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Lincoln Electric LN-25 User's Manual

1. o ES DIMENSIONS LN 25 PHYSICAL DIMENSIONS 16 60 14 00 E 7 21 00 LN 25 LINCOLN NOTES LN 25 LINCOLN NOTES LN 25 LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra o REPOR 7 amp nfdcsn zucct 7 ATUBHELTFEL e E GUB AER ES ft GH Oa CRM ER e Xe a Sal e sis Weal AMI W o Qi gaali Y O el ai 293931 d o lala AA ll JS dan Y Jio e Keep flammable materials away Mantenga el material co
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3. B 1 ERR assume a B 1 Recommended Processes and Equipment ss B 1 Welding Capability 2 2 1x rli Uere Gases HER MERE LATA ea nina ana B 1 Controls and Settings isa B 2 Sequence of Op ration tia co Gant n dace GR Ped dn cr Ha ENEE B 4 Loading tee B 4 Loading Wire RTE B 5 Idle Roll Pressure Setting A B 5 Presetting Wire Feed Speed iussi a Era wn EU E aa EFE E Pa B 6 Making VV EE B 7 Procedure at End of Gollu 1 112 dua RE Aen eee B 8 Automatic Protection Shutdown U u B 8 ee SECTION C 25 Option Chas 1 Options and Accessories AA C 2 K430 2 Gas Solenoid LEE C 2 1 Gas Flow Timer Kiku n ene de i ie rd eat C 2 K460 1 Pulse Power Adapter Kit ndr eret rt deret erre ree Errat C 3 K461 Pulse Power Control Cable Assembly iii C 3 K443 2 443 3 LN 25 Contactor Kits C 3 Remote Output Control Options and Control Cable 5 C 3 431 1 lee welt RE C 3 K433 Power Source Remote Don C 4 K432 Remote Control Cabl Assembly u u e p ee C 4 K439 Remote Extension Cable Assembly iii C 4 K624 1 42V Remote Output Control Module sisi C 4 K625 K626 K626 Remote Control Cable Assembly iii C 4 K444 K444 1 or K444 2 Remote Voltage Control Kit sisi C 5
4. i LLP NI G3TIV1SNI 38 ISN qHVO8 SLOWSY LNOHLIM SLINN NO Lut 3TIV1SNI LON SI UN 2 e 9 r bot 2 40078 IHL OL A11038IO S193NNOO 318VO LNdNI IHL ONY 49078 000 oo YOLONGNOD SAWOD HOLIMS ALIHY10d 3H1 OL GV31 29 GSN LON SI HOLOVINOO Y N3HM ooo oo QNVOS 2d 1OH1NOO L S22L1NV SLINN NI GATIVLSNI 39 NYO HOLOVINOO OK a E EEN S 300N 3WOS NO 1 3WOS QI3TIV LSNI AHOLOVA WALI S3HOLIMS 1V 1S03HH 40 MOVE SV SNOLLO3NNOO 96334 LON SI 1 dI G3TIV1SNI 38 15 n1d S310N vr gt 500 21777606 gt 5304 409 HOLIMS 229 4 OL 909 SLIOA DNV 066 gt 512 gt 607 woos s TOYLNOD LNdLNO 310W3H lt 002 0 20 lt quvos 1OMINOO 4 MEE 318vo Nn A NO Er OL Lie YOLOVINOD 1100 SLIOA YOLOWINOO ES A HOUMS 200 HN 9334 JAIM 1W1SOZHH TOHLNOO ES 3MIM MAOL TT
5. LN 25 polarity switch must match electrode polarity Jumper plug on control or option board may be loose or missing The power source O C V must be above 15 VDC But not more than 110 VDC The gun trigger may be faulty Replace gun Wire feeds for a short time but stops feeding When gun trigger is released and retriggered wire feeding starts but stops again The drive motor may be overloaded Check the wire feeding system EX Drive roll tension reel brake and gun cable liner Wire feeds OK but stubs or stops while welding If the power source is a constant current type supply the arc voltage may be dipping below 15 VDC causing the LN 25 to stop or hesitate Connect a constant voltage type power supply to the LN 25 Make sure wire feed mode switch 53 is in the proper position RECOMMENDED COURSE OF ACTION Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized field service facility for technical troubleshooting assistance before you proceed LN 25 LINCOLN E 2 E 3 TROUBLESHOOTING E 3 PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION FEEDING PROBLEMS Rough wire feeding or wire not Gun cable kinked and or feeding but drive rolls turning twisted Wire jammed in gun and cable
6. Incorrect size or installation of drive roll and guide tubes Drive roll loose Contact your local Gun cable dirty Lincoln Authorized Worn drive roll Field Service Facility Electrode rusty and or dirty Worn nozzle or cable liner Partially flashed or melted contact tip Incorrect idle roll pressure Wire reel brake tension set too high A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized field service facility for technical troubleshooting assistance before you proceed LN 25 LINCOLN E 4 PROBLEMS SYMPTOMS Solenoid does not close when trigger is pulled or purge button is pressed Wire feeds properly Variable or hunting arc TROUBLESHOOTING POSSIBLE CAUSE OUTPUT PROBLEMS 1 Make certain that plugs J2 and J3 are connected to the control board securely WELD PROBLEMS Worn and or melted contact tip Replace Worn work cable or poor work connection Loose electrode connect ions Check for loose or faulty connections Wrong electrode polarity for process being used Weld porosity narrow and ropey bead or electrode stubbing into plate when welding Contaminated weld joint or improper procedures Clean joint and check procedure wire speed and all voltage Motor feeds but there is no wire feed speed control Make sure all molex plugs
7. M17253 included with the K624 1 Kit 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 male pin connector connects to the power source per the Instructions M17253 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 or K460 1 Pulse Power Adapter 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 lead 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 ACCESSORIES LN 25 C 5 K577 1 REAR HANDLE KIT For LN 25 model codes above 9383 The fold down handle mounts to the rear of the LN 25 case per the Installation Instructions M16567 shipped with the kit This handle pro
8. 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 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 LINCOLN A 3 INSTALLATION c 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 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 Connection switch at appropriate position d Place power source toggle switch in Output Control at DC 600 position unless a remot
9. Factory Installed on K446 and K449 Models The kit permits the LN 25 to be used for Gas Metal Arc Welding GMAW processes with 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 Install by connecting a supply hose from the gas flow valve outlet to the 2 18 female inert gas fitting on the back panel of the LN 25 case The LN 25 can be used with any shielding gas recommended in the electrode s product literature at a maximum pressure of 60 psi 4 1 bar This may include gases such as Argon Helium Nitrogen and blended gasses such as Ar He Ar No 02 Ar CO CO 02 02 AWARNING CYLINDER may explode if damaged cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live elec trical circuits See
10. KOGI Rean Handie Kit o oto Sen ePi C 5 MAINTENANCE SECTION D Safety PreCautions S aaa EN aE Sa RAAE EEan aande D 1 Routine Ela Ee D 1 Circuit Protection and Automatic Shutdown iii D 1 Adjusting Speed Sensor db o He dites dee D 1 Calibration of the LN 25 Wire Speed Dial D 2 TROUBLESHOOTING IIS bue ner ennemis SECTION E How to Use the Troubleshooting Guide Ae E 1 Tro bleshooting GQUuIde u ee en E 2 WIRING SECTION PHYSICAL DIMENSIONS SECTION F PARTS MANUAL sci P333 SERIES A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS LN 25 Constant Voltage CV or 15 40 VDC 110VDC Maximum OCH Constant Current CC Rated current without contactor 500 Amps 60 Duty Cycle Rated current with contactor 300 Amps 60 Duty Cycle 50 700 Inches Per Minute IPM 023 to SOLID STEEL WIRE 045 to 4 CORED WIRE 035 to ALUMINUM WIRE HEIGHT WIDTH WEIGHT Handle Down w o Options 14 Inches 7 4 Inches 21 Inches 28 lbs 354 mm 187 mm 531 mm 13 kg TEM
11. American National Standard Z 49 1 Safety in Welding and Cutting published by the American Welding Society See GMA Gun Cable Gas Connection Installation instructions M19154 are included with the kit K434 1 GAS FLOW TIMER KIT Requires either a K431 1 Remote Output Control Kit K460 1 Pulse Power Adapter Kit K624 1 42V Remote Output Control Kit or internal contactor K443 1 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 output are energized is adjustable between at least 0 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 M17590 are included with LN 25 this kit LINCOLN C 3 K460 1 PULSE POWER ADAPTER KIT For use with K461 Pulse Power Control Cable No Longer Available This kit enables the LN 25 to pulse weld with a Pulse Power 500 power source above Code 9300 or lower Codes updat
12. Internal Contactor K443 2 is not used LN 25 When used with a K460 1 Pulse Power Adapter Kit the LN 25 does not need a clip lead NOTE The clip lead also serves as a work sensing lead for the LN 25 Voltmeter if installed If the clip lead is extended by the user beyond the standard 15 ft 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 AWG Maximum Length 14 25 Ft 7 6m 12 50 Ft 15 2m 10 100 Ft 30 5m 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 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 in Accessories Section LINCOLN B 3 BA SEQUENCE OF OPERATION LOADING ELECTRODE AWARNING ELECTRIC SHOCK can kill Unless an optional output control or internal contactor is used with the LN 25 the electrode cir
13. OPERATION The volts marks 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 WORK CLIP LEAD AWARNING ELECTRIC SHOCK can kill Do not touch metal portions of the LN 25 lead clip when welding power source is on AWARNING IMPORTANT SAFETY NOTE To avoid possible electrical shock do not touch the metal portions of the LN 25 work lead clip if the power source output is on The clip will be electrically HOT to work if the input electrode cable to the LN 25 is electrically HOT even if the gun trigger is off and even if an internal contactor is used Care should be taken to only handle the LN 25 work clip by its non metal insulated portions and or the welding power source should be turned off before handling the work clip The 15 ft 4 6m work clip lead attached to the front panel of the LN 25 case must be connected directly to the work using the spring clip on the end of the lead If not connected the LN 25 will not operate even if a K431 1 or K624 1 42V Remote Output Control option refer to Accessories Section is used However the electrode will still be electrically HOT when the clip lead is disconnected if K431 1 or K624 1 42V Remote Output Control Option or
14. Pin Amphenol Remote for Power Source w 14 Pin Amphenol 42VAC Remote Output Control Module 500 Amp Cable w Stud Type Output Terminals 350 Amp Cable w Stud Type Output Terminals 400 Amp Cable w Twist Mate Type Terminals Pulse Power Adapter Kit Pulse Power Control Cable 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 LN 25 LINCOLN 5 C 2 ACCESSORIES C 2 OPTIONAL ACCESSORIES 0 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 K430 2 GAS SOLENOID KIT For Codes above 10500 only
15. SI TVNOILdO SS37Nn 0311 15 38 Lem 39018 YOLINGNOD 01 A11938IQ SLIINNOI 318V9 ANANI JHL ONY 329018 YOLONGNOD IHL NOUA S3 02 HOLIMS ALIUVTOd 3Hl 01 0 31 19 0350 LON SI 304991409 V N3HM QHvO8 24 1051905 CON 1HVd M3H9IH YO 19 19 SLINN NI Q3TIVISNI 38 HOLIVLNOI 57340 3WOS NO IN3AdInO3 1VNOILdO QNV 513000 3AOS NO 0311 15 AYOLIVS WILI SSHOLIMS 1V1SO3HH 30 NOV WOHJ SY SNOII23NNOO 9NI38 SI LIX 340733 TWNOILdO SS3 Nn GATIVISNI Lamm 9nd s3dAnr AHL Q3Sf LON SI YOLOVINOD V N3HM S310N 053 NOLLAGHSNd 3091814 1 39und SS HILIMS HONI 0702 pS HOLIMS 300M 0333 3MIM S HOLIMS 39NVH VIO 03345 ZS HOLIMS ALIYV10d IS 943997 HASNNN ALIAVO 1 318v2 NNI HOLIMS 103333 Deo 103 2 399181 sr 19 TN HOLIMS ALINV10d lOMINOO 1Nd1NO QHVOS TOYLNOD 01 SLIOA 9 lt MOQULOT YOLOVINOD HO 310N3J OL 069 01083105 599 9114 08 774 301591409 We CAAT OST OPEN NI Xkkkkkkikkikkktt4 Irpaowmaoso 9 iD 310W34 IVNOLLdO 89901 29901 18 l gt 219 034 gt 995 gt TOULNOD X i c 96601 3405 SZ HOLIMS HN HOL
16. 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 SAFETY 7 WELDING SPARKS can gt 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 and 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 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
17. cannot be used with K431 1 or K624 1 Remote Output Control Kit or K460 1 Pulse Power Adapter Kit If remote voltage control is desired along with the internal contactor obtain a K444 K444 1 or K444 2 Remote Voltage Control Kit LN 25 ACCESSORIES C 3 CAUTION This kit can only be used with LN 25 s Code 10500 10558 To prevent possible damage to the LN 25 with internal 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 K443 3 LN 25 CONTACTOR KIT For Codes above 11100 only 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 L12319 are included with the kit NOTE The K443 3 cannot be used with K431 1 or K624 1 Remote Output Control Kit or K460 1 Pulse Power Adapter Kit If remote voltage control is desired along with the internal contactor obtain a K444 K444 1 or K444 2 Remote Voltage Control Kit A CAUTION This kit can only be used with LN 25 s above Code 11100 To prevent possible damage to the LN 25 with internal contactor do not connect to non Lincoln TIG or Sq
18. not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety wies gt minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by push ing on the throttle control rods while the engine is running 2 d 3
19. recommendations LINCOLN SAFETY PR CAUTIONS DE SURETE 7 Quand on ne soude pas poser la pince une endroit isol de la 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 suivantes S ret Pour Soudage L Arc 1 Protegez vous contre la secousse lectrique 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 humides ou sur un plancher met allique ou des grilles metalliques principalement dans le s 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 sou
20. 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 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 vollage POWER SOURCE WARNING The LN 25 should be used with a constant current machine only upon non critical weldments and after testing is done to assure quality is adequate for the application LINCOLN B 9 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 While welding with a continuously fed electrode weld current variations are continuously taking place There are many causes for these variations but predomina
21. 8 female inert gas fitting 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 le Length Weld Current otal Cabe Leng 60 Duty Cycle 50 100 100 150 150 200 200 250 200Amps 2 AWG 2AWG 1AWG 1 0 300Amps 1 AWG 1AWG 1 0 2 0 400Amps 2 0 2 0 3 0 3 0 500Amps 2 0 3 0 3 0 4 0 ELECTRODE CABLE CONNECTION 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 nut provided Secure the cable with the strain relief clamp provided All units are supplied with an optional pigtail for customers that prefer 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 INSTALLATION A 4 WIRE FEED DRIVE ROLL AND GUIDE TUBE KITS WARNING Turn off power source before installing or changing drive roll and or gu
22. AUTION Keep gun in 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 Press the gun trigger for several seconds 2 If the wire bird nests jams or breaks at the drive roll the idle roll pressure is too great Back the pressure setting out turn run new wire through gun and repeat above steps LN 25 LINCOLN 5 B 6 3 If the only result is drive roll slippage shut off the power source then loosen the gun cable clamping screw in the gearbox conductor block and pull the gun cable forward about six inches There should be a slight waviness in the exposed wire If there is no waviness the pressure is too low Increase the pressure setting 1 4 turn lock the gun cable in place and repeat the above steps PRESETTING WIRE FEED SPEED The LN 25 permits accurate presetting of the desired wire feed speed before welding in both CV and CC wire feed modes SETTING CONSTANT WIRE FEED SPEED CV MODE a b Set Wire Feed Mode switch to CV position Set D
23. Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X 2 d 4 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 2 4 5 Do not work next to welding power source Mar 95 LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a 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 freegloves to insulate hands 3 b 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 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 Manu
24. IMS JOW 0334 S Qquvog 2 d YOLIVLNOD 6 NOLLNGHSNd HONI 0702 GE ies 129 ON INT 8381 KT 1504 16 119 3HOM 01 TN HALINLIOA Juv 1VLSO3HH N1 WNV49VIQ 083345 33IM 201 H21IMS SONVY 10 03345 25 LN 25 LINCOLN D WIRING DIAGRAM F 2 F 2 y e JO uowyedeg eoruesg ou s ou sjeued einsoj oue eu euo uo eu pejsed si epoo ened e 10 siy Aq eq jou AjUO 104 SI 3141 310 64979 HO LdVQV H3MOd 3S Ind TVNOLLdO 9 9 OL quvog 1041NOO 4 SC 82 NO qasn ond i GE NO Ef OL 005 IN3NOdWOO 40 ONIHSN OL S1O3NNOO S13qON 1N3S3tHd OL SAOVIYNS TVLIW Q3S0dX3 AVMHLWd NV S3qIAONd LEP OLNI n1d LSNW SSANYWH 2d 3103 LNOHLIM SLINN NO SLOWSY 40 OLNI ON Id LSNW SS3NHVH HANIL GVO Od SLOWSY SLINN NO ooo NOILYTIYLSNI SSINYYH YINIL nuu Od SLOWSY 40 NI GATIVLSNI 38 LSNW 9908 Od SLOWSY SLINN NO
25. LN 25 PORTABLE CV CC SEMIAUTOMATIC WIRE FEEDER For use with machines having Code Number 10556 11144 10557 11145 10558 11282 RETURN TO MAIN MENU 11283 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful opera tion 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 OPERATING MANUAL 150 9001 P3 E x d signed an nder Qual NCOLN Copyright 2006 Lincoln Global Inc World s Leader 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 WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains chemi are known to the State of California to cause cancer cals known to the State of California to cause cancer birth defects and other reproductive harm birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PRO
26. NES SOU DER contre les chutes dans le cas ou on recoit un choc Ne jamais TRANSFORMATEUR ET enrouler le c ble lectrode autour de n importe quelle partie du corps REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel donc 1 a Utiliser 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 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 pantalons 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 o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que po
27. PERATURE RANGE OPERATION 40 C to 40 40 F to 104 STORAGE 40 C to 85 40 F to 185 LN 25 LINCOLN A 2 SAFETY PRECAUTIONS Unless optional output control 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 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 ELECTRIC 5 can kill Do not touch portions of the LN 25 lead clip when welding power source is on POWER SOURCE CONNECTION The LN 25 can be used with most 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
28. TECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do
29. 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 welding 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 electrode 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 M17584 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 K439 REMOTE EXTENSION CABLE ASSEMBLY The 50 ft Extension cable assemblies are used to extend the K432 Remote Control Cable Assembly when longer cable lengths are required Multiple K439 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 extensio
30. al 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 6 c and 8 L 5 f AUG 06 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 welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 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
31. and leads are securely connected to the control board Check speed sensor see maintenance section CAUTION E 4 RECOMMENDED COURSE OF ACTION Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized field service facility for technical troubleshooting assistance before you proceed LN 25 LINCOLN F 1 WIRING DIAGRAM F 1 ou BAIN Tu uop d 1 e JO uowyedeg eorueg 94 0 M ou sjeued einsoj oue y euo uo y si epoo e 10 siy Aq eq jou 31 JO S SIUL 310 52601 1 3862 0 3sond TYNOILAO Quvog 2 d YAWIL 01 moos y 1 219 lt 1 01 Be OHYO8 1081 02 01 HOLIMS AlINV Od 01 SLIOA Quvog 2 3LOW3H IOMINOO LNdLNO 310W3H IVNOILdO I d OL QuvOg 10381NO3 01 IN3NOdAOO JHL 30 SNIHSnH 3Hl Ol 5103 00 TN ANO 71300 NO 1N3S3Hd WHOM 01 530 34 5 1V13A 03509 3 AVMHIVd 053 NV SLINN NO G3SN HOLIMS 319901 0351
32. atement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS SAFETY PR SR SARA EP M i iv INSTALLATION E SECTION A ee e e EE A 1 Safely WEE A 2 Power Source Connections u u a Seege EES A 2 Gun Cable Connection to Feeder A 3 Weld Cable eut e EE A 4 Electrode Cable Conmiectiork iii A 4 Work Cable 6 ED A 4 Wire Feed Drive Roll and Guide Tube Kits A 4 OPERATIQN SECTION B Safety Precautions
33. ators 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 Oylinders should be located Away from areas where they may be struck or subjected to physical damage 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 follow the instructions on compressed gas cylinders associated equipment and CGA publication P l 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
34. cuit 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 LN 25 will require an optional K363 P Readi Reel Adapter which is required to load Lincoln 22 to 30 Ib Readi Reel coils 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 wires with the grooves in the molded adapter f Slide cage all the way onto the adapter until the retaining spring pops up fully AWARNING 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 OPERATION LN 25 B 4 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 Wir
35. der comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de masse Un court circuit accidental peut provoquer un chauffe ment 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 gal vanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence 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 pro duits 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 sedg PR CAUTIONS DE S RET POUR Dans le cas de travail au dessus du niveau du sol se prot ger LES MACHI
36. e 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 R3S 325 a Connect a jumper from 4 to 32 on the power source terminal strip so that the output will be energized when the R3S 325 is turned on b Connect the electrode cable to the output terminal of polarity required by electrode Connect work lead to other output terminal c Set power source per its instruction manual NOTE Use of the optional Line Voltage Compensator available for the R3S 325 is recommended if input line voltage variation exceeds 3 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 POSITIVE For electrode positive welding interchange t
37. e Drive Section MOUNTING 10 TO 30 LB SPOOLS For 12 Diameter Spools a Remove the locking collar and the Readi Reel adapter if so equipped 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 for loading instructions For 8 Diameter Spools Requires optional K468 Spindle Adapter for 8 Spools a Remove the locking collar and the Readi Reel adapter if so equipped 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 pin 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 if so equipped on the 2 diameter spindle adapter is not required b Mount K435 Spindle Adapter and Innershield c
38. e available range of the LN 25 wire feeder may not be suitable for all applications and the builder user is and must be solely responsible for welding settings 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 stated in Arc Welding Safety Precautions b 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 is to be used without the K432 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 NOTE If the K460 1 Pulse Power Adapter Kit is installed but the LN 25 is to be used without the K461 Pulse Power Control Cable Assembly then the instructions for returning the unit to across the arc operation included with the Installation Instructions L9636 must be followed 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 Po larity Switch to same polarity a
39. e work the arc voltage will essentially drop to zero and the short circuit current supplied by the CC power 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 OPERATION LN 25 been opened 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 stick out 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 D23 035 solid steel electrodes with Argon rich AUTOMATIC PROTECTION SHUTDOWN T
40. ed with Kit The kit includes a Remote PC board with output volt age control and control cable receptacle which mount and connect inside the LN 25 control box per the Installation Instructions L9636 included with the kit NOTE If the K460 1 Pulse Power Adapter Kit is in stalled but the LN 25 is to be used without the K461 Pulse Power Control Cable Assembly then the in structions for returning the unit to across the arc op eration included with the Installation Instructions L9636 must be followed K461 PULSE POWER CONTROL CABLE ASSEMBLY No Longer Available Requires K460 1 Pulse Power Adapter Kit installed in LN 25 The K461 control cable assemblies include an elec trode cable rated for up to 500 amps 60 duty cycle and a 9 conductor control cable The control cable pin connector connects to the LN 25 and the lugged leads connect to the Pulse Power Available in 25 50 75 and 100 ft lengths K443 2 LN 25 CONTACTOR KIT For Codes 10500 10558 only 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 L10923 are included with the kit NOTE The K443 2
41. f the wire drive gearbox 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 LN 25 as follows LINCOLN D 2 Be sure all power to the LN 25 is shut off at the power source Check that the module mounting plate is screwed securely to the side of the gearbox Gently screw the module into the mounting plate until it just touches and stops against the rotating part inside the gearbox 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 Set DIAL RANGE switch to LO and WIRE FEED MODE sw
42. for use with the LN 25 include the DC 250 400 600 CV 400 and R3S type transformer machines and the SAM 400 650 engine welders as well as the SA 200 250 or SAE 300 400 with CV Adapter and Pulse Power 500 with K460 1 LN 25 Kit WELDING CAPABILITY The LN 25 will handle up to 500 Amp 60 duty cycle welding currents However when equipped with a K443 2 Contactor the LN 25 will handle up to 300 Amp 60 duty cycle LN 25 LINCOLN Se OPERATION B 2 LN 25 INSTRUMENTS AND CONTROLS Refer to Figure B 1 for control locations REMOTE WIRE SPEED ARC VOLTAGE DIAL RANGE CONTROL SWITCH OPTIONAL WIRE SPEED DIAL d VOLT GAS POST METER PRE FLOW TIMERS OPTIONAL ELECTRODE POLARITY WORK CLIP SWITCH GAS FITTING GUN OPTIONAL CONNECTION BLOCK GUN TRIGGER AMPHENOL CONNECTOR OPTIONAL GAS INPUT j FITTING B PURGE BUTTON ELECTRODE CABLE FIGURE B 1 CONTROL LOCATIONS 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 electrode cable connection and the work clip lead 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 to the
43. he LN 25 control provides automatic electronic protection circuits which shut down the LN 25 for excessively high power source open circuit voltage or excessive motor overload 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 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 LINCOLN 5 B 9 C 1 ACCESSORIES ed How to use Table C 1 Determine which Kit No is to be used Locate that Kit No in the left hand vertical column Scan horizontally to determine which LN 25 model is required and what additional kits may be required TABLE C 1 LN 25 OPTION CHART CANNOT BE USED WITH X REQUIRED REQUIRES ONE OF THESE INCLUDED WITH SEE TEXT LN 25 MODELS LN 25 KITS Solenoid Kit Remote Output Control Module Remote Control Cable 115VAC Power Source Remote Box Gas Flow Timer Kit 50 Ft Ext Cable Contactor Kit Codes 10500 10558 Contactor Kit Codes 11144 amp Above Remote for Power Source w Terminal Strip Remote for Power Source w 6
44. he 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 the 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 Gas Solenoid Kit factory installed on K446 and K449 models See K430 1 Gas Solenoid Kit Section in Accessories Section for gas solenoid operation and gas supply LN 25 connection LINCOLN A 3 4 Install the barbed fitting and union nut to the 1
45. hing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de 105 humos Utilice ventilaci n aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria U C F V KEE ER 24752 else SUAS MAS sis PARAH 718 Assis power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e X7TTL2A UACRU D gt C F uv e SAUTER Do not operate with panel open guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setze
46. ial 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 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 VV CC MODE When using a constant current formerly variable voltage power source welding performance is im proved using arc sensing wire feed speed VV CC 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 VV 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 VV CO position OPERATION LN 25 B 6 Y DESIRED IN MIN 700 ARC VOLTS USED 350 300 250 200 FIGURE B 3 CC WIRE SPEED SETTING HI or LO Range b Referring to the graph located above the Mode switch also sho
47. ide 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 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 A2 TABLE A 2 Steel Wire Sizes 068 Cored 062 Cored or Solid Steel Can also be used for 052 045 and 052 Solid Steel 045 and 052 Cored 035 Solid Steel 035 Cored 030 Solid Steel 025 Solid Steel 653 ie 052 052C 035S 035C 0305 0255 Aluminum Wire 512 5 Yea 035 654 035A Drive rolls for only cored electrode sizes are 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 for aluminum wire sizes are stencilled with an A suffix to the wire sizes LINCOLN B 1 SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE AWARNING ELECTRIC SHOCK can kill Do not touch electrically live part or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves dangerous Do Use ventilation or exhaus
48. 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 and 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 INSTALLATION LN 25 A 2 AWARNING _ ELECTRIC SHOCK can kill Do not operate with covers removed 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 Connect electrode cable to the Innershield GMAW output terminal of polarity required by electrode Connect work lead to other Innershield GMAW output terminal c Place Set to CV Electrode Cable Polarity switch at appropriate position 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 Place mode switch in Innershield GMAW CV
49. itch to CV position Press gun trigger to feed wire and measure the wire feed speed IN MIN using a Portable Digital Wire Feed Speed Meter Lincoln K283 Take at least two readings to assure repeat able accuracy Feed Speed Meter Lincoln K283 Take at least two readings to assure repeatable accuracy MAINTENANCE Electrode will be electrically hot Do not allow fed wire to contact any metal common with welding work LN 25 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 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 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 LINCOLN D 2 E 1 TROUBLESHOOTING E 1 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
50. mbustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos U DOMTORRIER THEW EKA e 18 9 Vi S BET freA eis Ad d s Jo Aal AIX Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo R HAUSHERMRELTTF EU OMAR HRSRSORENE ez 119 59 43 4 Ally lan Cl aa Sawa READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN e Keep your head out of fumes Use ventilation or exhaust to remove fumes from breat
51. n e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas CH B EHTEEUSXVCREU e SER RTI BB st 2 8 ERE e wel Me z WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese oe lue chal ad gaal bacs ga d arin Mall oe Quad Aie Ab pha NM uu 0 ale AREY cuts 13 ai tha Jai e Aale Cut Al dl LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR fBodsudoesBox 5 o0d cm F ux ET AERE SUCR S TE fit D ECTS E EE sy AIXAM SALAD HAY zeit AS PSP HHCH veel dl illai J AAL Gail Ca L LINCOLN e World s Leader Welding and Cutting Products e e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
52. n the maximum welding current used should be less than 350 amps The K439 Extension cable end with the male pin connector 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 connection with electrical tape K624 1 42V REMOTE OUTPUT CONTROL MODULE For use with K625 K626 K627 Remote Control Cable 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 M17253 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 in LN 25 The K625 K626 K627 control cable assem blies include an electrode cable and a 8 conductor control cable LN 25 LINCOLN CA C 5 The cable assembly end with the socket pin connector connects to the LN 25 per the Instructions
53. nder away from areas where it may be dam aged e Never lift welder with cylin der attached e Never allow welding elec trode to touch cylinder eKeep cylinder away from welding or other live electri cal circuits WELDING A WARNING ARC RAYS can burn 2 not touch metal por tions of the LN 25 lead Clip when welding power source is on a Cut the electrode within approximately of the end of the contact tip for solid wire and within approximately of the extension guide for cored wire b Position electrode over joint End of electrode should be slightly off the work 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
54. 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 the 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 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regul
55. ntly they occur due to changes in electrical stick out operator hand movements nozzle tip contact variations 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 flat 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 VV 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 th
56. oil per the Instructions S18256 included with the K435 LINCOLN OPERATION FIGURE B 2 READI REEL INSTALLATION 2 O D SPINDLE BRAKE HOLDING PIN MUST ENGAGE HOLE IN ADAPTER RIB GROOVES 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 guide tube causing a bird nest c Insert the free end through the incoming guide tube to the drive roll d Turn on the welding power source Unless 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 When inching with trigger the electrode and drive mechanism are always hot to work and ground Use the cold inch switch on models with internal contactor READI REEL MOLDED ADAPTER RETAINING SPRING INSIDE CAGE WIRES THREAD LOCKING COLLAR 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 C
57. precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LINCOLN LN 25 TROUBLESHOOTING E 2 PROBLEMS SYMPTOMS No wire feed when gun trigger is pulled POSSIBLE CAUSE FEEDING PROBLEMS Power source must be on and open circuit voltage OCV present at weld terminals LN 25 work clip may not be connected
58. 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 lubri cate spindle MAINTENANCE D 1 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 GEAR BOX Every year examine the gear box Paint the gear teeth with molydisulfide filled grease Lincoln specification E2322 Do not use a graphite grease Check the motor brushes Replace if they are worn down to 7 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 assembly CIRCUIT PROTECTION AND AUTOMATIC SHUTDOWN CONTROL PC BOARD The Control P C Board has electronic protection for trigger circuit faults to the electrode circuit 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 o
59. s electrode e Set WIRE FEED MODE switch to CV or CC as appropriate for the power source then set the proper DIAL RANGE and WIRE SPEED dial set _ Desired IPM ting for the proper wire feed speed the VV CC Speed Setting r X 35 welding procedure FIGURE B 4 VV CC WIRE SPEED SETTING LN 25 LINCOLN B 8 OPERATION 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 WIRE 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 h Turn on the welding power source as well as the shielding gas supply if used A 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 and gas supplied to the nozzle area if used WARNING CYLINDER may explode if damaged e Keep cylinder upright and chained to support eKeep cyli
60. 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 or red 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 or blue dial range calibrated for 50 to 700 in min LINCOLN B 3
61. ssible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY product by Lincoln Electric We want you Thank You io take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty st
62. t to remove fumes from breathing zone 2 yi fire or explosion Keep flammable material away a tion FUMES AND GASSES can be Keep your head out of fumes WELDING SPARKS can cause ARC RAYS can burn Wear eye ear and body protec OPERATION B 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 Ib 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 quality 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 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
63. to Pins A amp C Drive Roll amp Guide Tube Wire Sizes Used Kit No 2 3 5 T 13355 2 4 072 amp 068 512024 1 L E Part No T 13355 1 062 Amphenol AN3057 10 or equiv S12020 6 L E Part No T 1595550526 045 052 Cored Amphenol MS 3106A 18 11P or equiv T 13355 052 045 052 Solid T 15010 035S 023 thru 035 Solid FIGURE C 2 SWITCH REQUIREMENTS Can also be used for 052 wire LN 25 LINCOLN D 1 SAFETY PRECAUTIONS AA 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 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 lubricant 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 other 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 e through electrode have a double set of teeth so they can be reversed for additional life Drive
64. uare Wave power sources TIG high frequency power should never be applied to the LN 25 REMOTE OUTPUT CONTROL OPTIONS AND CONTROL CABLE ASSEMBLIES Remote Output Control Options are available to pro vide the LN 25 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 LINCOLN C 4 ACCESSORIES 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 NOTE If the K431 1 Remote Output Control Kit is installed but the LN 25 is to be used without the K432 Remote Control Cable Assembly then the Re mote Board harness plug must be removed from the 16 pin receptacle on the Control Board and the jumper plug T13498 21 reinstalled K433 POWER SOURCE REMOTE BOX Requires K431 1 Remote Output 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 per the Installation Instructions M15324 and power source connection diagrams included with the kit
65. vides a means to also carry the LN 25 in the vertical position especially convenient for passing the unit through a manhole K363P READI REEL ADAPTER KIT Adapts Lincoln Redi Reel coils of electrode 30 Ib 14 kg and 22 Ib 10 kg to a 2 51mm spindle Durable molded plastic one piece construction Designed for easy loading adapter remains on spindle for quick changeover LINCOLN Se ACCESSORIES Se The following Figures C 1 and C 2 should serve as a guide to determine if a particular gun or switch can be connected to the LN 25 GUN CABLE CONNECTOR REQUIREMENTS TO PERMIT PROPER CONNECTION TO LINCOLN LN 25 WIRE FEEDER 7490 03x45 06R A Dia Hole 295 52 090 0 CONNECTOR MUST BE INSULATED IN THIS AREA 2 00 CH B Dia Hole 495 Max Dia LN 25 Cable Connector for 023 through 052 Wire For all other dimensions see above FIGURE NOTE Connector part with 749 747 diameter SWITCH REQUIREMENTS should be made from brass if it is to be part of the welding current carrying circuit Amp AC 24 Volts Inductive Amp DC 24 Volts Inductive A Dia Hole To be Concentric to 749 747 Wire Size Dia Within 008 F I M To Gun Switch 068 thru 125 Drill 062 078 Drill 045 amp 052 062 Drill 023 thru 035 055 54 Drill Connect Leads
66. 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 GASES can 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 spe cific welding procedure and application involved 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
67. wn in Figure B 3 1 Select the horizontal 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 VV 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 LINCOLN OPERATION Bs MAKING A WELD serviceability of product structure utilizing the LN 25 wire feeder is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the LN 25 wire feeder These variables include but are not limited to Desired In Min welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements Th

Lincoln Electric LN-25 User's Manual

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