 1 kit K444 K444 1 OR K444 2 REMOTE VOLTAGE CONTROL KIT Not required if using K431 1 or K624 1 Remote Output Control Kit The Remote Voltage Control Kit provides remote 10K ohm rheostat control of power source output arc voltage level K444 connects to power sources with control terminal strip Connections for le
50. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Aug 06 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MS md WELDING and CUTTING gt SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the
51. contactor do not connect to non Lincoln TIG or Square Wave power sources TIG high frequency power should never be applied to the LN 25 NOTE The K443 1 K443 2 or K433 3 cannot be used with K431 1 or K624 1 Remote Output Control Kit If remote voltage control is desired along with the internal contactor obtain a K444 K444 1 or K444 2 Remote Voltage Control Kit REMOTE OUTPUT CONTROL OPTIONS AND CONTROL CABLE ASSEMBLIES Remote Output Control Options are available to pro vide the LN 25 M with the following additional features 1 Cold electrode until the gun trigger is pressed and a fixed burnback time delay to prevent elec trode from sticking in the weld crater when the gun trigger is released 2 Remote 10K ohm rheostat control of power source output arc voltage level K431 1 REMOTE OUTPUT CONTROL KIT For use with K432 Remote Control Cable and K433 Power Source Remote Box The Kit includes a Remote PC board and control cable receptacle which mount and connect inside the LN 25 control box per the Installation Instructions M17584 included with the kit C 4 NOTE If the K431 1 Remote Output Control Kit is installed but the LN 25 M is to be used without the K432 Remote Control Cable Assembly then the Re mote Board harness plug must be removed from the 12 pin receptacle on the Control Board and the jumper plug T13498 21 reinstalled K433 POWER SOURCE REMOTE BOX Requires K431 1 Remote Outpu
52. diagram specific to your code is pasted inside one of the enclosure panels of your machine x Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o FE JE 9 ejg 5 cic Return to Section TOC Return to Master TOC G 3 WIRING DIAGRAM CODE 10556 THRU 10500 L10925 ELECTRICAL DIAGRAMS 52 WIRE SPEED DIAL ee 7 RANGE SWITCH N D N E L 621 3 OPTIONAL REMOTE 4 pui qm N L 523 NL J9 mk ee 522 N B CONTACTOR 1 7 500 7 gt 500A i P C BOARD 621 1 lt gt 9 15 15 gt 500 ELE 1 608 4 ee 7 9 t 607 1 9 607 E e 116 1 por 622 116 622A E 632 gt ee 92 3 jr pe 512 512 RI e 631 7727 x 114 f 624 4 624 45 7 2215 jac d Be E WIRE SPEED A BOARD PLUG ne e CONTROL RHEOSTAT 9 1t 206 E s T l 49 6 p p 621 6 62 Tn gt 5 poe 6224 15 622 ue gt 3 l 3 gt E o 2 Bo HIR 5 4 4 Eso 4 H OPTIONAL OPTIONAL TIMER myy T Va CONTACTOR PLUG 22 s P C BOARD PLUG N G 002 88
53. dive ably to access Access this connedor WIRE SPEED 10K u14 5 530a removing the wire CONTROL Ohms POT Supp 2111 L 3 530 zm POT ENTIM ETER 4 amp 2 830 291 Wipr 632 J4 1 WFS OLD Located behind the wire drive 5 Ffoptional Located on the case front 6334 8 N M ny Remove the wire drive W COM 4 V ASBLY to gain access N C 5 VDC at700 im M 47 Not C board schemati at50 im 1 13 16622 38 WFS RANGE 55 6215 mm cci FAN 1 4 622 NO saa For progaming at LECo Luo 725004 Located on the loner lef 13 5V O O on e J3 8 500A ss of the front of the case WFS nf 85 T isc Located on front of case J2 1 J14 7 4 3 441 046 24 DATA SELIM 5 Usd 22 oc GUN TREGER above WES contro knob 621 500 509 523 530 608 m Co nt rol The WES switch shown in low range REMOTE BD en nio optional o 9 pee EM qu m m rangeis inmin the gastic panel recu it 509 523 Q MODE gt OVC when ger i ole Input The mode switch is V It g shown in CC S2 ns Gun T 3 2 300 60
54. follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Return to Master TOC Return to Master TOC QU Return to Master PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits
55. for aluminum wire sizes are stencilled with an A suffix to the wire sizes LN 25 LINCOLN amp 5 A 6 LN 25 LINCOLN amp A 6 NOL 4 18 NOL 4 18 NOL 4 18 uinjeH NOL 4 18 DOL uonoes DOL uonoes DOL uonoes uunjeg DOL uonoes uunjeg Return to Master TOC Return to Master TOC o 0 Return to Master TOC SECUND TABLE OF CONTENTS OPERATION SECTION NA Section B Salety PrecauulonsS acu cc cecus in d dp B 2 General Description B 2 Recommended Processes and Equipment B 2 Welding Capability B 2 LN 25 Instruments and 5 B 3 Sequence of Operation B 5 Loading Electrode B 5 Mounting 22 to 30 Readi Reel Coils B 5 Mounting 10 to 30 Ib SpoolS B 5 Mounting 13 or 14 lb Innershield Coils B 5 Loading Wire Drive B 6 Idle Roll Pressure Setting B 6 Presetting Wire Feed Speed B 7 Setting
56. humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit
57. maintained See Figure E 3 When the LN 25 is connected to a constant current CC power source a variable wire feed speed INCLUDED ON CONTROL BOARD is desirable to compensate for the varying arc voltages associated with the constant current process To accomplish this the control board monitors the command voltage the feedback signal from the hall effect module and the arc voltage These three factors are monitored and compared and then the appropriate armature voltage is applied to the wire feed motor TRIGGER CIRCUIT When the gun trigger is closed the control board is signaled to apply armature voltage to the drive motor and to activate any auxiliary circuits that may be incorporated within the LN 25 M See Figure E 3 NOTE Unshaded areas of block logic diagrams are the subject of discussion LN 25 LINCOLN E 4 THEORY OF OPERATION E 4 O O 5 9 9 g 2 0912 gt cc Cc Return to Section TOC Return to Master TOC E O FIGURE 4 OPTIONAL CIRCUITS E o 9 815 OPTIONAL 9145 0 2 p eg 0912 4 CONDUCTOR GUN CABLE BLOCK oc L 2 2 61 77 AO d M GUN TRIGGER INCH HALL CONNECTOR SWITCH CONTACTOR EFFECT BOARD RF 0 ELECTRODE INPUT CABLE ARMATURE VOLTAGE TO WORK pice METER o lg SENSING LEAD CONTROL RPM FEEDBACK BOARD
58. metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when we
59. s 0 05 mm aaa DODONENT ON ALL ANGLES IS 1 5 OF A DEGREE BJECT 1 TOLERANCE UTOAGREE ENGINEER e Suc SUBJEC SCHEMATIC CONTROL PCB NUMBER REVISION PUBLISH H NETS MATERIAL HEFERENCE NA 02 07 2005 MERE CRM35795 3424 3F0 1 2 2 _ OO NOT SCALE THIS DRAWING APPROVED NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual EN 170 O o JE 9 2 8 8 JE cic x SOLID EDGE G 10 ELECTRICAL DIAGRAMS G 10 SCHEMATIC CONTROL PC BD CODE 10100 THRU 10500 G2194 IVA DYNAMIC BRAKING 03 n p de E 883 350V Vea TO e u s 15 7 68K 200m C2 MOTOR 75 90 V x3 0 12 2 87 9 5001 1 60 45848 5 22 2 188 9 50 acit C46 D22 _ 00 4 C45 T 47 amp 35 667 27 iN4B 5 144005 gt a ai c n ier 9 50VDC 1 m 038 n 2 i5a 201 n el 400v 660v 127 20 eu 100K 400V 8 amp 5
60. stated in Arc Welding Safety Precautions Check that the LN 25 is properly connected to the power source for the polarity and process to be used and appropriate power source settings are made for the procedure to be used Refer to power source operating and connection instructions NOTE If the K431 1 Remote Output Control Kit or K624 1 42V Remote Control Module is installed but the LN 25 M is to be used without the Remote Control Cable Assembly then the Remote Board harness plug must be removed from the 16 pin receptacle on the Control Board and the jumper plug T13498 21 reinstalled c Place the LN 25 conveniently near the work area in a location to minimize exposure to weld spatter and to avoid sharp bends in the gun cable d Connect the LN 25 Clip Lead to work and set Polarity Switch to same polarity as electrode e Set WIRE FEED MODE switch to CV or VV CC as appropriate for the power source then set the proper DIAL RANGE and WIRE SPEED dial set ting for the proper wire feed speed per the welding procedure For CV Set dial to the calibrated IN MIN desired Refer to Setting Constant Wire Feed Speed Section For CC Set dial to value determined from the CC Wire Speed Graph for the DESIRED IN MIN and ARC VOLTS to be used Refer to Setting Arc Sensing Wire Feed Speed Section NOTE If procedure permits a range of acceptable arc voltage use the middle of the range to determine proper WI
61. terminal strip so the output will be energized 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 of polarity required by electrode Connect work lead to other output terminal LN 25 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 4 Place Set to Same Polarity As Electrode Cable Connection switch at appropriate position d Place power source toggle switch in Output Control at DC CV 400 position unless a remote control is connected to 75 76 and 77 on the power source terminal strip or to the MS type connector e If power source has a mode switch set switch to Constant Voltage Innershield Initially set the output control on 6 DC 600 a Connect a jumper from 2 to 4 on the power source terminal strip so the output will be energized when the DC 600 is turned on For DC 600 below Code 8200 also jumper N to S b Connect the electrode cable to the output terminal of polarity required by electrode Connect work lead to other output terminal c Place Set to Same Polarity As Electrode Cable
62. the electrode has been removed g Load a new coil of wire and feed it through the cable as described in Loading Electrode Section OPEN ARC WELDING WITH A CONSTANT CURRENT formerly variable voltage POWER SOURCE Although a constant voltage CV power source is recommended for Innershield and gas metal arc GMAW open arc welding satisfactory general purpose welding may be obtained using the LN 25 with a constant current CC power source for non critical commercial quality mild steel welding applications LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O e 9 9 53 4 cc Cc Return to Section TOC Return to Master TOC B 10 CAUTION Do not use LN 25 models below Code 9200 with any or Square Wave welding power sources Do not use LN 25 models equipped with internal contactors with non Lincoln TIG or Square Wave welding power sources Damage to the LN 25 circuit can occur as a result of the high output inductance typically associated with these power sources TIG high frequency power should never be applied to the LN 25 M While welding with a continuously fed electrode weld current variations are continuously taking place There are many causes for these variations but predominantly they occur due to changes in electrical stickout operator hand movements nozzle tip contact vari
63. value set independent of arc voltage changes as long as the arc voltage does not drop below the value per the chart below for the max wire feed speed shown Maximum Speed Minimum Arc Volts 350 IPM 15V 400 IPM 17V 500 IPM 21V 600 IPM 24V 700 IPM 27V SETTING ARC SENSING WIRE FEED SPEED CC MODE When using a constant current formerly variable voltage power source welding performance is im proved using arc sensing wire feed speed CC VV mode In this wire feed mode the wire speed increases if arc voltage increases and decreases if arc voltage decreases but remains constant at any specific voltage level The LN 25 permits accurate CC mode presetting of the desired wire feed speed for the desired arc voltage to be used by setting the Wire Speed dial in the following manner before welding a Set Wire Feed Mode switch to CC position B 7 OPERATION B 7 FIGURE B 3 CC WIRE SPEED SETTING DESIRED IN MIN ARC VOLTS USED 700 35 650 31 600 29 550 27 500 25 450 23 400 21 350 300 250 200 150 100 50 50 100 150 200 250 300 350 400 450 500 550 600 650 700 CC Wire Speed Setting HI or LO Range b Referring to the graph located above the Mode switch also shown in Figure B 3 1 Select the hor
64. 0 1 LN 25 Kit WELDING CAPABILITY The LN 25 will handle up to 500 Amp 60 duty cycle welding currents However when equipped with K443 1 2 or 3 depending on code number Contactor the LN 25 will handle up to 300 Amp 60 duty cycle LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O Fie 9 9 53 4 cc Cc Return to Section TOC Return to Master TOC LN 25 INSTRUMENTS AND CONTROLS Refer to Figure B 1 for control locations FIGURE B 1 CONTROL LOCATIONS REMOTE WIRE SPEED ARC VOLTAGE DIAL RANGE CONTROL SWITCH OPTIONAL DIAL VOLT GAS POST METER PRE FLOW TIMERS OPTIONAL ELECTRODE POLARITY WORK CLIP SWITCH LEAD GAS FITTING GUN OPTIONAL CONNECTION BLOCK GUN TRIGGER AMPHENOL CONNECTOR OPTIONAL GAS INPUT FITTING GAS PURGE BUTTON ELECTRODE CABLE VOLTMETER Factory installed on model Codes above 9218 The 40V DC analog voltmeter is mounted to the front control panel of the LN 25 and is connected to read the arc voltage between the LN 25 M electrode cable connection and the work clip lead B 3 OPERATION B 3 NOTE 1 The Voltmeter will read zero if the LN 25 work clip lead is not connected to work even if the electrode is electrically hot to work 2 The Voltmeter will read below zero if the LN 25 polarity switch is not set
65. 0 512 690 LN 25 LINCOLN 22 Y 1 5 E N d LL NOL 4 18 uinjeH NOL 4 18 uinjeH NOL 4 18 NOL 491se N DOL uonoes uinjeg DOL uonoes DOL uonoes uinjeg DOL uonoes uinjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T Return to Section Return to Master TOC o 0 23 TROUBLESHOOTING AND REPAIR F 23 WIRE DRIVE MOTOR TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will determine if the wire drive motor is functional MATERIALS NEEDED Phillips Head Screwdriver Voltage Source variable 2 to
66. 00V CONTACTOR 5 135 27 R2 9 l J9 a 621 2 lt 212 co 02 33 2 5124 13 c 19 3300 300mA n az 5W 400V 9 27 LE lz 1000V t 49 150K e o 14 lt 2 Q 28K 456 221K 5 69K 9 Bs m X Q6 po 1 221K 224K 562K T J9 13 T dE i 5 J9 X5 S o m 100 RST 2N4401 j 829 Hene soov BY Q 05 Olo 512 5 lt 5 D 15 0K a 10 e 7 8A 9 D e a A Q R11 e 800V O 606 6 lt C9 C10 n T 5 Fie Es e 2N4403 100 cle 530A J9 p 07 REF C1 al 15 1 sis 50V E 5600 2 2 224K 2N4403 071 5 9 J9 221K 22 1K dii is 007 5 2 5 607 8 lt et i 1 EOV 1W 22 1K 5 1 82K TW Lo 8 TIMER BOARD Ren S A CE e 621 5 512 607 5 621 8186 5 i e e V cc J6 X3 990A 2 wen Vez 4 10 C e __ 512A 606 6 lt 512 i E lt amp 224K 8 e RB e T J6 X5 1 X3 2 67K 5 11 4 837 5 512A e 530 3 32K T RW PULL IN TIMER COLD INCH 21 9 SWITCH 8 a t v CONTACTOR ON 23 T RST 8 o 9 R12 e e By Q lo J7 4 X4 6 14 9 500 08 Q X3 e e 9 oiz n gm COLD INCH LOCK OUT E CURRENT LIMIT d 621 515 C8 kb 09 D D 512A 2700 1 10 cc
67. 0735 IN4005 DIODE IN4004 C7 C30 C31 C10 11 13 46 48 49 C14 C18 C19 C25 C 15 C21 C24 C44 C22 C26 C27 C45 C29 C32 04 01 04 027 03 05 07 08 09 010 011 Return to Section Return to Master TOC 6 00 Ceo mele 013 014 016 017 018 019 020 021 022 023 024 025 5 18395 29 12705 29 518395 14 518395 1 T 12702 19 T12702 11 T 13 160 134 T 13 160 135 T 13160 49 T13160 3 515000 9 18 105 3 T12704 55 T 12704 68 DIODE amp HEAT SINK ASSEMBLY DI ODE DIODE amp HEAT SINK ASSEMBLY DIODE amp HEAT SINK ASSEMBLY IN4742A IN4745A 4 PIN FEMALE RECEPTACLE 4 PIN MALE RECEPTACLE 12 PIN FEMALE RECEPTACLE PIN FEMALE RECEPTACLE 4N35 TRANSISTOR amp HEAT SINK ASSEMBLY TRANSI STOR 2N4401 D12 D30 031 C31 014 D21 s 020 123 022 015 C44 022 023 024
68. 1 513490 3 00477400 gt ____________1 513498 42 1 975 c4 E oleg 9 10 11155681 1 44 al 5 5 Q 8 1047458 5 JU 011 818248 6 __ 6 PIN REEPTAdE 9 ______________ 8188 4 518248 14 HEADER 2 1 1 1 112794455 TRANSISTOR _ B 03 06 x 221 11 12704 72 TRANS SS 5 G8 1 27 71 TRANS 55 51 5 2 ______________ 519408 3382 352 OHM 1 48 100 1 44 84 24 519400 1502 519400 1821 5 1 51940 1821 5 R6 R7 R9 813 R25 R26 128 519400 2212 22 1 174W 819400 5621 519400 3321 1 619400 1003 190K 1 44 me 1 1 1 1 91940 1902 iok isaw R20 150K 1 4W 519400 2801 2 8 1 4M 12300 85 R31 R32 2 xi x2 777 122 sisa VOLTAGE REF 7 44 5191998 ws 2 fia PIN Gua 1491 CMOS 145588 55 LEL DESCRIPTION REQ D CONTACTOR P C BOARD BLANK ADHESIVE a5 az INDUCTANCE HENRYS CAPACITORS MFD VOLTS ON 2 PLACE DECIMALS I 02 ON 3 PLACE DECIMALS 15 55 002 ON ALL ANGLES 5 4 5 OF A DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS ON HOLE SIZES PER E2056 8 8 AE E TE 5 FOR PARTS ORDERS SEND L10863 AND 518250 589 INCLUDE 1 T14477PRINT AND 1 521416 m NOTE Lincoln Electric assumes no responsibili
69. 23 VDC Volt Ohmmeter LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O 9 0 953 cc Cc Return to Section TOC Return to Master TOC F 24 TROUBLESHOOTING AND REPAIR F 24 FIGURE F 12 HALL EFFECT MODULE AND DRIVE MOTOR LEADS IN LINE CONNECTORS DRIVE MOTOR LEAD IN LINE CONNECTOR HALL EFFECT MODULE LEAD IN LINE CONNECTOR TEST PROCEDURE 1 Open the case door Remove the wire reel b 4 removing the retaining collar See Figure F 5 2 Remove the screws holding the control box cover in place and remove the control box cover See Figure 5 3 For codes 10148 and above separate the in line connector containing the drive motor leads located behind the mylar insulation Be 6 sure to identify the correct in line connector There is also an in line connector for the hall effect module behind the mylar insulation See Figure F 12 For codes 9812 and below remove the two motor leads 539 white and 541 black from the control board See Figure 10 LN 25 LINCOLN N Apply a variable DC voltage to the drive motor from lead 541 black to lead 539 white When the supply voltage is varied from 2 to 23 VDC the drive motor speed RPM should vary accordingly If the motor does not run or vary in speed the motor gearbox or motor brush
70. 3 234401 014 07 011 112704 64 1 818397 2 TRANS amp H S AS MBLY 5 5 e 09 811 1 14648 25 105880000222 2 23 85 817 837 873 5 519400 1800 109 1 48 Ro 1 1619400 2671 2 67K 1 484 899 R190 R15 R20 21 829 R30 R34 17 514400 2212 22 1 1 48 R79 R88 R82 189 190 R18 R19 R24 R26 860 853 619400 1002 R76 100 OHM TRIMMER 827 11 11 519489 1004 11 1 484 5 1519400 2672 26 7 1748 714648 18 68 58 R42 R88 2 519400 243 2 43 1 4W 844 895 2 1619400 6811 16 818 t 4M 846 1 519400 4752 47 5 1 44 R5 519498 1652 16 5K 1 48 _____________ 25 O 1 1619408 1023 102K 1 4W _______________ 55 1 si94w0 2801 2 8K 1 48 R57 1 619400 2670 R69 R74 R77 513400 1502 33 2K 1 49 519400 7681 7 68 1 4W _______________1 519408 1381 1 3K 174W _______________ 4 od N B X3 1 S15018 4 1 14584 S5 X4 1 Mi3552 2 _ FREO TO VOLTAGE CONVERTER 02121 1515018 10 14 PIN I C 55 __________ NB 1 S15018 6 DIGITAL INTEGRATED CIRCUIT SS o 1 1 5219 4 P C BOARD BLANK _________ NA _2 8 514020 4 EXPANSION d dem mod a 4 com 9 d FOR PARTS ORDERS 7 INCLUDE T13498 21 CAPACITORS MFD VOLTS RESISTORS OHMS
71. 3490 39 18 15 10 i MAKES 4 BOARDS PER PANEL SEE ELECTRONIC FOR ADDITDNAL NFORMATDN C16 1 813490 62 0033 200 10 47 1 813490 95 33 50 10 PANEL SIZE PER E1911 C21 1 513490 76 001 400 10 2 C22 513490 12 C24 C44 C57 3 516668 7 CAPACITOR CEMO 820p 50V 5 C26 1 520500 1 0 1 1000 10 C27 C45 2 13490 25 CAPACITOR TAEL 4 7 35V 10 C29 C32 C51 3 513490 42 CAPACITOR TAEL 1 0 35V 10 C38 C39 C40 C4T 042 053 8 516668 11 54 60 C59 516668 13 0104027 8 12199 4 2 03 05 07 08 010 011 013 22 12199 1 D14 D16 D17 D18 D19 D20 D21 D22 D23 D24 D25 D28 D29 D33 06 518395 32 9 084 2 T12705 34 O 032 1 T12199 2 DIODE AXLDS 1A 1000V DZI 1 T12702 19 022 023 074025 4 T12702 11 Ji 1 518248 4 CONNECTOR MOLEX MINI PCB 4 PIN 2 1 518248 6 6 D NA J3 1 518248 6 16 34 518248 14 515000 10 Q1 1 518105 3 TRANSISTOR N T220 5A 1000V MJE 18004 amp 518104 1 5 Q2 1 12704 55 TRANSISTOR NPN TO226 0 3A 400V MPS A44 9 4 03 04 05 06 010 012 013 9 T12704 68 6 5 0226 0 5 40 2 4401 014 016 07011017 3 12704 69 5 f 08 1 18397 3 TRANSISTO
72. 520500 17 0 1 630 5 C41 813490 210 CAPACITOR ALEL 8200 50V 20 R25 R26 R27 R28 R29 R30 R31 19400 1002 RESISTOR MF 1 4W 10 0K 194 Olio C45 513490 212 CAPACITOR ALEL 180 350V 2096 R32 R33 48 516668 5 CAPACITOR CEMO 022 50 209 R34 R36 R108 25923 5101 RESISTOR STAND UP MF 5W 5 1K 5 09 046 051 4 12705 59 DIODE AXLDS 3A 600V UFR Fido Ha 525923 3301 RESISTOR STAND UP MF 5W 3 3K 5 D2 D3 D4 05 D D7 08 12705 34 DIODE AXLDS 1A 400V FR 1N4936 R38 R41 819400 1503 RESISTOR MF 1 4W 150K 1 170 D10 011 D12 013 014 815 D16 R43 R44 519400 2000 RESISTOR MF 1 4W 200 1 017 018 D19 021 022 024 025 R45 R46 R47 R48 R49 519400 6881 RESISTOR MF 1 4W 68 1 1 9 026 027 028 029 032 033 034 24 T12199 1 DIODE AXLDS 1A 400V R50 R51 R52 R53 519400 2001 5 5 1 4 2 00 1 D35 036 037 038 039 040 041 19400 4750__ RESISTOR MF 1 4W 475 1 9 4 D42 D43 D49 D53 D54 D56 R55 R56 R57 R58 R95 519400 1003 RESISTOR MF 1 4W 100K 196 020 052 12199 4 DIODE AXLDS 1A 600V R59 R60 R61 R62 R94 R109 6 S19400 2212 RESISTOR MF 1 4W 22 1K 1 044 12199 2 DIODE AXLDS 1A 1000V R66 R96 519400 2211 RESISTOR MF 1 4W 2 21K 196 aie D47 D55 T12705 65 DIODE AXLDS 1A 600V FR 1N4937 R68 R69 19400 5111 5 5 1 4 5 11 1 2 D48 T12705 66 DIOD
73. 9 TROUBLESHOOTING AND REPAIR F 29 CONTACTOR amp CONTACTOR PC BOARD TEST continued FIGURE F 16 CONTROL BOARD L12253 112253 4 5 Return to Section Return to Master TOC E Return to Section TOC Return to Master TOC 500 512 Contactor 690 1 Check to be sure that plug P14 is connected to the Control Board and is secure Q O O O E 510 ak 0912 cic 2 Apply at least 25vdc but no more than 100vdc to the LN 25 from the Electrode cable to the Work sensing Lead Observe the polarity and set the Polarity Switch accordingly 3 Check for the applied voltage at Plug J1 pins 1 and 3 leads 667 and 621 See Figure F 16 4 With the Trigger closed and a normally operating contactor connectedthe voltag measured at Pins 1 and 9 of J14 should be approximately 1 0VDC not the Control Board may be defective Return to Section TOC Return to Master TOC LN 25 LINCOLN 30 Y 1 5 E e LL NOL 4 18 NOL 4 18 uinjeH NOL 4 18 NOL 491se N DOL uonoes DOL uonoes uinjeg DOL uonoes uinjeg DOL uonoes uinjeg F 31 TROUBLESHO
74. 9670 1 CONTACTOR PC BOARD ASSEMBLY BELOW CODE 9900 19185 2 LN 25 LINCOLN G 1 G 2 ELECTRICAL DIAGRAMS WIRING DIAGRAM ABOVE CODE 11140 G4679 OPTIONAL 42 VOLT REMOTE OUTPUT CONTROL O O O O i 912 54 ST p REMOTE TIMER P C 2 COLD INCH CONTROL BOARD o amp PUSHBUTTON 5300 k id 5308 6 lt gt 7 BOARD o SWITCH 1 6 4 500 5 d d O 16 oa 7 530A lt gt S gt 500 512 15 2 411 606 K lt 9 607 o 05 607 gt 116 622 N M ead 530 gt 1 13 512 one 500 2 530A 3 10 4 d 10 OPTIONAL 14 624 Ji4 2 TIMER PLUG lt ell ae 77 75 VOLTMETER 4 NH N G 11 gt 530 76 o 621 eI 606 2 667 6 621 gt 5 gt 622A 621 667 3 gt 1 2 5 Co M Ms TRIGGER 6557 24 CONNECTOR gt A cT 51 S1 D JA 621 POLARITY j 9 WORK CLIP SWITCH m vr E Uns cjs ss r wt 11 812 PURGE NEM 22222221
75. 99 MKES 10BOARDS PER PANEL D3 1 T12705 59 DIODE 600V 3A SEE ELECTRONIC FR ADDITINAL NFO D5 D6 D8 D9 D10 D11 6 12199 1 154004 BLANK PART NUMBER 110863 DZ1 DZ2 2 T12702 11 1N4745A 2 76 1 818248 6 HEADER N A 7 1 818248 2 HEADER 9 1 818248 14 HEADER 01 1 12704 56 5A 1000V TRANSISTOR 5 02 1 12704 55 TRANSISTOR 03 06 2 712704 68 254401 04 07 2 T12704 69 2N4403 0 159 N C NB Q5 1 12704 87 TRANSISTOR NMF SS 9 0 500 Q8 1 T12704 71 HEXFET TRANS SS 0 2 R1 1 T14648 5 3 3K 5W olo 3 m R2 1 819400 3382 33 2 1 4W r 2 ip R3 R11 R29 3 19400 1000 100 1 4W c 5 22 R4 R24 2 819400 1502 15K 1 4W 191 as R5 1 819400 1821 1 82K 1 4W 3 80 8S9 R6 R7 R9 R13 R25 R26 R28 8 819400 2212 22 1K 1 48 5 00 R36 4 x R10 R27 2 819400 5621 5 62K 1 4W v LIP 81 a R12 R37 2 819400 3321 3 32 1 4W e Xa 4 000 R14 1 819400 1003 100K 1 4W 3 pum R15 1 819400 5110 511 1 4W m ul 5 e s 22 2 Bf 46 R19 1 T12300 79 1 WATT 1 OHM 1 RESIS 5 amp R20 1 819400 1503 150K 1 4W Rs R21 R22 2 819400 2801 2 8K 1 4W Olo R23 1 819400 2211 2 21K 1 4W 9 2 d o LB NU 01 R31 R32 2 T13165 11 2 7 OHM 5 WATT RESIS J oe eee X1 X2 2 815128 10 IC 431 VOLTAGE REF 55 Of eS 2 O 3 5 2 815128 11 14 PIN QUAD COMP 9 3 As N B
76. AK 5 CIPKXRSQXR2Z67 IZ6T4R204 RS 5V G 8 Vi 35V 15AMPS 125VDC 05 m AD LA ER 100 400V 400V 2 6 05 on WIA 9 50 ne 55 05 E CONTACTOR DRIVE Rad 55 45V B Cer 038 i 1667 0 SENSE ms 382V 500V D39 boak 45V SOK 400 1 827 SENSE ARC VSENSE 1550V 500 024 1A i GND a PROGRAMMING SPI TEST DEV 681 Jap2 R48 gt NC 55 60 gt NC MOSI 59 2252 5 DATA MIS 65 5 5 gt sax 681 9 He gt e gt XRES NC USE J4 PIN FOR 5V USE 14 PINS FOR GND C46 1K 35 5V PROPRIETARY amp CONFIDENTIAL trier PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRES 5 COMPONENTS OR EQUIPMENT TYPE LN 25 THE INTERCHANGE SCHEMATIC CONTROL PCB on GENERAL INFORMATION ELECTRICAL SYMBOLS PER 1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 1A400V UNLESS OTHERWISE SPECIFIED LABELS SUPPLY VOLTAGE POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION 771 7 FRAME CONNECTION EARTH GROUND CONNECTION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC NOT BE DUP
77. AND REPAIR F 21 HALL EFFECT MODULE TEST continued FIGURE F 11 CONTROL PC BOARD CODES ABOVE 10500 500 512 4 Apply at least 25 VDC but no more than 100 represents the correct feedback voltage from VDC to the LN 25 from the electrode cable to the hall effect device to the control board the work sensing lead Observe polarity and set polarity switch 7 If the above voltage reading is not correct the hall effect device may need to be adjusted see the Maintenance Section replaced See the 5 Check for the presence of 12 VDC from lead 512 to lead 500 If the 12 VDC is not present or low the control board may be faulty See Figure F 110r F 11 a NOTE Machines with L12253 PC Boards react 6 Activate the LN 25 trigger circuit make sure the differently to loss of feedback Instead of drive motor is running and check for the running full speed the motor voltage is presence of approximately 6 0 VDC from lead held to approximately 14VDC 555 to lead 500 The value of 6 0 VDC FIGURE F 11 a CONTROL PC BOARD CODES ABOVE 10500 TED 12253 4 2253 4 50
78. Board or Remote Control PC Board if previously removed Install the control box cover and secure by installing the screws previously removed Install the wire reel and retaining collar and close the case door F 39 TROUBLESHOOTING AND REPAIR F 39 CONTACTOR REPLACEMENT FOR CODES BELOW 10500 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TOOLS REQUIRED Phillips Head Screwdriver 5 16 Nut Driver 11 16 Wrench Return to Section TOC Return to Master TOC O10 O O Fie 9 953 4 cc Cc Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O O Fie 9 0 8 8 cc Cc Return to Section TOC Return to Master TOC F 40 TROUBLESHOOT
79. Cut fed wire off at the end of the gun tip and accurately measure its length d Multiply the measured length by 2 to obtain the wire speed IN MIN e Repeat above steps to assure repeatable accuracy 4 Carefully slip speed knob onto potentiometer shaft so it points precisely to the wire speed measured in step 3 then secure the knob set screw without disturbing the position Recheck by repeating step 3 LN 25 LINCOLN 5 D 4 LN 25 LINCOLN amp D 4 NOL 4 18 NOL 4 18 NOL 4 18 uinjeH NOL 4 18 DOL uonoes DOL uonoes DOL uonoes uunjeg DOL uonoes uunjeg Return to Master TOC Return to Master TOC 4 o 0 Return to Master TOC Section E TABLE OF CONTENTS Section E THEORY OF OPERATION SECTION Theory of Operation cheese whe dee eu seesaw eked eae eee Section E General Description E 2 Control Circuit Operation E 2 Input Power Circuit E 2 Welding Current Circuit E 2 Feedback and Control Circuits E 3 Trigger Circuit E 3 Optional cassi A boca Chee E 4
80. E 621 N 8128 gt _ 2 A i 2 7 Cx 1 SW 10001 05 244401 lt x 500 512 s lt P b h 18 RIZ Ja BK to 56 e 13 4 K 2434 0 05 BAON OJO 100 O O 5304 lt 81 a E 2 4483 0 9 e q4 2 2 T 224 olg TIMER BOARD d e 16 2 5304 ee 46 606 4g g J amp 10 512 4 J6 it 500 E 512A 1 R18 539 Je n 2 21 PULL IN TIMER COLD INCH 05 olo SWITCH 2241 224 C4 14 B 7 D IW 5308 02 40 2 500 4 645 m D4 3 32K 3 32K o2 538 3 M RI CURRENT LIMIT I D8 621 d 5124 2780 2700 5 2 e 50 gt 05 2 D GENERAL INFORMATION LAST USED 16 3 ELECTRICAL SYMBOLS PER E1537 R 35 CAPACITORS 022 50 UNLESS OTHERWISE SPECIFIED C 13 CS Ce x3 X4 j C X5 V 621 621 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIEO LABELS 0 8 4200 18 DIODES 16 4090V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET 50 LM2981 MC145388 20V LM2901 NOTES POWER SUPPLY SOURCE POINT SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 5 COMMON CONNECTION WITHOUT
81. E T0247 30A 600V UFR 519400 2671 RESISTOR MF 1 4W 2 67K 1 t 21 022 023 0211 12702 45 ZENER DIODE 1W 18V 5 1N4746A 519400 2002 _ RESISTOR MF 1 4W 20 0K 1 024 0213 0714 T12702 29 ZENER DIODE 1W 15V 5 1N4744A 19400 3012 __ RESISTOR MF 1 4W 30 1K 1 DZ10 T12702 50 ZENER DIODE SW 17V 5 1N5354B R74 R86 892 519400 3321 RESISTOR MF 1 4W 3 32K 1 0212 12702 37 ZENER DIODE 1W 43V 5 1N4755A DZ15 0216 0217 3 712702 38 ZENER DIODE 1W 30V 5 1N4751A R75 R91 2 525831 0082 RESISTOR MF FLAMEPROOF 3W 0 2 5 0218 12702 53 ZENER DIODE 1W 3 3V 5 1N4728A R76 R77 R78 R79 R80 R81 R82 R83 R98 R99 R100 R101 R102 16 1 519400 10 0 R103 R104 R105 Ro 1 91940 6880 5 1 44 6814 7 RESISTOR MF 1 4W 10 0 196 6 00 04 A 5 5 62 r E V 2 CONTROL Ke OIO DENTFLATDN CODE R114 R115 519400 3320 5 5 1 4 332 1 O R116 519400 3322 RESISTOR MF 1 4W 33 2K 1 E R117 519400 3922 __ RESISTOR MF 1 4W 39 2K 1 REFERENCE G46163F1 R121 819400 1212 RESISTOR MF 1 4W 12 1K 1 35179 520375 22 TRANSFORMER PWM FLYBACK ICA 1313 Olg T 520375 23 TRANSFORMER PWM FLYBACK ICA 1314 5 t Ti364 1K MOV 180VRMS 45J 14MM 9 NB X 1 515128 4 OP AMP QUAD 224 9 1T NBJX2 1 S1790024 IC CMOS GATE NAND 2 INPU
82. EFERENCES PART NUMBER DESCRIPTION Q8 12704 103 _ TRANSISTOR N T0220 11A 600V IRFB16N60L SS Zz M 1 15253650805 RESISTOR STAND UP WW SW 0 05 5 K REFERENCE NFORMATDN 7 5 14 15 16 20 516668 11 CAPACITOR CEMO 0 1 50 10 1 R3 R4 8119 3i lsi 22050105 5 C20 C31 2 516668 6 CAPACITOR CEMO 4700pF 50V 10 519400 1500 RESISTOR MF 1 4W 150 1 PLETE AS 112253 4 LAYER BOARD PER E3281 C21 C46 S16668 8 57 22 C23 C37 516668 3 CAPACITOR CEMO 100pF 100V 5 1 519400 1580 RESISTORMF 1 4W 15 0 196 MAKES 4 BOARDS PER PANEL SEE ELECTRONIC ADDITONAL NFORMATDN C24 Cao 3 516668 9 CAPACITOR CEMO 150pF 100V 5 C26 C27 C47 513490 173 1 0 63 10 EO em C29 1 TM57746K __ 0 05 600 80 20 R15 R16 R17 R70 R97 R111 14 519400 1001 RESISTOR MF 1 4W 1 00K 196 C30 C42 520500 16 CAPACITOR PPMF 0 0033 630V 5 BOX 34 44 513490 199 220 25V 20 LOW ESR R18 R67 R118 R120 519400 4751 1 4 4 75 196 C35 36 43 513490 197 __ CAPACITOR ALEL 82 35V 20 LOW ESR R19 R20 R21 R22 R24 519400 2672 RESISTOR MF 1 4W 26 7K 1 C38 C39 513490 209 CAPACITOR ALEL 470 350V 20 R23 R63 R64 R65 519400 1502 RESISTOR MF 1 4W 15 0K 1 C40
83. ERTER 555 0 10 gee OVER VOLTAGE SHUT DOWN CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD 1 4 147 2_4 25 258 J6 2 43K lee i 3 021 c10 12 2 20 iW sov 512 NEGATIVE SUPPLY 3 32 4 KHZ OSCILLATOR C19 pes t 18 18 15V 15V 11827 1 00M 22 1K ACTUAL SPEED BUFFER COMPARATOR ACCELERATION 5 62K 1 0 10K 35V 9 224K 9 SHOOT THRU PROTECTION N C N D N E 512 8 CONTROL BOARD 5 5 5 4 PPP GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS mfd VOLTS 022 25 UNLESS OTHERWISE SPECIFIED RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED N J DIODES 1A 400V UNLESS OTHERWISE SPECIFIED COMMON CONNECTION N L SOURCE POINT CIRCUIT LOCATION CONNECTOR CAVITY NUMBER P a 9 s a
84. GRAM BELOW CODE 9900 L7545 _ 2 WIRE SPEED DIAL RANGE SWITCH 9 9 lt Return to Master Return to Section TOC Return to Master TOC x COMPONENT SIDE OF BOARD ELECTRICAL SYMBOLS PER E1537 ig VOVNYO 7776267 1 8150 2 HI 3 2 621 6 1 64 500444 2 9 o WHITE Jl 27 06122000 667 3 E 2 4 522 512 P BOARD 6224 4 lt 541 O BLACK gag 530A ou 2 5 N C BOARD PLUG i5 ds 2 Td NA 2 7 5304 2 p oe m 10K Poles 214008 1 500 WIRE SPEED 606 116 SOLENOID CONTROL RHEOSTAT Eo T BOARD PLUG P Ro i35 996 3 GAS L 530 1 41 e 3 622 128622 N B 500 15 N usd Pa 551 1 a M ical i N D l l l Jr N D 5 530A X m l H 530A VALVE 8 t ji 667 ARC SOLENOID Gu olo ARC d 7 624 i gt 624 P C BOARD Od x VOLTMETER OPTIONAL gt 8 gt 500A i gt 500A CONTROL s TIMER BOA
85. ING AND REPAIR F 40 CONTACTOR REPLACEMENT continued FIGURE F 25 CONTACTOR REPLACEMENT 11 16 BRASS NUTS VOLTAGE SENSING LEAD 67 gt j IN LINE CONNECTORS REEL STAND ASSEMBLY WELDING CABLES CONTACTOR 27 BAFFLE 5 16 SCREW REPAIR PROCEDURE 8 Carefully remove the contactor from the LN 25M 1 Open the case door Remove the wire reel b removing the retaining collar See Figure F 5 9 Install a new contactor in the LN 25 2 Remove the screws holding the control box 10 Connect the contactor coil lead in line cover in place and remove the control box connectors behind the reel stand assembly cover See Figure F 5 See Figure F 25 For codes 9812 and below install the contactor coil leads onto the 3 Remove the baffle from in front of the contactor contactor PC board See Figure F 19 See Figure F 25 11 Install the welding cables and voltage sensing 4 Remove the 5 16 screw holding the contactor lead 67 to the contactor and secure with the in place two 11 16 brass nuts See Figure F 25 Remove the two 11 16 brass nuts holding NOTE Be sure brass nuts are tight 11 ft lb cables to the contactor 12 Install the 5 16 screw to secure the contactor 6 Disconnect the contactor coil leads by in place separating the two in line connectors behind the reel stand assembly For codes 9812 and 13 Install the baffle in front of the
86. K 196 gt R33 R62 R66 519400 1503 RESISTOR MF 1 4W 150K 1 R35 R56 R59 R70 R75 19400 2672 __ RESISTOR MF 1 4W 26 7K 1 9 4 SCHEMATIC REFERENCE 63424 3 R36 R45 2 519400 1501 5 5 1 4 1 50 1 R37 1 819400 3382 RESISTOR MF 1 4W 33 2 196 c R38 1 T14648 18 RESISTOR WW 5W 68 5 SQ 5 E Fede R41 1 519400 3922 RESISTOR MF 1 4W 39 2K 196 R42 R88 19400 2431 __ RESISTOR MF 1 4W 2 43K 1 342542 844 519400 8251 RESISTOR MF 1 4 8 25 196 R46 1 819400 4752 _ RESISTOR MF 1 4W 47 5K 1 R47 T12300 77 RESISTOR WW 7W 0 1 1 R50 R53 R65 519400 4422 RESISTOR MF 1 4W 44 2K 1 MAKE PER F1911 R51 1 519400 1652 RESISTOR MF 1 4W 16 5K 196 ENCAPSULATEW E1844 R54 1 81940021023 RESISTOR MF 1 4W 102K 196 TEST PER 2747 R55 1 19400 2801 RESISTOR MF 1 4W 2 80K 196 R57 1 19400 2670 RESISTOR MF 1 4W 267 196 R69 R74 R77 519400 1502 RESISTOR MF 1 4W 15 0K 196 CAPACHORS MED JVOLTS R78 R110 2 19400 3322 RESISTOR MF 1 4W 33 2K 1 RESISTORS OHMS R87 519400 7681 __ RESISTOR MF 1 4W 7 68K 1 R91 819400 1301 RESISTOR MF 1 4W 1 30K 1 R112 819400 1821 RESISTOR MF 1 4W 1 82K 1 R114 T12300 79 RESISTOR WW 1W 1 0 1 R117 R118 2 519400 4750 RESISTOR MF 1 4W 475 1 1 1 13640 11 MOV 150VRMS 45J 14MM 2 2 15128 10 VOLTAGE REF ADJ PRECISION 4311 N B X3 515018 4 IC CMOS INVERTER SCHMITT
87. LDER EXTENDS FROM THE PAD DIAMETER UP THE PIN AT A MINIMUM ANGLE OF 45 DEGREES N D ANCHOR ITEMS C2 C5 C8 AND C9 BOARD WITH 25 WIDE 50 LONG BEAD OF ITEM 5 MAKE PER 191 ENCAPSULATE WITH E1844 TEST PER 2141 MANUFACTURED AS G2196 1A0 IDENTIFICATION CODE NOT 10 BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE UNC LN ELECTIIC CO THe SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE OWNED BY THE LINCOLN ELECTRIC CO AND is ON HOLE 555 5205 Lm epe 2 68 C9 3 513490 106 233 634 C35 C36 C374 C38 C39 C40 C41 C42 C43 C47 1 81849035 3300 50 WO BONN NN I ETC CTECINNG T ___ _ CENE 18890577 21 24 44 1 490 7 35 0 35 005 DIODE 4004 27 45 c32 01 04 027 03 05 07 08 09 01 01 013 014 016 017 018 018 020 021 022 023 024 2 1 02 maa N 02000 4 51313 gt le NIN nN 2 T12199 1 D25 D28 D29 D32 N C 06038 o 1 518106 012 T12785 29 Nc 031 1 1 518395 1 02 _______________ 12702 19 0011 1 515882 9 4135 E ae oe ee en ee al 01 O 1 512105 3 TRANS AND H S AS MBLY 112704 55 TRANSISTOR 03 04 05 06 018 012 01
88. LE 295 290 CONNECTOR MUST to BE INSULATED 200 IN THIS AREA 1 2 00 1 4125 LN 25 Connector for 1 16 062 through 5 64 Wire STYLE B 03 x 45 A DIA HOLE LN 25 Cable Connector for 023 through 052 Wire 495 For all other dimensions see above DIA FIGURE C 2 SWITCH REQUIREMENTS NOTE Connector part with 749 747 diameter should be made from brass if it is to be part of the welding SWITCH REQUIREMENTS current carrying circuit Amp AC 24 Volts Inductive gt Amp DC 24 Volts Inductive A Dia Hole To be Concentric to 749 747 Dia Within 008 068 thru 125 Drill 062 078 Drill CONNECT LEADS TO Kit No epp m AMPHENOL ANSUSI 10 OR EQUIV 512020 6 LE PART NO AMPHENOL MS 3106A 18 11P OR EQUIV Can also be used for 052 wire LN 25 LINCOLN Return to Master TOC Return to Master TOC 4 o 0 Return to Master TOC TABLE OF CONTENTS MAINTENANCE SECTION Maintenance Section D Safety 012 D 2 Routine Maintenance D 2 Drive Rolls and Guide Tubes D 2 Wire Reel Spindle D 2 Control 4 5 a ee D 2 Wire Drive Motor an
89. LICATED COMMUNICATED S WRITTEN OF LINCOLN GLOBAL INC 16 2 1 MATERIAL APPROVAL 49 5 2007 OROECT 9207 4616 5 G 9 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BD CODE 10556 THRU 10558 G3424 3 E ENGINEERING CONTROLLED CHANGE DETAIL ADDED OBSOLETE NOTE a ES HOJE voveo JMANUFACTURER No Ead E i gt 512 lt ct E EE d NEGATIVE q SUPPLY S62K S m S 221K aes 8 F V CONVERTER TO 100K P L KHZ EFFECT sit EE 019 FACH INPUT OSCILLATOR SENSOR 0 X4 1000F rm 221K TACH INPUTLL E 409 5 ast epee lt OE ae LM2907 F pen y ads _ u f 17 22 0033 yx 33 M 5 v M Vou 200 aov _ 9 2 E 2 512 FM KR TEUER 27729014 220 10 0K 25 150 8 o 2 me Ed 5 FET DRIVER 100v my ACTUAL SPEED qom 50 isis Via BUFFER hae DI 3 EN 1200 2
90. Located inside case Uu n ri g ger ES 5 Protection ne c jS IrCcul 0 VDC Open _ Contactor oS 2 INPUT ELECTRODE 12 VDC coil Located inside case CABLE CONNECTION PWM Contoled below voltmeter PURGE NO 621 608 N A CAVI Y NUM BERING SEQUENCE AS VIEWED FROM CCM PONENT SIDE OF BOARD dori rm N B CAVI Y NUM BERING SEQUENCE AS VIEWED ROM LEAD SIDE CONNECTOR Local N C OGGLE SWITCHES AND POT ENTIM ETERS SHOWN ROM CONNECTION SIDE OF SWITCH of case OPTDN BOARD EXPLANATDN There are thee cptenaTboaxdis avaibbk forthe IN 25 The wing assocated with these boards indicated by dashed hes and the acborevatens are as Model Ranger 8 9 Classic Ranger 250 305 V350 DC 400 600 Square Wave TIG Miller Inverters STT II Note pm p NM Commander 300 400 500 Digital 300 355 Most semiautomatic wire n C JS Standard W ing Boards 5 169 This wirhg jmpermustbe isad notpresent Common Analog Controls welding processes Jc OptonalContactorBoaid Controls perform better using t 6 it h OptimalRenote Board K449 Recommended Recommended for Recommended for CV Recommended for Recommended Not recommended Recommended Not recommended constant voltage power n pu WI C es JT OpttralTin erBoard IEtnerkts notnstaTed and em ote board Enotpiesent then jmpers hstaled n Jl1 Across the A
91. MFD VOLTS RESISTORS OHMS O O e 6 9 no 0 oiz 215 Ch ge Sht No EQUIP visse THE LINCOLN ELECTRIC LN 25 5 Pc G 15 ELECTRICAL DIAGRAMS G 15 olo SCHEMATIC CONTACTOR PC BD ABOVE CODE 10500 M10965 o 5 906 LIN 01 59 CONTROL BOARD 7w BACK UP COIL SUPPLY gt 9 id bd ii 0 D2 TO ped J9 600V A 111007 624 4 4
92. Master TOC 4 o 0 F 6 TROUBLESHOOTING AND REPAIR F 6 Troubleshooting Guide see Wiring Diagrams for location of specified components See Wiring Diagrams for troubleshooting of specific circuits PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Continued Observe Safety Guidelines detailed in the beginning of this manual The wire feed motor runs ata constant speed with no control NOTE Loss of tach feedback may result in MAX speed ora motor voltage of approx 14VDC depending on the Control Board being used The gas solenoid valve will not function The contactor does not function Make sure the mode switch S3 is in the CV mode Make sure the wire speed control and the wire speed range switch S2 are set correctly Make sure the LN 25 is equipped with a gas solenoid valve and properly connected Make sure the gas supply is adequate and the gas hoses are not loose or kinked NOTE Control Boards L12253 or higher do not use a Gas Solenoid PC Board 1 Make certain the LN 25 5 equipped with a contactor and properly connected 2 Check the connections to the contactor PC board NOTE Control Boards L12253 or higher do not use a Contactor PC Board 1 Perform the Hall Effect Module Test 2 Perform Wire Drive Motor 3
93. NNECTS DIRECTLY TO THE CONDUCTOR BLOCK N G JUMPER PLUG MUST BE INSTALLED UNLESS OPTIONAL TIMER IS USED N H TOGGLE SWITCH USED ON EARLIER UNITS N J PROVIDES AN ESD PATHWAY FROM EXPOSED METAL SURFACES TO THE WORK PRESENT ON EUROPEAN MODELS ONLY N L CONNECTS TO THE BUSHING OF THE COMPONENT LINCOLN ELECTRIC LEGEND 51 POLARITY SWITCH 52 WIRE SPEED DIAL RANGE SWITCH 53 WIRE FEED MODE SWITCH 54 COLD INCH SWITCH 5 PURGE PUSHBUTTON CONNECTOR CAVITY NUMBER CLEVELAND OHIO U S A REMOTE OR CONTACTOR BOARD TIMER P C BOARD J10 NOR J12 P C BOARD SOU REMOTE P C BOARD REMOTE BOARD ARC VOLTS TO POLARITY SWITCH TO CONTROL BOARD PTIONAL P POWER ADAPTOR KIT OPTIONAL PULSE D OR KI 10 23 98E L10925 NOTE This diagram 15 for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code 15 pasted inside one of the enclosure panels of your machine x Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC G 4 WIRING DIAGRAM CODE 10100 THRU 10500 19644 rimis 4 E D 5 1 L 1 4 TERES i ECT boa ter esc DE PRI B a E y
94. OC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TOOLS REQUIRED Phillips Head Screwdriver Return to Section TOC Return to Master TOC O10 O O Fie 9 953 4 cc Cc Return to Section TOC Return to Master TOC LN 25 LINCOLN F 36 TROUBLESHOOTING AND REPAIR F 36 CONTROL PC BOARD REPLACEMENT continued FIGURE F 20 CONTROL PC BOARD PLUG LOCATIONS CODES 10148 AND ABOVE Return to Section TOC Return to Master TOC eio ele E 5 0 REPAIR PROCEDURE o 1 Observe the static electricity precautions 5 For codes 9812 and below remove the four detailed in PC Board Troubleshooting plugs J1 J2 J3 and J4 Also tag and remove Procedures at beginning of this section the five individual leads three hall effect leads Dlo 500 512 and 555 and two drive motor leads 2 Open the case door Remove the wire reel b 539 and 541 connected to the control PC removing the retaining collar See Figure F 5 board See Figure F 21 Remove the screws holding the control box NOTE For Codes above 10148 wit
95. OTING AND REPAIR F 31 CONTACTOR PC BOARD REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TOOLS REQUIRED Phillips Head Screwdriver Return to Section TOC Return to Master TOC O10 O O Fie 9 953 4 cc Cc Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O o gt cc Cc Return to Section TOC Return to Master TOC Return to Master TOC F 32 TROUBLESHOOTING AND REPAIR F 32 CONTACTOR PC BOARD REPLACEMENT continued FIGURE 17 CONTACTOR PC BOARD CODES 10148 AND ABOVE REPAIR PROCEDURE 1
96. R IGBT 1247 1200V 45A FAST SS WITH S1 m 7 09 1 18395 33 TRANSISTOR IGBT 1247 1200V 45A FAST SS 015 1 520630 1 SBS 10226 7 5 9 0V MBS4993 c a O18 T12704 72 R1 1 T14648 25 RESISTOR WW 5W 10 596 8Q R2 R72 R86 3 T14648 5 RESISTOR WW 5W 3 3K 596 8Q R3 R5 R17 R73 R109 5 19400 1000 RESISTOR MF 1 4W 100 1 R4 R119 2 19400 10RO 5 5 1 4 10 0 1 R6 519400 3072 R7 R95 2 19400 6811 __ RESISTOR MF 1 4W 6 81K 196 R8 R113 2 819400 2671 __ RESISTOR MF 1 4W 2 67K 1 R9 R81 R83 R96 R97 R98 R99 10 819400 1001 RESISTOR MF 1 4W 1 00K 1 R100 R101 Rit eee ee R10 R52 R64 3 819400 1372 _ RESISTOR MF 1 4W 13 7K 1 R11 1 816296 3 TRIMMER MT 1 2W 500 10 LINEAR R12 R43 R84 R85 R94 5 819400 4751 RESISTOR MF 1 4W 4 75K 196 R13 R14 14648 11 RESISTOR WW 5W 4 7K 5 SQ R15 R20 R21 R29 R30 FG4 R39 R40 R49 R67 R68 R71 R79 R80 R82 R89 R90 R102 R104 R105 R106 R115 R116 R16 R61 R107 519400 1003 RESISTOR MF 1 4W 100K 1 O R18 R19 R24 R26 R60 R63 819400 1002 __ RESISTOR MF 1 4W 10 0K 1 P C BOARD BLANK R76 8 EXPANSDN NUT R22 1 516296 2 TRIMMER MT 1 2W 100K 10 LINEAR 5 70408 2861 823 1 519400 6812 RESISTOR MF 1 4W 68 1K 1 R25 R32 819400 3321 RESISTOR MF 1 4W 3 32K 1 D R27 1 19400 1004 RESISTOR MF 1 4W 1 00M 196 R28 R58 R108 819400 5621 __ RESISTOR MF 1 4W 5 62K 196 R31 1 819400 1822 RESISTOR MF 1 4W 18 2
97. RD 9 gt 530 EM gt 530 1 1 4 441 41 2 c PLUG FYK 9 10 606 1 1 606 ur E 667 621 oom Ss 621 I o rx 621 1 518 SmalS 606 512 608 5 7 N G 9 12 gt 622A rk 622A oz T i E 624A 621 95 4 ea eS N D 9 TO p OPTIONAL REMOTE 123456789 KIT PLUG Pe e Y YYYYrrY 555 cc l D O 5 BANBANE 500 621 500 621 TO WORK CLIP jez 4 _ 5308 530 p e 8 o u 4 man TE s s m BLACK COLD INCH WIRE FEED See MODE SWITCH 62 LEGEND Sj NEG x uult 51 POLARITY SWITCH POLARITY SWITCH 52 WIRE SPEED DIAL RANGE SWITCH SWITCH 53 WIRE FEED MODE SWITCH 5 67 _66 S4 COLD INCH SWITCH 5 5 Leste N H B N D N H 8 lg E Fle NOTES 5 5 WHEN CONTACTOR IS NOT USED THE 33 0 JUMPER PLUG MUST BE INSTALLED UNLESS OPTIONAL REMOTE KIT IS BEING USED 4 o2 N B CONNECTIONS AS VIEWED FROM BACK OF 818 RHEOSTAT AND SWITCHES 5 5 MC FUSE USED ON EARLIER MODELS ONLY Ir 29 J5 ON 61757 2 THRU 01757 5 CONTROL P C
98. RE SPEED setting f If using the optional Gas Flow Timer set the de sired PREFLOW TIME and POSTFLOW TIME g Be sure the proper contact tip for the wire size being used is in the gun and the gun is safe from work contact Use the LN 25 insulated gun holder LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 h Turn on the welding power source as well as the shielding gas supply if used WARNING Unless an optional output control or internal contactor is used the electrode is electrically hot when the power source is on The gun trigger controls wire feed only WARNING CYLINDER may explode if damaged e Keep cylinder upright and chained to support eKeep cylinder away from areas where it may be dam aged e Never lift welder with cylinder attached e Never allow welding elec trode to touch cylinder eKeep cylinder away from welding or other live electrical circuits WELDING A WARNING ARC RAYS can burn e Do not touch metal portions of the LN 25 lead Clip when welding power source is on 22 a Cut the electrode within approximately of the end of the contact tip for solid wire and within approxim
99. Repair Section F Electrical Diagrams Section G Parts Manual below code 10500 P 175 Parts Manual above code 10500 P 333 LN 25 LINCOLN amp Section TABLE OF CONTENTS Section A INSTALLATION SECTION D Installation Section A Technical Specifications A 2 ps Safety Precautions rd Regens 3 3 Power Source Connection A 3 25 3 DC 400 CV 400 A 3 DC 6000 wade bed Pea eee eee le A 4 SAM 400 650 A 4 SA 200 250 SAE 300 400 A 4 Invertec CV300 and other newer Lincoln Power Sources A 4 Gun Cable Connection to Feeder 4 Weld Cable Connection A 5 Electrode Cable Connections A 5 5 Work Cable Connection 5 Wire Feed Drive Roll and Guide Tube A 5 0 9 D 0 9 H D D 0 9
100. Return to Section TOC O10 O O e 9 953 cc Cc Return to Section TOC Return to Master TOC Return to Master TOC F 9 TROUBLESHOOTING AND REPAIR F 9 GAS SOLENOID VALVE AND SOLENOID PC BOARD TEST continued FIGURE F 2 SOLENOID LEADS SOLENOID LEADS SOLENOID LEADS 3 Locate and remove the two solenoid leads from 6 If the solenoid does not activate and allow gas the solenoid valve For codes 9812 and below to flow then the solenoid is faulty Replace remove the two leads from the Solenoid PC Board See Figure 22 7 The normal solenoid resistance is approximately 20 to 27 ohms 4 Make sure the gas supply for the solenoid is hooked up and then apply 12 VDC to the gas solenoid 5 If the solenoid activates and allows gas flow then the solenoid valve is good NOTE There should not be any gas flow until the solenoid is activated LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O Fie 9 953 cc Cc Return to Section TOC Return to Master TOC F 10 TROUBLESHOOTING AND REPAIR F 10 GAS SOLENOID VALVE AND SOLENOID PC BOARD TEST continued FIGURE APPLIED VOLTAGE POLARITY ELECTRODE CABLE POLARITY SWITCH WORK SENSING LEAD 4 SOLENOID PC BOARD 1 Apply at
101. SECTION ELECTRICAL DIAGRAMS a aaa 24 24 4 WIRING DIAGRAM ABOVE CODE 11140 04679 WIRING DIAGRAM CODE 10556 THRU 10558 110925 WIRING DIAGRAM CODE 10100 THRU 10500 19644 WIRING DIAGRAM BELOW CODE 9900 17545 COMPLETE MACHINE SCHEMATIC CODES ABOVE 11140 05366 COMPLETE MACHINE SCHEMATIC BELOW CODE 9900 ONLY G1833 CONTROL PC BOARD SCHEMATIC ABOVE CODE 11140 G4616 3 CONTROL PC BOARD SCHEMATIC CODE 10556 THRU 10558 63424 1 CONTROL PC BOARD SCHEMATIC CODE 10100 THRU 10500 62194 CONTROL PC BOARD ASSEMBLY CODES ABOVE 11140 L12253 3 CONTROL PC BOARD ASSEMBLY CODE 10556 THRU 10558 63425 3 CONTROL PC BOARD ASSEMBLY CODE 10100 THRU 10500 62196 1 CONTROL PC BOARD ASSEMBLY BELOW CODE 9900 61757 6 CONTACTOR PC BOARD SCHEMATIC ABOVE CODE 10500 M10965 CONTACTOR PC BOARD SCHEMATIC CODE 10100 THRU 10500 17621 CONTACTOR PC BOARD SCHEMATIC BELOW CODE 9900 175354 CONTACTOR 15428 CONTACTOR PC BOARD SCHEMATIC BELOW CODE 9900 L9185 CONTACTOR 17139 CONTACTOR PC BOARD ASSEMBLY ABOVE CODE 10500 110863 1 CONTACTOR PC BOARD ASSEMBLY CODE 10100 THRU 10500 1
102. SSEMBLY CONTACTOR ABOVE CODE 10500 L10863 1 E He 698011 ENGINEERING CONTROLLED CHANGE DETAIL COM PON ENTS AND PART NM BERS AND UPDATED CR APHICS ER REQD PART NO IDENTIFICATION MANUFACTURER 0 1 813490 107 5600 35V 5 2 C2 1 816668 6 4700pF 50 gt 1 813490 42 1 0 35 0 c4 1 816668 7 820pF 50 9 9 C5 1 813490 92 3300 50 6 7 9 15 4 816668 5 022 50 5 C8 C14 2 816668 4 2700pF 50 5 C10 1 516668 11 1 50 cc Cc C11 1 813490 19 1 8 20 C16 1 816668 1 22 100 2 2 C17 1 813490 39 18 15 1 1 12705 29 DIODE P C BOARD BLANK NFORMATDN MAKE FRM 5193
103. T QUAD SCHM SS pe EL NB 515018 9 ____ CMOS DRIVER MOSFET 2113 SS 2 NBNCIX4 1 5250739 5 50 8 8 27443 28 55 5 NB M15458 8 IC PWM CONTROLLER IMODE 2843A N C 6 1 1585285 3 1 5 22 cc 2 02 NOTES CAPACIDRS MFD WOLT NA DO NOT ENCAPSULATDN MATER AL RESBTORS OHMS NB CAUTDN THS DEVICE SUBJECT TO DAMAGE BY STATI MAKE PER 1911 ELECTRICITY SEE E2454 BEFORE HANDLING ENCAPSULATE TW CEW E1844 TEST PER E4143 38 NC PROGRAM PER 5 AND 4 W PART NUMBER OF ITEM 5 00 FOR PARTS ORDERS NCIUDE T13498 21 ma lorl ___ FEI ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING APPROVED ENGINEER EF 12253 3 SOLID EDGE EN 168 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the de
104. TANDARDS DO NOT SCALE THIS DRAWING NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ON 3 PLACE DECIMALS IS 002 APPROVED EN 170 Flr 5 o gt 8 8 4 x SOLID EDGE Return to Section TOC Return to Master TOC Return to Section TOC O O o 9 21 9 091 9 cr Return to Section TOC Return to Master TOC Return to Master TOC G 7 SCHEMATIC COMPLETE MACHINE BELOW CODE 9900 ONLY G1833 SE WIRE SPEED DIAL RANGE SWITCH HI LO ee 52 Bete 633 631 10K OHMS NB WIRE SPEED CONTROL RHEOSTAT WIRE FEED VOLTMETER MODE SWITCH B i VV CV Pun 1 667Q Q 621 PA 53 N B 524 1 509 TO WORK BLACK CLIP 51 POLARITY POS SWITCH O 667 4 N B 621 lt gt 667 que T 622A x gt 622A 48 PURGE SOLENOID TRIGGER N F KIT PLUG connector 27 i 0 4 GUN CABLE 1 gt 1 SEE SOLENOID KIT n LLL SCHEMATIC 0 606 4 GAS SOLENOID VALVE 539 W 5094x 524 4 8 R E 541 EFFECT 522 523 633 Q CONTACTOR COIL PRIUS 632 n CONTACTOR P C BD PLUG P N H MAT q OPTIONAL __ Re REMOTE PLUG eu E KP
105. THE INTERCHANGEABILITY OF 4 COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY GF CONTROLS HAVING A COMMON CODE NUMBER UNLESS OTHERWISE SPECIFIEO TOLERANCE ON HOLES SIZES PER 2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS THE LINCOLN ELECTRIC CO LN 25 CLEVELAND OHIO U S A CONTACTOR SCHEMATIC __ __ _ for Mc th 3 28 98 17139 _ 828 KE 100 a X4 50V 8 2N4403 07 400 01 284403 02 REF 35V N 16 Cs 042 6 16 M V 7621 a 5124 19K E 18 z RIS 5128 2 21 PULL IN TIMER 5 62 R7 5 C4 001 o 14 amp 5 400 19 T E CURRENT LIMIT 621 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 LAST USED CAPACITORS MFDi 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 4087 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT COMMON CONNECTION 7777 FRAME CONNECTION lt gt EARTH GROUND CONNECTION FILE M17139 2BB NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRICAL DIAGRAMS G 19 PC BOARD A
106. TOR PART CONTROL PC BOARD 435 2 e N F WHEN IS NOT USED THE 67 LEAD TO THE POLARITY NC SWITCH COMES FROM TH CONDUCTOR BLOCK AND THE INPUT CABLE 2 4 N ND N E CONNECTS DIRECTLY THE CONDUCTOR BLOCK Je 102 N G JUMPER PLUG MUST INSTALLED UNLESS OPTIONAL TIMER IS USED UM m N H TOGGLE SWITCH USED ON EARLIER UNITS 211111 25 ARC VOLTS PROVIDES AN ESD PATHWAY FROM EXPOSED METAL SURFACES TO THE WORK aN 15 35 484 37 bs 606 LIRE LEGEND PRESENT ON EUROPEAN MODELS ONLY 21 gt 8 622 SWITCH 5 81 POLARITY SWITCH N L CONNECTS TO THE BUSHING OF THE COMPONENT o D i 1 92 WIRE SPEED DIAL RANGE SWITCH JNNEC 2 23 WIRE FEED MODE SWITCH CONNECTOR CAVITY NUMBER gt 0 54 COLD INCH SWITCH t Y 5 PURGE PUSHBUTTO T UM gt 3 OPTIONAL PULSE POWER ADAPTOR KIT c ji 6 Sui ee ee ee ee ee 2 TR i Bei Te EEEE 5 de CLEVELAND OHIO USA E 818 2003 4 2011 ez 52 x x NOTE This diagram is for reference only may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine 0 5 ELECTRICAL DIAGRAMS WIRING DIA
107. TS WITH AN L12253 1 CONTROL PC BOARD 4 oi WHEN CONTACTOR IS NOT USED THE 67 LEAD TO THE POLARITY SWITCH COMES FROM THE CONDUCTOR 75 o oOo 00000 9 BLOCK AND THE INPUT CABLE CONNECTS DIRECTLY TO THE CONDUCTOR BLOCK 76 mcs 2203 74 4 6 6 10 N G IF TIMER KIT IS NOT INSTALLED 46 19 7 15 31 16 2 11 14 ON UNITS WITHOUT REMOTE PC BOARD JUMPER MUST BE INSTALLED IN J11 4 83 4 7 4 ON UNITS WITH REMOTE BOARD JUMPER MUST INSTALLED IN J6 OF REMOTE PC BOARD 5 ARC VOLTS N H TIMER KIT HARNESS INSTALLATION UO 120458 Jes 29 o Ooooogo ET lazos HHBHHEHHH ON UNITS WITH REMOTE PC BOARD TIMER HARNESS MUST PLUG INTO J6 OF REMOTE PC BOARD NYY POLARITY 8 45 T ON UNITS WITHOUT REMOTE PC BOARD TIMER HARNESS MUST PLUG INTO J11 9 607 SWITCH olo P N J PROVIDES AN ESD PATHWAY FROM EXPOSED METAL SURFACES TO WORK 310 512 0 16 N K PRESENT ON EUROPEAN MODELS ONLY pex Ele N L CONNECTS TO BUSHING OF COMPONENT J3 ON N M 14 JUMPER PLUG USED ON K428 ONLY CONTROL BOARD olo CONNECTORS VIEWED FROM INSERTION END C N gt TO TIMER BOARD 018 OPTIONAL PULSE POWER ADAPTOR KIT B 2 12 818 CLEVELAND U S A G4679 5 c c NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring
108. The control board may be faulty Replace 1a Perform the Solenoid PC Board and Gas Solenoid Valve Test NOTE Test is code specific Codes above 10100 may or may not have a Solenoid PC Board 2 If a K434 1 gas flow timer kit is installed in the unit disconnect and plug in the timer jumper plug If the gas solenoid functions then replace the K434 1 kit The contactor board or remote control board if used may be faulty The control board may be faulty Replace 1 Perform the Contactor Test NOTE Test is code specific Codes above 10100 may or may not have a Contactor PC Board 2 he Contactor PC board or the Control Board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 LINCOLN F 7 TROUBLESHOOTING AND REPAIR F 7 GAS SOLENOID VALVE AND SOLENOID PC BOARD TEST FOR CODES BELOW 10500 ONLY WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Ret
109. a DC arc FIGURE E 2 INPUT POWER CIRCUIT OPTIONAL CONTACTOR 701 CONDUCTOR GUN CABLE BLOCK L l 1 GUN OPTIONAL TRIGGER INCH E OPTIONAL E SWITCH CONTACTOR E BOARD FT MODULE ELECTRODE INPUT CABLE ARMATURE VOLTAGE TO WORK SENSING LEAD CONTROL RPM FEEDBACK BOARD RANGE WIRE FEED SWITCH MODE SWITCH 1 L EDU WIRE SPEED OMA CONTROL SOLENOID GAS PC BOARD SOLENOID EARLY MODELS ONLY LATER MODELS HAVE CIRCUITRY CONTROL CIRCUIT OPERATION INPUT POWER CIRCUIT The DC arc voltage from the power source is applied to the LN 25 through the electrode cable and work sensing lead This DC voltage is connected to the polarity switch which allows the wire feeder to be used in either electrode positive or electrode negative polarity The voltage is then coupled to the voltmeter and control board A wire feed mode switch is included to give the user the capability of using a constant voltage or in some processes a constant current power source See Figure E 2 INCLUDED ON CONTROL BOARD WELDING CURRENT CIRCUIT The electrode voltage is also applied to the conductor block through a heavy current carrying cable The welding gun cable is connected to the conductor block This combination of welding cable optional contactor conductor block and gun cable constitute the welding current path to the elect
110. ad If not connected the LN 25 will not operate even if a 431 1 624 1 42V Remote Output Control option refer uL 15 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 1 2 or3 is not used 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 4 6m length the voltmeter reading will be lower than the actual arc volts due to the LN 25 motor control current 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 B 4 OPERATION B 4 AWG Maximum Length 14 25 Ft 7 6m 12 50 Ft 15 2m 10 100 Ft 30 50 6 200 Ft 61m REMOTE ARC VOLTAGE CONTROL OPTIONAL This rheostat control allows you to control the power source output arc voltage level Refer to K444 K444 1 and K444 2 Remote Voltage Kits in the Accessories section GAS FITTING OPTIONAL Provides gas output connection to the welding gun for the GMAW process Refer to K430 1 or 2 Gas Solenoid Kit in the Accessories Section GAS POST PRE FLOW TIMERS OPTIONAL Allows for variable adjustment of gas pre flow amp post flow at the start and end of the weld Refer to K434 1 Gas Flow Timer Kit
111. ad numbers 75 76 and 77 K444 1 connects to power sources with a 6 pin control receptacle NOTE To use a K444 1 with power sources with only a 14 pin control receptacle a K864 Adapter is required to connect to K444 1 and if using a power source without an output control switch a K484 Jumper Plug will also be required to jumper the output pilot circuit 2 4 K444 2 connects to power sources with a 14 pin control receptacle and provides a 2 4 jumper to activate power source output Installation Instructions are included with the kit K577 1 REAR HANDLE KIT For LN 25 model codes above 9383 The fold down handle mounts to the rear of the LN25 case per the Installation Instructions M16567 shipped with the kit This handle provides a means to also carry the LN25 in the vertical position especially convenient for passing the unit through a manhole LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O e 9 9 53 4 cc Cc Return to Section TOC Return to Master TOC C 6 ACCESSORIES C 6 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 M FIGURE C 1 GUN CABLE CONNECTOR REQUIREMENTS TO PERMIT PROPER CONNECTION TO LN 25 WIRE FEEDER D 7490 747 620 03 x 45 STYLE A 7 A DIA HO
112. all machines covered by this manual THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE 941 7000 EQUIK OWNED BY THE LINCOLN ELECTRIC CO AND is ON HOLE SIZES PER E2056 125 98 THE LINCOLN ELECTRIC LN 25 _ NOT BE REPRODUCED DISCLOSED OR USED 3 PLACE DECIMALS IS 4 002 9 13 918 CLEVELAND U S A i OPERATING SCHEMATIC WITHOUT THE EXPRESS PERMISSION OF ON ANGUS 1S 5 OFA Dre SUBJECT aa ERIAL t ae 3 THE LINCOIN ELECTRIC CO WITH PUBUSHED Saban 20000001 00000000 Jr 5 22 92 CHK _THP D2 REF __ 9 4 87 NO G 1833 G 7 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O O o FE JE 9 ejg 5 4 cic Return to Section TOC Return to Master TOC G 8 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BD ABOVE CODE 11140 G4616 5 x TACHOMETER RED 5 BLUE 12 R26 Back lt 74 TT 5 GND 2667 C26 63V 036 400V 1A 15 150 135V 15 150 POWER SUPPLY NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 15 150 0 SUPPLY R33 ACTIVATE_SOLENOID 5 B 50V CY8C27443 24PI ACTIVATE FEEDER ARC VSENSE VIM PE
113. assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC TOOLS REQUIRED Phillips Head Screwdriver 3 4 Wrench Pliers QO o O O e 2 2 9 cc Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 O Fie 9 953 cc Cc Return to Section TOC Return to Master TOC Return to Master TOC F 44 TROUBLESHOOTING AND REPAIR F 44 GAS SOLENOID VALVE AND OR SOLENOID PC BOARD IF PRESENT REPLACEMENT continued FIGURE F 27 GAS SOLENOID ASSEMBLY WIRING CODES 10148 THRU 10500 SOLENOID GAS SOLENOID PC BOARD VALVE PURGE SWITCH SOLENOID LEADS PLUG J11 REPAIR PROCEDURE the two solenoid leads from the gas solenoid valve and disconnect the purge switch leads 1 Open the case door Remove the wire reel by See Figure F 27 removing the retaining collar See Figure F 5 4a For codes above 10500 remove leads 690 amp 2 Remove the screws holding the control box 691 from the solenoid valve See Figure F 28 cover in place and remove the control box cover See Figure F 5 4b Using a 5 16 nut driver remove the two screws holding the solenoid amp purge button assembly NOTE only the gas solenoid valve needs replacing to the case Remove the assembly it may not be necessar
114. ately of the extension guide for cored wire b Position electrode over joint End of electrode should be slightly off the work B 9 OPERATION B 9 c Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used NOTE If the arc voltage is not within the proper procedure range adjust the power source output control The CC mode WIRE SPEED setting should not be changed from the preset procedure value for the proper arc voltage d To stop welding release the gun trigger and then pull the gun away from the work Store the gun in the LN 25 insulated gun holder when not welding PROCEDURE AT END OF COIL When the wire on the reel is used up the following procedure is to be followed for removing the old wire from the gun cable and loading a new reel a Shut off power source if a Remote Output Control Option or internal contactor is not used b Cut the end of the electrode off at the gun end Do not break it off by hand since this puts a slight bend in the wire and makes it difficult or impossible to pull it back through the nozzle c Uncouple the gun conductor cable from the LN 25 d Lay the cable out straight e Using pliers to grip the wire pull it out of the cable from the connector end Do not pull it from the gun end f Put the conductor cable back on wire drive unit after
115. ations etc and the dynamic metal transfer characteristics of the process or procedure being used short arc globular transfer etc When using a CV power source these current variations have essentially no effect on the welding arc stability since CV power sources can provide a wide range of weld current levels with virtually no change in average arc voltage These slope CV power sources therefore provide the arc power required to produce the best welding characteristics and ease of operation for most open arc constant wire feed speed welding processes CC formerly VV power sources on the other hand permit the arc voltage to decrease with increases in welding current The output characteristics of these power sources can range from a drooping slope which provide minor arc voltage changes with weld current variations to steep slope which provide broad voltage changes with only minor current variations The steeper the slope the more difficult it becomes to maintain arc voltage stability with a constant wire speed open arc process To aid in stabilizing the arc voltage when welding on CC power sources the LN 25 is provided with a CC wire feed mode This arc voltage sensing feed mode decreases or increases the wire speed when the arc voltage decreases or increases However if the electrode shorts to the work the arc voltage will essentially drop to zero and the short circuit current supplied by the CC p
116. c Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 O O e e c 9 28 o 9 gt TOOLS REQUIRED 5 3 E Phillips Head Screwdriver 3 4 Wrench 5 8 Wrench 7 16 Wrench Slot Head Screwdriver O10 O O e 9 953 4 cc Cc Return to Section TOC Return to Master TOC LN 25 LINCOLN 48 TROUBLESHOOTING AND REPAIR F 48 DRIVE MOTOR AND GEARBOX REPLACEMENT AND ACCESS TO HALL EFFECT MODULE continued FIGURE F 32 WIRE DRIVE ASSEMBLY REPLACEMENT Return to Section TOC Return to Master TOC 5 0109 016 2 MYLAR INSULATION IN LINE 5 CONNECTORS 9 ELECTRODE CABLE 1 2 BOLT WIRE DRIVE 4 ASSEMBLY Ee E 918 p r4 o 06 gt gl EIE WIRE DRIVE ASSEMBLY 818 ___ MOUNTING BOLTS elo 8 4 PLACES REPAIR PROCEDURE line connectors behind the mylar insulation See Figure F 32 For codes 9812 and below 1 Observe the_static electricity precautions remove the two armature leads 539 and 541 detailed in PC Board Troubleshooting and the three hall effect module leads 500 512 Procedures lat the beginning of this section and 555 from the control board 2 Open the case door Remove the wire reel b removing the retaining collar See Figure F5 Figure F 5 5 Remove the 1 2 bolt securing t
117. ce de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN RETURN TO MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page cl i ee ee ee ee ee eee i iv Jer ew ete wa Section A Operation E Section B lt Section ete ese Section D Theory of Operation uua uoce opo oue Rr tee Section E Troubleshooting and
118. contactor below remove the two contactor coil leads from the contactor PC board See Figure F 25 14 Install the control box cover and secure by installing the three screws 5 Figure 5 7 Cut or remove any cable ties or harness tape 15 Install the wire reel and retaining collar and n rv close the case door See Figure F 5 LN 25 LINCOLN F 41 TROUBLESHOOTING AND REPAIR F 41 CONTACTOR REPLACEMENT FOR CODES ABOVE 10500 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 9 TOOLS REQUIRED 2 818 Phillips Head Screwdriver 5 5 5 16 Nut Driver 11 16 Wrench E 3 4 Wrench 5 8 Wrench O O O O 9 9 2 0912 cc Cc Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Sect
119. ction TOC Return to Master TOC Return to Master TOC F 28 TROUBLESHOOTING AND REPAIR F 28 CONTACTOR amp CONTACTOR PC BOARD TEST continued FIGURE F 15 CONTROL BOARD CONTACTOR PC BOARD TEST 1 2 Check to be sure plug 9 on contactor board and plug J3 on the control board are present and secure See F 14 and 15 If optional gas timer pc board is installed remove plug J6 from contactor board and install jumper plug See Wiring Diagram Apply at least 25VDC but no more than 100VDC to the LN 25 from the electrode cable to the work sensing lead Observe polarity and set polarity switch Check for the applied voltage at plug J9 pins 1 2 lead 667 621 Seg Figure F 14 1 1 With the trigger activated and a normally operating contactor connected the voltage measured at the contactor leads J9 pins 13 amp 14 is approximately 1 0 VDC See Figure F 14 See the Wiring Diagram If the 1 0 VDC is not present when the trigger is activated the contactor board may be faulty Be sure to reconnect all plugs previously removed Note If the original Control Board has been replaced with L12253 See Figure F 16j and follow instructions for that Control Board LN 25 LINCOLN F 2
120. ctory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the 2 machine Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o FE JE 9 ejg 5 cic Return to Section TOC Return to Master TOC G 20 ELECTRICAL PC BOARD ASSEMBLY CONTACTOR CODE 10100 THRU 10500 L9670 1 x 1 0296 1 COMPONENT SIDE CIRCUITRY OPPOSITE SIDE CIRCUITRY MAKE FROM 519399 MAKES 10 BOARDS BLANK PART L96 0 A NOTES DO NOT COAT WITH ENCAPSULATION MATERIAL CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING ANCHOR CAPACITORS TO BOARD WITH 25 WIDE 50 LONG BEAD OF ITEM 3 2 PLACES DIAGRAMS MANUFACTURED AS app cedi MEE L96 0 1A0 IDENTIFICATION CODE MAKE PER E1911 ENCAPSULATE WITH E1844 TEST PER E2T4T K gt gt gt Zz to tu N B 2 E 519400 1502 15K 1 4W tem ea Se c _ 11 _____________ 513498 127 560035 __ C2
121. d and or wiring harness may be faulty Refer to the wiring diagrams in the Electrical Diagrams Section The appropriate jumper plugs may be used to isolate and check suspect contactor or remote control boards LN 25 LINCOLN F 12 Y 1 5 E NOL 4 18 NOL 4 18 uinjeH NOL 4 18 NOL 4 18 DOL uonoes DOL uonoes DOL uonoes DOL uonoes uinjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Lr 4 9 J Return to Section Return to Master TOC b o 0 TROUBLESHOOTING AND REPAIR F 13 GAS SOLENOID VALVE AND CONTROL PC BOARD TEST FOR CODES ABOVE 10500 ONLY WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou b
122. d Gearbox D 2 Gun and Cable Maintenance D 2 Circuit Protection and Automatic Shutdown D 2 Control PC Board D 2 Automatic Protection Shutdown D 2 Adjusting Speed Sensor Module D 2 Calibration of LN 25 Wire Speed D 3 LN 25 LINCOLN Section D Return to Section TOC Return to Master TOC Return to Section TOC O10 O O Fie 9 0 9 53 4 cc Cc Return to Section TOC Return to Master TOC Return to Master TOC D 2 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill not operate with covers removed Turn off power source before installing or servicing Do not touch electrically hot parts Turn the input power to the welding power source off at the fuse box before working in the terminal strip Only qualified personnel should install use or service this equipment ROUTINE MAINTENANCE DRIVE ROLLS AND GUIDE TUBES After feeding every coil of wire inspect the drive roll section Clean it as necessary Do not use a solvent for cleaning the idle roll because it may wash the lu bricant out of the bearing The drive roll idle roll and guide tubes are stamped with the wire sizes they will feed If a wire size o
123. d repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems function prob lems wire feeding problems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each spec
124. des 11144 amp Above Hemote for Power Hemote for Power Remote for Power cust Praner le 42 Remote MP Output Control Module K625 500 Amp Cable w Stud Type Output Terminals K626 350 Amp Cable w Stud Type Output Terminals 400 Amp Cable w Twist Pulse Power Pulse Power Sateen 1 LLLI IMPORTANT SAFETY NOTE This wire feeder provides COLD electrode when gun trigger is released if equipped with K431 1 K432 or K433 remote output control system or K443 2 internal contactor kit This feature and the use of a DC Constant Voltage welder provide an added margin of safety when welding must be performed under electrically hazardous conditions such as Damp locations While wearing wet clothing On metal structures or In cramped positions sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground O O Fie 9 0 953 4 cc Cc S 2515 jejeje e 1119 11 e Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0
125. dy pro tection GENERAL DESCRIPTION The LN 25 is a lightweight portable semiautomatic wire feeder designed for across the arc operation 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 coils or spools The wire drive controls and wire reel are fully enclosed in a rugged molded plastic case providing a compact and versatile welding package ideally suited to on the go field welding applications in virtually any environment RECOMMENDED PROCESSES AND EQUIPMENT When combined with the drive roll kits and accessories available for use with the LN 25 a versatile portable welding system can be provided to meet the specific needs of Innershield submerged arc or gas metal arc welding applications within the wire feed capabilities of the LN 25 M The LN 25 provides constant wire feed speed for use with constant voltage CV power sources and arc sensing wire feed speed for use with constant current CC formerly variable voltage power sources Wire speed is presettable on a dual range calibrated dial The power sources recommended for use with the LN 25 M include the DC 250 400 600 CV 400 and 835 type transformer machines and the SAM 400 650 engine welders as well as the SA 2001 250 SAE 300 400 with CV Adapter and Pulse Power 500 with K46
126. e tube causing a birdnest c Insert the free end through the incoming guide tube to the drive roll d Turn on the welding power source WARNING Unless an optional output control or internal contactor is used with the LN 25 the electrode circuit is electrically hot when the power source is on e Press the gun trigger and push the electrode until it just enters the drive roll WARNING When inching with gun trigger the electrode and drive mechanism are always hot to work and ground Use the cold inch switch on models with internal contactor MOLDED ADAPTER RETAINING SPRING THREAD LOCKING COLLAR INSIDE CAGE WIRES f Inch the electrode through the gun g Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped Do not over tighten CAUTION Keep gun LN 25 gun holder when not feeding wire to prevent accidental arcing IDLE ROLL PRESSURE SETTING The idle roll pressure is set at the factory backed out two turns from full pressure This is an approximate setting For small wire sizes and aluminum wire the optimum idle roll pressure varies with type of wire surface condition lubrication and hardness The op timum idle roll setting can be determined as follows 1 Press end of gun against a solid object that is electrically isolated from the welder output Pre
127. end plate lock washers and screws Position the wire drive assembly inside the case and secure to the bottom of the case with the 11 12 13 four bolts Secure the electrode cable to the conductor block with the 1 2 bolt For codes 10148 and above connect both in line connectors and position them behind the mylar insulation See Figure F 32 For codes 9812 and below install the two armature leads 539 and 541 and the three hall effect module leads 500 512 and 555 onto the control board See Figure F 33 Install the control box cover and secure by installing the screws previously removed Install the wire reel and retaining collar and close the case door FIGURE F 33 CONTROL BOARD OO 0000 0000 0000 000 000 000 539 541 31757 500 2 LN 25 LINCOLN 555 512 50 TROUBLESHOOTING REPAIR 50 DRIVE MOTOR AND GEARBOX REPLACEMENT AND ACCESS TO HALL EFFECT MODULE continued FIGURE F 34 DRIVE MOTOR REPLACEMENT Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HALL EFFECT MODULE GEARBOX O10 O O Fie 9 953 cc Cc REAR END PLATE LOCKWASHER END PLATE p a MOUNTING SCREW gt FLAT WASHER LOCKWASHER
128. es may be faulty Check or replace Check the resistance between each of the motor leads 541 black and 539 white and the motor case The resistance should be very high at least 500 000 ohms If the resistance is low the motor is grounded to the motor case and should be replaced 25 TROUBLESHOOTING AND REPAIR 25 4 CONTACTOR PC BOARD TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION Return to Section TOC Return to Master TOC The following test will determine if the contactor is functional MATERIALS NEEDED Phillips Head Screwdriver 12 VDC Supply Volt Ohmmeter NOTE LN 25 units with the L12253 Control Board do not use a Contactor Board Codes above 10100 may have been upgraded to use this Control Board and must be tested accordingly O O Fie
129. eturn to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual x G 11 ELECTRICAL DIAGRAMS 0 11 PC BOARD ASSEMBLY CONTROL ABOVR CODE 11140 L12253 3 E FEL c E eSccLH1 ENGINEERING CONTROLLED CHANG E D48 AND MANUFACTURED PART BER DENTIFI TICN CO DE AND SCHEMATIC REFERENCE IEM QTY PART NUMBER DESCRIPTION MANUFACTURER ITEM USED WITH SASENUHHER PESCHIETON 1 518248 4 CONNECTOR MOLEXMINI PCB 4 PIN 0 11112553 PC BOARD BLANK 518248 6 6 1 12253 7 PC BOARD BLANK NA S18248 16 CONNECTOR MOLEX MINI PCB 16 PIN gt 2 8 514020 4 PLASTIC EXPANSION NUT 0 25 ________ 1 051824814 __ CONNECTOR MOLEX MINI PCB 14 PIN 3 08 520590 1 HEAT SINK SLIP 220 9 4 Q4 048 3 520590 3 HEAT SINK EXTRUDED FOR TO 247 0 E 5 1 1 00750 4 SOFTWARE 21 02 09 T12704 68 TRANSISTOR NPN TO226 0 5A 40V 2N4401 X4 1 jY007504 SOFTWARE m 1 T12704 106 TRANSISTOR NMF TO247 600V 47A SS sis REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW T12704 102 6 5 0247 600 26 55 NB 112704 104 TRANSISTOR N T0220 47A 55V P77NO6S2 12 SS 2 R
130. g of specific circuits Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O 9 953 cc Cc PROBLEMS SYMPTOMS FEEDING PROBLEMS POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION NOTE Many options and possible option combinations are available for the LN 25 In many cases it is best to disconnect the options and test the LN 25 in its basic form In this manner many possible faulty circuits can be isolated and or eliminated from the troubleshooting procedure Major physical or electrical damage is evident when the box cover is removed When gun trigger is pulled there is no wire feed NOTE On codes above 10100 the motor leads 541 amp 539 are in Control Board Connector J4 pins 13 amp 14 Contact Lincoln Electric Service Department 1 888 935 3877 Check to see if the drive rolls are turning when the gun trigger is pulled If the drive rolls are turning then check for a mechanical restriction in the wire feed path If the drive rolls do not turn then check to ensure the power source is on and an open circuit voltage OCV is present at the weld terminals Make sure the LN 25 work clip is connected to the work piece or work terminal Ensure the LN 25 polarity switch matches the elect
131. h newer Control cover in place and remove the control box Board L12253 and a contactor remove cover See Figure 5 plug J14 Figure F 22 4 For codes 10148 and above remove the four 6 On older codes the control PC board is larger plugs J1 J2 J3 and J4 See Figure F 20 It may be necessary to remove the Contactor PC Board or the Remote Control PC Board if installed FIGURE F 21 CONTROL PC BOARD CODES 9812 AND BELOW O o Slo 9 8 1 gt cc Cc OK o O O o Lic eec 2 0000 PID g 2 8 gt 5 5 5 5 500 555 512 LN 25 M LINCOLN Return to Section TOC Return to Section TOC Return to Master TOC Q O O o Fle gs 2 953 5 4 Return to Section Return to Master TOC Return to Master TOC F 37 TROUBLESHOOTING AND REPAIR F 37 FIGURE F 22 PLUG LOCATIONS FOR L12253 CONTROL BOARD Aon OI XE 23 5 o N o Kea 1 E t a Ota e olo Q5 a i Ole 2s 1 5 555 J14 691
132. he electrode 3 Remove the screws holding the control box cable to the gear box conductor block Remove the four bolts mounting the wire drive assembly cover in place and remove the control box cover See Figure F 5 to the bottom of the case See Figure F 32 6 Carefully remove the wire drive assembly See 4 For codes 10148 and above separate both in Figure F 32 Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 T T Return to Section Return to Master TOC o 0 F 49 10 TROUBLESHOOTING AND REPAIR F 49 DRIVE MOTOR AND GEARBOX REPLACEMENT AND ACCESS TO HALL EFFECT MODULE continued Remove the two screws and lock washers holding the rear end plate to the gearbox and remove the rear end plate Remove the three drive motor mounting screws flat washers and lock washers one is inside the gearbox housing See Figure F 34 Carefully remove the drive motor from the gearbox NOTE To access Hall Effect Module for adjustment or replacement see Adjusting Speed Sensor Module in the maintenance section of this manual Install the replacement drive motor onto the gearbox and secure with the three screws flat washers and lock washers Install the rear
133. he possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing SAFETY LINCOLN 8 CYLINDER may explode E if damaged 7 a Use only compressed cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and
134. he power source being used c The output voltage is set with the voltage control on the CV Adapter NOTE Refer to the Instruction Manual provided with the machine for details on connection and operation of the LN 25 with the power source INVERTEC CV300 AND OTHER NEWER LINCOLN POWER SOURCES Refer to the instruction manual provided with the power source for details on connection and operation of the LN 25 with these newer machines GUN CABLE CONNECTION TO FEEDER Lay the cable out straight Insert the connector on the welding conductor cable into the brass conductor block on the front of the wire drive unit Make sure it is all the way in and tighten the hand wheel clamp Keep this connection clean and bright Connect the control cable polarized amphenol plug into the mating 5 cavity receptacle on the front panel of the wire feeder case FOR GMA GUN AND CABLES Requires installation of K430 1 or K430 2 Gas Solenoid Kit factory installed on K446 and K449 models See K430 1 K430 2 Gas Solenoid Kit Section in Accessories Section for gas solenoid operation and gas supply connection LN 25 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O O O 5 o 5 9 2 clic Return to Section TOC Return to Master TOC Install the barbed fitting and union nut to the 18 female inert gas fitting
135. ific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 LINCOLN LN 25 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 TROUBLESHOOTING REPAIR ps PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the mos
136. in Accessories Section LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC L 4 Return to Section Return to Master TOC o 0 SEQUENCE OF OPERATION LOADING ELECTRODE WARNING ELECTRIC SHOCK can kill e Unless an optional output control or internal contactor is used with the LN 25 M the electrode circuit is electrically Hot when the power source is on Turn off the power source while mounting electrode coils MOUNTING 22 TO 30 LB READI REEL COILS The early models of the LN 25 were factory equipped with K363 P Readi Reel Adapter which is required to load Lincoln 22 to 30 Readi Reel coils Later models require the optional 63 adapter kit a Make certain that the threaded locking collar is tight and securely locks the adapter on the spindle See Figure B 2 b Rotate the spindle and adapter so the retaining spring is at the 12 o clock position c Position the Readi Reel so that it will rotate in a clockwise direction when feeding wire is to be dereeled from bottom of the coil d Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab e Lower the Readi Reel to depress the retaining spring and align the other inside cage
137. ion TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O O Fie 9 0 953 cc Cc Return to Section TOC Return to Master TOC 7 Disconnect the contactor coil leads by 8 Cut or remove any cable ties or harness tape F 42 TROUBLESHOOTING AND REPAIR F 42 CONTACTOR REPLACEMENT continued FIGURE 26 11 16 BRASS ELECTRODE CABLE IN LINE CONNECTORS VOLTAGE SENSING LEAD 67 ELECTRODE LEAD POLARITY WELDING CABLES SWITCH _ A O otk 2 WORK SENSING LEAD REPAIR PROCEDURE 9 Carefully remove the contactor assembly from the LN 25 1 Open the case door Remove the wire reel b removing the retaining See Figure F 5 10 Install a new contactor in the LN 25 2 Remove the screws holding the control box 11 Connect the contactor coil lead in line cover in place and remove the control box connectors behind the reel stand assembly cover See Figure F 26 3 Remove the two fiber baffles from the area in 12 Place contactor assembly in position front of the contactor See Figure F 25 13 Install the 5 16 screw to secure the contactor 4 With a 3 4 wrench remove the electrode to the spindle assembly 14 Install the welding cables and voltage sensing 5 Using the 11 16 wrench remove the two lead 67 to the contactor and secure with the brass nuts f
138. ive Motor and Gearbox Replacement Procedure and access to the Effect Modulel in the Troubleshooting and Repair Section 3 Gently screw the module into the mounting plate until it just touches and stops against the rotating part inside the gearbox 4 Back the module out turn then snug the module lock nut without rotating the module position Do not over tighten lock nut CALIBRATION OF LN 25 WIRE SPEED DIAL Calibration of the LN 25 Wire Speed dial is achieved by proper mounting of the dial knob to the speed potentiometer shaft Whenever the knob is removed the dial is recalibrated as follows 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 D 3 MAINTENANCE D 3 WARNING Electrode will be electrically hot Do not allow fed wire to contact any metal common with welding work An alternate means to measure wire feed speed is as follows a Cut wire off at the end of the gun tip b Press trigger to feed wire for exactly 30 seconds C
139. izontal line representing the DE SIRED IN MIN for the welding procedure See example arrow line for 375 in min 2 Select the diagonal line representing the ARC VOLTS to be used for the welding procedure See example arrow line for 29 volts 3 Determine the vertical line representing the CC WIRE SPEED SETTING where the above two lines cross See example arrow line for 450 c Set the Wire Speed dial to the value determined in Step 3 above 450 for example used Use HI Dial Range if value to be set is over 350 The wire will feed at the DESIRED IN MIN speed when the welding power source is set to the arc voltage to be used for the weld procedure 375 in min at 29V for example used A chart representation of the CC wire speed setting graph is shown in Figure B 4 giving the Wire Speed dial setting required for the DESIRED IN MIN and ARC VOLTS used for the welding procedures LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O 9 0 9 53 4 cc Cc Return to Section TOC Return to Master TOC B 8 OPERATION B 8 FIGURE B 4 VV CC WIRE SPEED SETTING Arc Volts Used In Min VV CC Speed Setting Desired IPM 35 Arc Volts MAKING A WELD SETUP a Connect work cable to metal to be welded Work cable must make good electrical contact to the work The work must also be grounded as
140. 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 When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase t
141. ks around the HI range calibrated dial indicate the minimum arc volts required to obtain the indicated HI range wire feed speeds For example if wire speed is set to 400 in min a welding procedure arc voltage of at least 17V would be required to obtain the 400 in min wire feed speed LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o WORK CLIP LEAD 0 ELECTRIC SHOCK can kill Do not touch metal portions of the LN 25 M lead clip when welding power source is on 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 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 le
142. l or contactor is used with the LN 25 the electrode circuit including welding wire wire drive and welding gun is electrically hot when the welding power source is on The gun trigger controls wire feed only Disconnect or shut off welding power source before making connections or installations to the LN 25 M Welding gun should be stored in the insulated gun holder located near the rear on the top of the LN 25 case to avoid accidental arcing The LN 25 should be positioned upright on a horizontal surface WARNING ELECTRIC SHOCK can kill e Do not touch metal portions of the LN 25 lead clip when welding power source is on POWER SOURCE CONNECTION The LN 25 can be used with any DC welding power source A constant voltage power source is recommended however the LN 25 can also be used with a constant current power source as long as the open circuit voltage is less than 110V DC CAUTION Do not use LN 25 models below Code 9200 with any TIG or Square Wave welding power sources Do not use LN 25 models equipped with internal contactors with non Lincoln TIG or Square Wave welding power sources Damage to the LN 25 circuit can occur as a result of the high output inductance typically associated with these power sources TIG high frequency power should never be applied to the LN 25 If not using an LN 25 Remote Output Control option See Remote Output Control Options a
143. lding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved
144. least 25 VDC but no more than 100 VDC to the LN 25 from the electrode cable to the work sensing lead Make sure the polarity switch is set to match the polarity of the electrode cable For example if the electrode cable is positive and the work sensing lead is negative set the polarity switch to positive See Figure LN 25 LINCOLN F 11 TROUBLESHOOTING AND REPAIR F 11 GAS SOLENOID VALVE AND SOLENOID PC BOARD TEST continued FIGURE F 4 PC BOARD FOR K430 1 GAS SOLENOID KIT Return to Section TOC Return to Master TOC 512 624A 621 olo O o T J11 olg olg 9 BOARD FOR K430 GAS SOLENOID KIT cle 5 2 15202 Qc 606 olo pe 5 5 5 2 7 gt 2 2 912 8 621 O10 O O e 9 3 4 cc Cc Check for the presence of the DC voltage applied from lead 624A to lead 621 See Figure F 4 Check for the presence of 12 VDC from lead 512 to lead 621 Check for the presence of 10 VDC from lead 606 to lead 621 When the LN 25 trigger circuit is activated the voltage should drop to about 1 VDC If the above voltage readings are good and the solenoid valve is functional the Solenoid PC Board may be faulty If the above voltage checks are not correct the control board contactor board if used remote control board if use
145. leshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the gas solenoid valve or the control PC board valve actuation circuitry is functional MATERIALS NEEDED Phillips Head Screwdriver 12 VDC Supply Volt Ohmmeter DC Voltage Source 25 to 100 VDC NOTE LN 25 units with the L12253 Control Board do not use a Contactor Board Codes above 10100 may have been upgraded to use this Control Board and must be tested accordingly LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O O Fie 9 953 cc Cc Return to Section TOC Return to Master TOC F 14 TROUBLESHOOTING AND REPAIR F 14 GAS SOLENOID VALVE AND CONTROL PC BOARD TEST FOR CODES ABOVE 10500 ONLY continued FIGURE F 5 CONTROL BOX COVER REMOVAL CONTROL BOX WIRE REEL RETAINING COLLAR TEST PROCEDURE GAS SOLENOID VALVE 1 Open the case door Remove the wire reel by removing the retaining collar See Figure F 5 2 Remove the screws holding the control box cover in place and remove the control box cover See Figure F 5 LN 25 LINCOLN 15 TROUBLESHOOTING AND REPAIR 15 GAS SOLENOID VALVE AND CONTROL PC BOARD TEST FOR CODES ABOVE 10500 ONLY continued FIGURE 6 SOLENOID LEADS Return to Section TOC Return t
146. n hole c Place the spool on the spindle so the adapter tab enters one of the holes in the back side of the spool Be sure the wire comes off the spool in a clockwise direction when dereeled from the bottom of the coil d Replace and tighten the Locking Collar e Load wire into wire drive per Loading Wire Drive Section MOUNTING 13 OR 14 LB INNERSHIELD COILS Requires Optional K435 Spindle Adapter for 14 Ib Coils a Remove the locking collar and the Readi Reel adapter shipped on the 2 diameter spindle adapter is not required b Mount K435 Spindle Adapter and Innershield coil per the Instructions S18256 included with the K435 LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC L 4 Return to Section Return to Master TOC o 0 FIGURE B 2 READI REEL INSTALLATION 2 O D SPINDLE BRAKE HOLDING PIN MUST ENGAGE HOLE IN ADAPTER RIB GROOVES READI REEL LOADING WIRE DRIVE a Turn the reel or spool until the free end of the electrode is accessible b While tightly holding the electrode cut off the bent end and straighten the first six inches Cut off the first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing guid
147. nd Cable Assemblies Section the power source output must be electrically hot at all times when the power source is turned on See the power source instruction manual for proper power source connections and setting required A 3 INSTALLATION 3 WARNING ELECTRIC SHOCK can kill Do not operate with covers removed Turn off power source before installing or servicing Do not touch electrically hot parts Turn the input power to the welding power source off at the fuse box before working in the terminal strip Only qualified personnel should install use or service this equipment DC 250 a Connect a jumper from 2 to 4 on the power source terminal strip so the output will be energized when the DC 250 is turned on b Connect electrode cable to the Innershield GMAW output terminal of polarity required by electrode Connect work lead to other Innershield GMAW P output terminal c Place Set to CV Electrode Cable Polarity switch at appropriate position d Place power source toggle switch in Output Control at DC 250 position unless a Remote Control is connected to 75 76 and 77 on the DC 250 terminal strip e Place mode switch in Innershield GMAW CV position Set CV arc control to 2 or NORMAL on some machines Initially set the output control on 7 DC 400 AND CV 400 a Connect a jumper from 2 to 4 on the power source
148. nic protection circuits which shut down the LN 25 under various fault conditions OVERVOLTAGE SHUTDOWN If the power source open circuit voltage exceeds about 110 120 volts the LN 25 will not operate until the power source voltage drops below about 102 110 volts MOTOR OVERLOAD SHUTDOWN If excessive motor overload occurs due to prolonged excessive feeding force jammed drive rolls or shorted motor leads the LN 25 M will shut down within a few seconds after the overload occurs CONTROL PC BOARD Codes above 9900 The Control P C Board has electronic protection for trig ger circuit faults to the electrode circuit The shutdown will reset automatically when the gun trigger is released but will reoccur if the situation is not remedied LN 25 LINCOLN Return to Master TOC Return to Master TOC 4 o 0 Return to Master TOC Section C TABLE OF CONTENTS ACCESSORIES SECTION MCCCSSONCGS PNE SEES ie Section C LESS Option Cha es occu SUPPE EE Ed C 2 Optional Accessories C 3 GaS Solenoid KIE CFR TT 3 K434 1 Gas Flow C 3 E25 5 oe 4 Remote Output Control Options and Control Cable Assemblies 4 K431 1 Remote Output Control Kit
149. o nee Md 1 2 Se 1 1 m 876 91 0 1 8 i 3 10K D25 33 2K 5041 oq lt nt I LE i 508 1 LM2901 LM2901 MCI40138 e07 lt 2 Vo 1 lc Ki C qo ES SHOOT THRU PROTECTION a OPTIONAL OPTIONAL JUMPER CONTACTOR REMOTE PLUG PLUG PLUC GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS 01 822 50 UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 174W UNLESS OTHERWISE SPECIFIED LABELS DIODES 14 400 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTACE NET POWER SUPPLY SOURCE POINT V COMMON CONNECTION FILE 62194_1BA FRAME CONNECTION d EARTH GROUND CONNECTION OVER VOLTAGE SHUT DOWN NOTES i EQUIP N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE PEGIF WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY Tos SES ase m 222223 THE LINCOLN ELECTRIC CO TYPE LN 25 CONTROL BOARD NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE ON 2 PLACE DECIMALS IS 02 CLEVELAND OHIO U S A SUBJECT SCHEMATIC NUMBER ON 3 PLACE OECIMALS IS 002 11 8 460 ON ALL ANGLES IS 9 5 OF A DEGREE SCALE eee MATERIAL TOLERACE TO p 0 EM FF DATE 2 4 92 _ 08 SPS 16 62194 R
150. o Master TOC SOLENOID LEADS O 9 c 4 Return to Master Ee c 9 2 o gt 9 2 3 Locate and remove the two solenoid leads 690 6 If the solenoid does not activate and allow gas and 691 from the solenoid valve See Figure to flow then the solenoid is faulty Replace 6 2 C 7 The normal solenoid resistance 15 4 Make sure the gas supply for the solenoid is approximately 20 to 27 ohms hooked up and then apply 12 VDC to the gas solenoid 5 If the solenoid activates and allows gas flow then the solenoid valve is good NOTE There should not be any gas flow until the solenoid is activated Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 O O Fie 9 953 cc Cc Return to Section TOC Return to Master TOC Return to Master TOC F 16 TROUBLESHOOTING AND REPAIR F 16 GAS SOLENOID VALVE AND CONTROL PC BOARD TEST FOR CODES ABOVE 10500 ONLY continued FIGURE F 7 APPLIED VOLTAGE POLARITY ELECTRODE CABLE POLARITY SWITCH _ WORK SENSING LEAD CONTROL PC BOARD SOLENOID CIRCUITRY TEST 1 Apply at least 25 VDC but no more than 100 VDC to the LN 25 from the electrode cable to the work sensing lead Make sure the p
151. ol before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding a EDO engine parts ana igniting dis current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated Return to Master TOC 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 posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known E 1 6 In some cases it be necessary to remove safety d All welders should use the following procedures in order to guards to perform required maintenance Remove minimize exposure to EMF fields from the welding circuit guards only when necessary and replace them when the maintenance requiring their removal is complete 2 0 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible parts 2 4 2 Never coil the electrode lead around yo
152. olarity switch is set to match the polarity of the electrode cable For example if the electrode cable is positive and the work sensing lead is negative set the polarity switch to positive See Figure F 7 LN 25 LINCOLN 17 TROUBLESHOOTING AND REPAIR GAS SOLENOID VALVE AND CONTROL PC BOARD TEST FOR CODES ABOVE 10500 ONLY continued FIGURE F 8 CONTROL PC BOARD Return to Section TOC Return to Master TOC 13 Return to Section TOC Return to Master TOC 500 512 690 2 Check for the presence of the DC voltage applied from plug J1 pin 1 667 to plug J1 pin 3 621 See Figure F 8 or F 8 a NOTE Machines with Codes above 10100 that have been upgraged to the L12253 3 Check for the presence of 5 to 6 VDC from lead Control boardhave thesme connection 690 to lead 691 at solenoid valve points ad shown in Figure F 8 for the The LN 25 trigger circuit must be activated supply and solenoid voltages or the purge button must be pressed 4 If the above voltage reading is not correct at the solenoid valve check for 5 to 6VDC at plug J2 pin 3 lead 690 amp pin 6 lead 691 See Figure F 8 5 If the above voltage check is not correct the control board may be faulty Refer to the wiring diagrams in the Electrical Diag
153. olenoid which allows shielding gas to flow through the gun to the arc Later Models Only Above 10500 The solenoid PC board circuitry has been added to the Control board and the solenoid PC board has been eliminated NOTE Unshaded areas of block logic diagrams are the subject of discussion LN 25 LINCOLN 5 THEORY OF OPERATION PROTECTIVE DEVICES AND CIRCUITS OVERVOLTAGE SHUTDOWN If the power source open circuit voltage exceeds about 110 120 volts the LN 25 will not operate until the power source voltage drops below about 102 112 volts Return to Section TOC Return to Master TOC MOTOR OVERLOAD SHUTDOWN If excessive motor overload occurs due to prolonged excessive feeding force jammed drive rolls or shorted motor leads the LN 25 will shut down within a few seconds after the overload occurs The shutdown will reset automatically when the gun trigger is released but will reoccur if the overload situation is not remedied CONTROL PC BOARD FUSES G1757 2 thru 5 part no PC boards the 1 8 amp fuse interrupts the 500A lead to the trigger switch On G1757 1 PC boards a 5 amp fuse was used to interrupt the 667 lead The LN 25 will not operate if either fuse is blown Return to Section TOC Return to Master TOC On G1757 6 or higher part no PC boards the 1 8 amp fuse was replaced with electronic protection for trigger circuit faults to electrode circuit O O o Fle
154. on the front panel of the LN 25 case Connect the I D gas hose from the gun cable to the barbed fitting When the gun is to be removed this fitting can be easily detached by loosening the union nut WELD CABLE CONNECTION The size of the electrode cable and work cable must be sufficient for the maximum weld current and total cable length to be used Refer to table A 1 TABLE A 1 Total Cable Length Weld Current 60 Duty Cycle 50 100 100 150 150 200 200 250 200Amps 2 AWG 2AWG 1 AWG 300Amps 1AWG 1 AWG 1 0 400Amps 2 0 2 0 3 0 500Amps 2 0 3 0 3 0 ELECTRODE CABLE CONNECTION On units without an internal contactor route the electrode cable through the oval hole in the LN 25 rear panel then along the case floor behind the reel Support and around the door side of the wire drive Connect the electrode cable to the LN 25 using the bolt on the front of the wire drive On units with an internal contactor connect the electrode cable to the LN 25 electrode input cable with the nut and bolt provided Tape the bolted connection ELECTRODE CABLE CONNECTION FOR LATER CODE NUMBERS ABOVE 10500 Route the electrode cable through the oval hole in the lower portion of the LN 25 rear panel Connect the electrode cable to the LN 25 input stud using the the 1 2 nut provided Secure the cable with the strain relief clamp provided All units are supplied with an optional pigtail for customers that prefer
155. ower source or a flatter slope output 3 Make sure the wire feed mode switch S3 is in the correct position for the power source being used and proper speed setting is used for the procedure mechanical restrictions in the wire feed path lf more current through either of the armature leads 539 or 541 A typical value is 4 amps DC If 5 amps or less is indicated and the armature voltage is being disabled by the control board then the control board may be faulty Replace than 5 amps is indicated then the motor is drawing too much armature current Check and or replace the motor brushes The motor or gearbox may be faulty Replace Monitor the motor armature voltage leads 539 to 541 Normal range is 2 to 23 VDC If the armature voltage is proper then check or replace the motor brushes If the motor armature voltage is not correct then the control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T Return to Section Return to
156. ower source may not provide enough power to re establish the arc 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 OPERATION B 10 Arc shorting is more difficult to avoid when using a CC power source and requires a more refined operator technique than when using a CV power source Improved performance can be obtained on CC power source applications within the following guidelines 1 Flatter slope power sources with higher arc force short circuit current will improve performance over steep slope machines The steeper the slope the more critical it is to hold proper electrode stickout to maintain arc stability Welding techniques such as weaving will be more difficult to control Use the highest output current tap or setting capable of providing the voltage adjustment required for the procedure 2 Use spray or non shorting small ball type transfer processes at higher procedure voltage levels Generally open arc processes with procedure voltage levels over 22 volts perform satisfactorily Arc stability at procedure voltage levels below 22 volts may be more difficult to control with the general exception of fine 023 035 solid steel electrodes with Argon rich shielding gas or NR 152 and NR 211 Innershield CIRCUIT PROTECTION AND AUTOMATIC SHUTDOWN The LN 25 control provides automatic electro
157. rams Section Olio O Fie 5 0 21 oils oiz 913 cic The appropriate jumper plugs may be used to isolate and check suspect contactor or remote control boards Return to Section TOC Return to Master TOC LN 25 LINCOLN F 18 0 ae z 2 LL NOL 4 18 uinjeH NOL 4 18 uinjeH NOL 4 18 NOL 491se N DOL uonoes uinjeg DOL uonoes DOL uonoes uinjeg DOL uonoes uinjeg 19 TROUBLESHOOTING AND REPAIR 19 HALL EFFECT MODULE TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the hall effect module is functioning correctly Return to Section TOC Return to Master TOC MATERIALS NEEDED Phillips Head Screwdriver Volt Ohmmeter
158. rc all CV operation operation Wire operation CV operation for CV and for STT operation sources Be sure board present then impers hstaTed hI oftemote Feed Module Not recommended operation because the sense proper power source is Required for use when customer may operation used for your application The OptonalBoards are cn th prhtforchriy Contactor life may be shortened in applications using CC machines with high OCV pulse welding experience short Not contactor life from recommended inductive nature of for use when the power source pulse welding Not recommended with high frequency TIG starting THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUFACTURIN OLERAN PER E2056 UNLESS OTHERWISE SPECIFIED TOLERANCE DESIGN INFORMATION FREFERENCEY EQUIPMENT TYPE LN 25 AC ROSS THE ARC PAGE 1 oF 1 MACHINE SCHEMATIC DOCUMENT EETA ON 2 PLACE DECIMALS I 02 ENGINEER DIDION SCALE REVISION MATERIAL APPROVAL PROJECT NA AR ROV 10 4 2004 10 4 2004 CRM36946 CRM36946 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE 1 TO AGREE WITH PUBLISHED S
159. rode polarity Check if the jumper plug on the control board or contactor board if used is loose or missing Make certain the power source open circuit voltage is above 15 VDC but not more than 110 VDC Check if the gun trigger is faulty Repair or replace On older control boards check the 1 8 amp fuse blown the gun may be faulty With the gun trigger circuit activated and the mode switch in the CV position check for the presence of 2 to 23 VDC at leads 539 to 541 This is the normal range for armature voltage which is dependent on the wire speed setting If the normal armature voltage is present at leads 539 to 541 then the motor or motor brushes may be faulty Check or replace If the correct armature voltage is missing then remove any option plugs that may be connected to J3 on the control board Install the jumper plug into the J3 receptacle If the problem is solved then the option board may be faulty Check the wire speed control range switch and associated wiring to the control board If the correct armature voltage is still not present at leads 539 to 541 then the control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877
160. rode wire See Figure E 2 NOTE Unshaded areas of block logic diagrams are the subject of discussion LN 25 LINCOLN E 3 THEORY OF OPERATION E 3 O O Fie 5 9 9 0912 gt cc Cc Return to Section TOC Return to Master TOC E O FIGURE CONTROL CIRCUITS Fg 515 OPTIONAL 5 2 CONTACTOR pape CONDUCTOR GUN CABLE 82 BLOCK Sic L ae 8 2 GUN o COLD TRIGGER INCH OPTIONAL T HALL CONNECTOR IswitcH CONTACTOR EFFECT m BOARD T MODULE ELECTRODE INPUT CABLE ARMATURE VOLTAGE TO WORK SENSING LEAD CONTROL RPM FEEDBACK BOARD c 5 2 RANGE 2 MODE SWITCH 5 5 WIRE SPEED CONTROL SOLENOID GAS PC BOARD SOLENOID EARLY MODELS ONLY LATER MODELS HAVE CIRCUITRY FEEDBACK AND CONTROL CIRCUITS The combination of the range switch and wire speed control provides a command voltage for the control board The hall effect module transforms the motor RPM to a digital voltage frequency that is fed back to the control board When operating in the constant voltage CV mode the control board monitors the feedback signal compares it to the command voltage and delivers the appropriate armature voltage to the wire feed motor In this manner a constant wire feed speed is
161. rom the contactor terminals two 11 16 brass nuts See Figure F 26 Be Remove the heavy leads and lead 67 from sure brass nuts are tight 11 ft lb torque is the terminals Note location of lead 67 See recommended Figure F 26 15 Install the baffles in front of the contactor 6 Remove the 5 16 screw holding the contactor bracket to the spindle bracket 16 Install the control box cover and secure by installing the screws previously removed 17 Install the wire reel and retaining collar and separating the two in line connectors behind close the case door the reel stand assembly 18 Install the two 5 8 screws previously removed as necessary from the bottom of the machine LN 25 LINCOLN F 43 TROUBLESHOOTING AND REPAIR F 43 GAS SOLENOID VALVE AND OR SOLENOID PC BOARD IF PRESENT REPLACEMENT WARNING Service and repair should performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting
162. sign and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 12 PC BOARD ASSEMBLY CONTROL CODE 10556 THRU 10558 G3425 3 ELECTRICAL DIAGRAMS G 12 H ENGINEERING CONTROLLED CHANGE DETAIL ADDED OBSOLETE NOTE WITH PARTS ORDERS INFORMATION AND REMOVED PARTS ORDERS INFORMATION ITEM REQ D PART DESCRIPTION MANUFACTURER Ci 1 T11577 46 CAPACITOR CD 05 600V 80 20 C2 C8 C9 3 13490 106 470 350 30 2096 o C3 C6 C12 C15 C20 C28 C33 13 516668 5 022 50V 20 Ola 34 35 36 37 43 47 is 04 023 2 513490 8 C5 1 513490 92 CAPACITOR ALEL 3300 50V 30 10 7 30 31 61 4 13490 19 1 8 20 1096 4 BARD BLANK REFERENCE INORMATDN C10 1 813490 73 1 20 50 75 1096 clc C11 056 2 516668 4 BUY COMPLETE AS G3425 F 4 LAYER BOARD PER E3281 13 46 48 49 4 516668 3 14 18 19 25 4 81
163. ss the gun trigger for several seconds 2 the wire birdnests jams or breaks at the drive roll the idle roll pressure is too great Back the pressure setting out turn run new wire through gun and repeat above steps 3 If the only result is drive roll slippage shut off the power source then loosen the gun cable clamping LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 screw 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 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 c Set Wire Feed dial to the desired wire feed speed on the selected calibrated dial range The wire speed will remain constant at the
164. struction Designed for easy loading adapter remains on spindle for quick changeover LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 K439 REMOTE EXTENSION CABLE ASSEMBLY The 50 ft Extension cable assemblies are used to ex tend the K432 Remote Control Cable Assembly when longer cable lengths are required Multiple 439 Extensions may be used however to prevent excessive weld cable voltage drops the 500 amp max rating of the K432 should be reduced by at least 50 amps for each K439 Extension used For example if three K439 Extensions are used 150 ft total extension the maximum welding current used should be less than 350 amps The K439 Extension cable end with the male pin con nector connects to the K433 Remote Box and power source per the Instructions included with the K433 kit The K439 Extension cable end with the socket pin connector connects to the mating K432 cable end or next K439 Extension cable end The electrode cables are connected using the bolt and nut provided with the K439 Extension Properly insulate the bolted con nection with electrical tape K624 1 42V REMOTE OUTPUT CONTROL MODULE For use with K625 626 627 Remote Control Cable
165. t Control Kit installed in LN 25 using K432 Remote Control Cable The Remote Box is designed to mount and connect to Lincoln Idealarc semiautomatic power sources the Installation Instructions and power source connection diagrams included with the kit The Remote Box provides the proper welding power source control interface and isolated 24V AC input supply for the LN 25 equipped with the K431 1 Remote Output Control Kit Remote Box requires 115V AC 50 60 Hz input and a welding power source using a contact closure output pilot circuit as available on appropriate Lincoln weld ing power sources K432 REMOTE CONTROL CABLE ASSEMBLY Requires K431 1 Remote Output Control Kit installed in LN 25 and K433 Remote Box mounted to power source with 115V AC auxiliary power The K432 control cable assemblies include an elec trode cable rated for up to 500 amps 60 duty cycle and a 6 conductor control cable with pin connectors on both ends Available in 25 50 75 and 100 ft lengths The cable assembly end with the socket pin connector connects to the LN 25 per the Instructions included with the K431 1 kit The cable assembly end with the male pin connector connects to the K433 and power source per the In structions included with the K433 kit K363P READI REEL ADAPTER KIT Adapts Lincoln Redi Reel coils of electrode 30 Ib 14kg and 22 Ib 10kg to a 2 51mm spindle Durable molded plastic one piece con
166. t likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board 15 properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment ATTENTION frame Static Sensitive you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent Static build up Be sure not to touch any electrically live parts at the same time Devices Handle only at Static Safe Workstations Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag the PC board uses protective shorting jumpers don t remove them until installation is complete lf you return a PC board to
167. ther than that stamped on the rolls is to be used the rolls and guide tubes must be changed The drive rolls for 035 through 052 cored electrode and Zethrough 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 sizes have no teeth but use two grooves so they also can be reversed for additional life See Wire Feed Drive Roll and Guide Tube Kits Sec tion for roll changing instructions WIRE REEL SPINDLE No routine maintenance required Do not lubricate spindle CONTROL BOX Every six months open and inspect the control sec tion The accumulated dirt should be gently blown off all of the electrical components Be sure the air that is being used is dry Check that lead plugs are secure in their receptacles WIRE DRIVE MOTOR AND GEARBOX Every year examine the gearbox Paint the gear teeth with molydisulfide filled grease Do not use a graphite grease Check the motor brushes Replace if they are worn down to or less When ordering feed motor brushes give all information from the motor nameplate GUN AND CABLE MAINTENANCE See IM manual provided with the gun and cable as sembly CIRCUIT PROTECTION AND AUTOMATIC SHUTDOWN CONTROL PC BOARD FUSE On G1757 6 or higher part no PC boards the amp fuse was replaced with electronic protection for trigger circuit faults to electrode circuit On G1757 2 through 5 part no
168. ting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine SOLID EDGE O o FE JE 9 2 215 JE cic NOTE Return to Section TOC Return to Section TOC Return to Master TOC O O o 9 21 9 091 9 cic Return to Section TOC Return to Master TOC Return to Master TOC G 13 PC BOARD ASSEMBLY CONTROL CODE 10100 THRU 10500 G2196 1 x NOTE COMPONENT SIDE CIRCUITRY MULTIPLE MAKE FROM 19399 ELECTRICAL DIAGRAMS OPPOSITE COMPONENT SIDE CIRCUITRY MULTIPLE TL etas cami Linco MAKES 4 BOARDS BLANK PART 62196 A 04 4 RIS d 1 5 aod T ANN EA 155 d TAT m tzz ta 81 1 7 R53 fe 2 9 00 NOTES DO NOT COAT WITH ENCAPSULATION MATERIAL CAUTION THIS DEVICE 15 SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING N C HEAT SINK PIN SOLDER CONNECTIONS 2 PER HEAT SINK SHALL BE BUILT UP SUCH THAT THE SO
169. to make a taped and bolted connection externally WORK CABLE CONNECTION Connect a work lead of sufficient size between the proper output stud on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact Poor work lead connections can result in poor welding performance 5 INSTALLATION 5 WIRE FEED DRIVE ROLL GUIDE TUBE KITS WARNING Turn off power source before installing or changing drive roll and or guide tubes NOTE The maximum wire sizes the LN 25 will satisfactorily feed are cored and solid electrodes The electrode sizes that can be fed with each roll and guide tube are stencilled on each part Check the kit for proper components See the instructions included with the drive roll kit to install these parts on new machines or replace them on used machines Refer to table A 2 TABLE A 2 Steel Wire Sizes 068 Cored 653 062 Cored or Solid Yis Steel Can also be used for 052 045 and 052 Solid Steel 052 045 and 052 Cored 052C 035 Solid Steel 0355 035 0305 0255 035 Cored 030 Solid Steel 025 Solid Steel Aluminum Wire Sizes KP654 A6A 364 035 035 Drive rolls for only cored electrode sizes stencilled with a C suffix to the wire sizes Drive rolls for only solid electrode sizes are stencilled with an S suffix to the wire sizes Drive rolls
170. to the same polarity as the electrode 3 The Voltmeter will read power source open circuit voltage when the gun trigger is open even if the LN 25 is equipped with the internal contactor ELECTRODE POLARITY SWITCH The polarity switch is located on the front panel of the LN 25 case Set the switch to the same polarity as the electrode lead connection to the power source If the switch is not set for the correct polarity the wire feeder will not operate WIRE FEED MODE SWITCH The CV VV CC Wire Feed Mode switch is located inside the LN 25 case The toggle switch extends from beneath the control box just above the wire drive 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 formerly variable voltage welding power sources WIRE SPEED DIAL AND RANGE SWITCH The Wire Speed control dial on the front panel of the 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 inside white dial range calibrated for 50 to 350 in min When switched to the HI range position the constant wire feed speed CV Wire Feed Mode is set on the outside black dial range calibrated for 50 to 700 in min The volts mar
171. ty for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 20 9 21 ELECTRICAL DIAGRAMS G 21 olo PC BOARD ASSEMBLY CONTACTOR BELOW CODE 9900 L9185 2 Q 2 ERN 2 ata we 21 0 PART No meNrIFICATION ITEM REQ D PART NO IDENTIFICATION COMPONENT SIDE CIRCUITRY OPPOSITE SIDE CIRCUITRY SILKSCREEN 81 82 3 8 ____ ____ 2 2 1____________ 1 513498 127 olo C2 1 813490 3 00477400 EE 813490 42 1 0 35 2 cic 041 1 813498 76 001 400 ala 513490 92 2 6 2255 3 16668 5 1 022 50 ac 16668 11 x Ci i 513490 14 1 8 20 Di 1 T12705 29 DIODE 1 lt 04 05 06 08 4 2199 1 5 46 11011 3150 5 6 PIN RECEPTACLE __________________ 5182484 HEADER ___ CONTACTOR 022211 112704 56 58 19007 Olo 112704 68 o 016 12704 69 ric NB o 1 2704 72 5 cls 88
172. ued FIGURE 19 CONTACTOR PC BOARD REPLACEMENT 6 Remove the four screws from the front panel holding the contactor PC board assembly in place Carefully remove the contactor PC board assembly See Figure F 19 7 Place the new contactor PC board assembly in 10 position behind the front panel Secure the contactor PC board assembly by installing the four screws into the front panel 8 For codes 10148 and above install plug J9 and olug J7 onto the contactor PC See Figure F 17 9 For codes 9812 and below install the contactor LN 25 LINCOLN CONTACTOR PC BOARD ASSEMBLY coil leads and plug J7 onto the contactor PC board See Figure F 18 Also for codes 9812 and below install plug J3 onto the control PC board See Figure F18 Install the control box cover and secure by installing the screws previously removed Install the wire reel and retaining collar and close the case door 35 TROUBLESHOOTING AND REPAIR F 35 CONTROL PC BOARD REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section T
173. ur body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler 2 04 3 Do not place your body between the electrode and by pushing on the throttle control rods while work cables If the electrode cable is on your right the engine is running side the work cable should also be on your right side A Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Return to Master TOC LINCOLN 8 Return to Master TOC Return to Master TOC QU gt Return to Master SAFETY ELECTRIC SHOCK can kill The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 6 Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on
174. urn to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the gas solenoid valve or the solenoid PC board are functional Return to Section TOC Return to Master TOC MATERIALS NEEDED Phillips Head Screwdriver 12 VDC Supply Volt Ohmmeter DC Voltage Source 25 to 100 VDC O10 O O Fie 9 953 4 cc Cc Return to Section TOC Return to Master TOC LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O O Fie 953 cc Cc Return to Section TOC Return to Master TOC F 8 TROUBLESHOOTING AND REPAIR F 8 GAS SOLENOID VALVE AND SOLENOID PC BOARD TEST continued FIGURE CONTROL BOX COVER REMOVAL CONTROL BOX COVER CASE DOOR WIRE REEL RETAINING COLLAR TEST PROCEDURE GAS SOLENOID VALVE 1 Open the case door Remove the wire reel by removing the retaining collar See Figure F 1 2 Remove the screws holding the control box cover in place and remove the control box cover See Figure F 1 LN 25 LINCOLN Return to Section TOC Return to Master TOC
175. utput are energized is adjustable between at least O to 1 second 2 Postflow Control Provides flow of shielding gas to the work after welding is stopped Delay of the shut off of the solenoid valve after the gun trigger is released is adjustable between at least 0 5 to 5 seconds Installation instructions are included with this kit LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Return to Section Return to Master TOC o 0 4 ACCESSORIES LN 25 CONTACTOR KIT 443 1 For coves BELOW 10500 K443 2 FOR CODES 10500 TO 10558 OR K433 3 FOR CODES ABOVE 11144 Factory installed in K449 Model The internal contactor provides cold electrode until the gun trigger is pressed and a fixed burnback time delay to prevent electrode from sticking in the weld crater when the trigger is released The contactor is rated for use up to 300 amps A cold inch switch allows the wire to be loaded into the system without being electrically hot Installation Instructions are included with the kit CAUTION These kits can only be used with LN 25 s above Code 9200 with LN 25 s equipped with a G1757 3 or higher part number Control PC board To prevent possible damage to the LN 25 with internal
176. ve harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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 Return to Master TOC Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp 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 0 dh s avoid scalding do P al 5 radiator pressure cap when the engine is powered equipment AA 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 52 ELECTRIC AND MAGNETIC FIELDS 1 Do not add the fuel near an open flame weld M may be dangerous ing arc or when the engine is running Stop the engine and allow it to co
177. wires with the grooves in the molded adapter f Slide cage all the way onto the adapter until the retaining spring pops up fully WARNING Check to be sure the retaining spring has fully returned to the locking position and has securely locked the Readi Reel cage in place Retaining spring must rest on the cage not the welding electrode B 5 OPERATION B 5 g To remove Readi Reel from Adapter depress re taining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands It is not necessary to remove adapter from spindle h Load wire into wire drive per Loading Wire Drive MOUNTING 10 TO 30 LB SPOOLS For 12 Diameter Spools a Remove the locking collar and the Readi Reel adapter shipped on the 2 diameter spindle adapter is not required b Place the spool on the spindle so the brake holding pin enters one of the holes in the back side of the spool Be sure the wire comes off the spool in a clockwise direction when dereeled from the bottom of the coil c Replace and tighten the locking collar d See Loading Wire Drive section loading instructions For 8 Diameter Spools Requires optional K468 Spindle Adapter for 8 Spools a Remove the locking collar and the Readi Reel adapter shipped on the 2 diameter spindle adapter is not required b Slide 518221 Spindle Adapter onto the 2 spindle so the brake holding pin enters the adapter pi
178. y to disconnect all of the wiring Disconnect wiring only as needed 3 For codes 10148 thru 10500 remove plug J11 from the solenoid PC board Also disconnect FIGURE F 28 GAS SOLENOID ASSEMBLY WIRING FOR CODES ABOVE 10500 691 690 LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O O Fie 9 953 cc Cc Return to Section TOC Return to Master TOC F 45 TROUBLESHOOTING AND REPAIR F 45 GAS SOLENOID VALVE AND OR SOLENOID PC BOARD IF PRESENT REPLACEMENT continued FIGURE F 29 SOLENOID ASSEMBLY WIRING CODES 9812 AND BELOW SOLENOID PC BOARD SOLENOID LEADS P PURGE SWITCH LEADS 4c Remove the gas hose from the solenoid nipple See Figure F 30 4d Using the 3 8 nut driver remove the purge 4f Reassemble in reverse order and reconnect button nut from the assembly Remove the leads as necessary purge button 4e Remove any necessary brass fittings required FIGURE F 30 GAS SOLENOID ASSEMBLY FOR CODES ABOVE 10500 BRASS FITTING 7 4 _ gt GAS SOLENOID VALVE GAS SOLENOID NIPPLE GAS HOSE GAS SOLENOID VALVE MOUNTING SCREW GAS SOLENOID ASSEMBLY BRACKET LN 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O Fie

Lincoln Electric LN-25 SVM114-C User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents