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Lincoln Electric 11389 Welder User Manual

1. ses A 4 Procedure to Install Drive Rolls and Wire Guides A 4 Pressure Arm Adjustment nase uos dx RN UR DS FUN UE A 5 Loading Spools UU a A 5 GUN Gone ULU 5 Power Source to LN25 PRO EXTREME Cable Connection Diagrams A 6 thru A 8 SE AON nce este eu es a nv we nce E een Section B oale y HOS B 1 Graphic Symbols that appear on this Machine or in this Manual B 1 Definition of Welding Terms T Too nen B 2 General DeserIption o m mmm 2 Recommended Processes Equipment Limitations Recommended Power Sources B 2 Case Fronit Controls uuu uuu uu uu B 3 thru B 5 lida ROn atts ee Sc sce one cerca mae anc iets due een B 6 Internal Controls Decription r B 7 Constant Current Wire un ne een 8 RE CONTO tae acca ee ee B 9 9 Power Up Sequence anna ann B 9 ACGESSOrIES Eee ernennen Section C Factory Installed Equipment Om C 1 Bae Bicis on C 1 Accessories SO ane een C 2 thru C 4 priiis et Section D een en u apayasqa ied d M D 1
2. zul s J al gll s sig Slate agil g il LINCOLN World s Leader in Welding and Cutting Products e 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
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5. 035 0 9mm WIRE Steel Wires 045 1 2mm 052 1 4mm 1 16 1 6mm 035 045 0 9 1 2mm 040 1 0mm 030 035 0 8 0 9mm 040 045 1 0 1 2 052 1 4 1 16 1 6mm 068 072 1 7 1 8mm 5 64 2 0mm Cored Wires 035 0 9 mm 040 1 0mm 3 64 1 2mm 1 16 1 6mm Aluminum Wires KP1696 030S 1696 0355 1696 0455 1696 0525 1696 1 165 1696 1 1696 2 KP1697 035C KP1697 045C KP1697 052C KP1697 1 16C KP1697 068 KP1697 5 64 KP1697 3 32 KP1695 035A KP1695 040A KP1695 3 64A KP1695 1 16A Red D Arc Welderentals ACCESSORIES FACTORY INSTALLED EQUIPMENT Includes 2 V groove drive rolls and inner wire guide Includes 2 Knurled drive rolls and inner wire guide Includes 2 polished U groove drive rolls outer wire guide and inner wire guide LN 25 PRO EXTREME d N ACCESSORIES 2 Includes 1 0 Coaxial weld cable of length xx Ends of K1796 xx AWG 1 0 Co Axial Power Cable the weld cable have lug con nections Use for Pulse weld ing Includes AWG 1 Coaxial weld cable of length xx 2593 AWG 1 Coaxial Power Cable Ends of the weld cable have lug connections Use for Pulse or STT welding Includes Twist Mate to Lug 2 0 cable 14 1 2m long with K1803 1 Work and Feeder Cables Package Ground Clamp and Twist Mate to Lug 2 0 Cable 9 2 7m long K1840 xx Weld Power Cable Twist Mate to Includes
6. 9 Turn power OFF 10 Replace the cover and secure with the screws FIGURE D 2 LN 25 PRO EXTREME Red D Arc Welderentals E 1 TROUBLESHOOTING 1 HOW USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you 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 Authorized Field Service Facility If you do not
7. 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 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 du corps PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant approprie REDRESSEUR ainsi qu un verre blanc afin de se proteger les yeux du ray onnement de et des projections quand on soude ou quand on regarde Porter des v tements convenables afin de proteger la peau de soudeur et des aides contre le rayonnement de Proteger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 2 Des gouttes laitier fusion sont de soudage Se prot ger avec des v tements de protection libres 3 de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 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 possibl
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9. EXTREME Red D Arc Welderentals SAFETY PRECAUTIONS DE SURETE a 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 humides ou sur un plancher metallique 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 defonctionnement 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 prec
10. SVD k lt pe vf n OL SLOANNOO ac Les ge gt 97 AL v1 lt lt lt gt G gt lt lt gt 169 v s p E gt W299 1 od g DL 9 9 900401 8 SS3NHVH NO 069 1 4 3i OL SLOINNOO 109 9 lt H3WIL OL g 8 9 s9 s lt S193NNOO k Ln XO8uV35 ab a gt QION310S v e THOLOW yb ML La br Svo 809 109 8 HOVL E HUNE T 8 99 MAP 909 lt 808 OL 909 lt 9 99 909 amp dlVld 0 T 9f N gy k p lt 094 333 TT Ef d be gt u goos 1 6 crm jj O Y Ri 22 gt VALS N I X YY Y aspect p ON p 9o1 199 N vid D 24 TOHLNOO I I li i Y Y Bu M _ 089 p lt voeg VOEG e de 0333 v ve29 voo e LY 9 99 Lez EN ES 608 629 lt VECS 3609 eo 9109 o 186 186 HOLO3NNOO ML 29 019 80 zes 219 N ES 4399IHL ge 00 0 veos eze N 605 608 lt 2608 N EN Ex WL ene e 019 dd L3sdHd NO ON tomb 219 er OL SLOSNNOO L 609 9214 Ta E H313ILTOA SSANYVH NO ZP X313 8 OL SLO3NNOO ja 9 Juv HOLIMS AONINMOHS __ d31S Z NMOHS NOLLNEHSNd
11. Twist Mate to Lug Lug 1 0 cable of length xx IIncludes Lug to Lug 3 0 Cable of length xx for lengths K1842 xx Weld Power Cable Lug to Lug up to 60 18 3m Lug to Lug 4 0 Cable of length xx for lengths greater than 60 18 3m LN 25 PRO EXTREME Red D Arc Welderentals C 3 ACCESSORIES C 3 K910 1 Ground Clamp Includes One 300 Amp Ground Clamp K910 2 Ground Clamp Includes One 500 Amp Ground Clamp Gun Receiver Bushing for guns Includes Gun receiver bush K1500 1 with K466 1 Lincoln gun connec ing set screw and hex key tors Innershield and Subarc guns wrench Gun Receiver Bushing for guns with K466 2 K466 10 Lincoln gun Includes Gun receiver bush connectors Magnum 200 300 400 ing with hose nipple set screw guns and compatible with Tweco and hex key wrench 2 4 Includes Gun receiver bush ing with hose nipple set screw and hex key wrench Gun Receiver Bushing for guns with K613 7 Lincoln gun connec tors Magnum 550 guns and com patible with Tweco 5 LN 25 PRO EXTREME Red D Arc Welderentals 1500 4 1500 5 489 7 K435 K468 K586 1 I ACCESSORIES Gun Receiver Bushing for gun with K466 3 Lincoln gun connec tors compatible with Miller amp guns Gun Receiver Bushing compatible with Oxo guns Gun Receiver Bushing for Lincoln Fast Mate guns Spindle Adapter for mounting 14 I
12. gas The gas supply is OFF or empty 1 Verify the gas supply is ON and flowing The gas hose is cut or crushed Route the gas hose so it avoids sharp corners and make sure nothing is on top of it Repair or replace damaged hoses The flow meter valve is closed Open the flow meter valve Dirt or debris is in the solenoid Apply filtered shop at 80psi to the solenoid to remove dirt There is a loose solenoid connec 5 Remove the cover and check that tion all connections are in good condi tion The solenoid has failed Inconsistent wire feeding or wire not 1 The gun cable is kinked 1 Keep the gun cable as straight as feeding but drive rolls turning twisted possible Avoid sharp corners or TP bends in the cable The wire is jammed in the gun 2 Remove the gun from the wire cable feeder and pull the jammed wire out of the gun and cable The gun liner is dirty or worn Blow dirt out of the liner with low pressure 40psi or less Replace the liner if worn The electrode is rusty or dirty Use only clean electrode Use quality electrode like L 50 or L 56 from Lincoln Electric The contact tip is partially meltedf5 Replace the contact tip or has spatter Improper gun liner tip drive 6 Verify the proper parts are and or inner wire guide installed Incorrect tension arm pressure 7 Adjust the tension arm per the the drive rolls Instruction Manual Most ele
13. or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released Do not operate with covers panels or guards removed or open e Only qualified personnel should perform mainte nance work The LN25 PRO EXTREME comes with a K1500 2 gun adapter installed See Figure A 4 To install a gun 1 Turn power OFF 2 Remove the thumb screw 3 Push the gun the completely into the gun bushing 4 Secure the gun in place with the thumb screw 5 Connect the trigger cable from the gun to the trigger connector on the front of the feeder Note Not all gun bushings require the use of the thumb screw FIGURE A 4 THUMB SCREW GUN EN LN 25 PRO EXTREME Red D Arc Welderentals 6 INSTALLATION A 6 POWER SOURCE TO LN25 PRO EXTREME CABLE CONNECTION DIAGRAMS ACROSS THE ARC SET UPS CC Power Sources with Output Terminals Always Hot See Figure A 5 CC Power Source FIGURE A 5 Ranger 250 250 LPG Ranger 305G 3050 Commander 300 Vantage 300 400 500 Air Vantage 500 LN25 PRO EXTREME Ranger 10 000 g Across the Arc L k Ranger3 phase SAE 400 with CV adapter Engine Driven welder with Wire Feed Module If the power source has a Remote Local switch place the switch in the Local position K26
14. roll pressure arm 3 Remove the outer wire guide by turning the knurled thumbscrews counter clockwise to unscrew them from the feed plate 4 Rotate the triangular lock and remove the drive rolls LOCKED POSITION UNLOCKED POSITION 5 Remove the inner wire guide Insert the new inner wire guide groove side out over the two locating pins in the feed plate 7 Install a drive roll on each hub assembly secure with the triangular lock 8 Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews 9 Close the idle arm and engage the idle roll pressure arm Adjust the pressure appropriately LN 25 PRO EXTREME Red D Arc Welderentals 5 INSTALLATION A 5 PRESSURE ARM ADJUSTMENT WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the weld ing power source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released not operate with covers panels or guards removed or open e Only qualified personnel should perform mainte nance work The pressure arm controls the amount of force the drive rolls exert on the wire Proper adjustment of the pressure arm gives the best welding performance Set the pressure arm as f
15. understand or are unable to perform the Recommended Course of Action safely contact your local Authorized Field Service Facility WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds the gun trigger is released Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes e Only qualified personnel should perform maintenance work 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 LN 25 PRO EXTREME Red D Arc Welderentals 2 TROUBLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Digital Display Models Error Codes Fault Code Description Possible Adjustments Err81 Motor overload long term 1 The wire drive motor has over 1 Check that the electrode slides heated easily through the gun and cable Remove tight bends from the gun and cable Check that the spind
16. 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 LN 25 PRO EXTREME Red D Arc Welderentals 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 free gloves to insulate hands 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 e 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 b
17. worn and or melted 1 Replace the contact tip contact tip Worn work cable or poor work 2 Verify all work and electrode con connection nections are tight and that the cables are in good condition Clean replace as necessary Wrong polarity Adjust polarity to the recommend ed procedure The gas nozzle is extended 4 Adjust the gas nozzle and shorten beyond the contact tip or the wire the stickout to 3 8 to 1 2 inches stickout is too long Poor gas shielding on 5 Check gas flow and mixture requiring gas Remove or block sources of drafts Digital display models The Run In switch is ON the Run In switch to the When the trigger is pulled the wire OFF position feeds slowly Digital display models The preset voltage calibration inf1 Use the set up menu to change The preset voltage does not match the feeder has been selected fora the preset voltage calibration in the power source voltage different power source the feeder to match the power source Poor arc starts with sticking 1 blast offs weld porosity narrow Improper procedures or tech f1 See Gas Metal Arc Welding Guide GS 100 and ropy looking bead CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you p
18. 00 or equivalent 7 16 open end wrench To verify if calibration is necessary 1 Turn power OFF 2 Set the wire feed speed per the table Wire Feed Speed Acceptable Range Normal Speed 400 in min 69 77 rpm 3 Remove the plastic cover from the lower portion of the wire drive with a 7 16 wrench 4 Connect the LN25 PRO EXTREME to the constant voltage DC welding power source The work lead of the LN25 PRO EXTREME must be connected to the work terminal of the power source 5 Turn power ON 6 Measure the motor rpm when the COLD FEED button is pressed 7 Verify the rpm is within the acceptable range FIGURE D 1 To change the wire feed speed calibration See Figure D 2 Tools required 5 16 nut driver RPM meter e Shorting plug The shorting plug shorts pins 1 amp 5 of connector J2 on the p c board J2 is a 6 pin molex connector 1 Turn power OFF 2 Remove the 4 screws holding the rear cover inside the feeder and remove the cover 3 Open the idle arm 4 Set the wire feed speed per the table Model gearing Wire Feed Speed Normal Speed 400 in min 5 Connect the LN25 PRO EXTREME to the constant voltage DC welding power source The work lead of the LN25 PRO EXTREME must be connected to the work terminal of the power source 6 Turn power ON 7 Insert the shorting plug into connector J2 on the p c board The shorting plug shorts pins 1 amp 5 8 Remove the shorting plug
19. 1 ITEM DESCRIPTION Analog Voltmeter Wire Feed Speed Knob 5 pin gun trigger connector Work sense lead Thermal LED MOTOR OVERLOAD Polarity LED 1 ANALOG VOLTMETER The analog voltmeter shows the voltage between electrode and work On across the arc models the voltmeter shows open circuit voltage when the wire feeder is not welding The voltmeter is polarity insensitive and the range is 0 40VDC LN 25 PRO EXTREME Red D Arc Welderentals B 3 B 4 OPERATION B 4 2 WIRE FEED SPEED KNOB The large calibrated wire feed speed knob makes for easy and accurate adjustment of the wire feed speed The knob rotates 3 4 turn Turn the knob clockwise to increase the wire feed speed and counter clockwise to reduce the wire feed speed Models with analog voltmeters have a calibrated scale printed around the wire feed speed knob using units A separate decal with m min units is included with these models wire feeder Models with digital displays show the wire feed speed on the display Wire Feed Speed CV Operation When Across the Arc models are operated with CV power sources the wire feed speed will remain a con stant value independent of arc voltage changes as along as the arc voltage does not drop below the val ues per the following table CV Operation Maximum WFS Minimum Arc Volts Wire Feed Speed CC Operation When Across the Arc models are operated with CC power sources the wire f
20. 13 3 LN25 PRO EXTREME KP1695 XX Drive Roll Kit Place the CV CC switch in the feeder in the CC posi KP1696 XX Hen KP1697 XX See Magnum Literature Welding Gun CC power Source K1803 1 Welding Cables CV Power Sources with Stud Connectors and Remote Local Switch See Figure A 6 FIGURE A 6 CV 655 DC 400 DC 600 Electrode DC 655 V 450 Pro LN25 PRO EXTREME Across the Arc Place the power source Remote Local switch in the Local position K2613 3 LN25 PRO EXTREME KP1695 XX KP1696 XX Drive Roll Kit KP1697 XX ee magnum Literature Welding Gun Place CV CC switch in the feeder in the CV position ep _ CV power Source K1803 1 Welding Cables LN 25 PRO EXTREME Red D Arc Welderentals 7 INSTALLATION A 7 CV Power Sources with Stud Connectors and no Remote Local Switch See Figure A 7 Jumper FIGURE A 7 LN25 PRO EXTREME Across the Arc Electrode Place CV CC switch in the feeder in the CV position K2613 3 LN25 PRO EXTREME KP484 Jumper Plug Kit KP1695 XX 1696 Drive Roll KP1697 XX See Magnum Literature Welding Gun sss CC power Source K1803 1 Welding Cables CV Power Source with Twist Mate Connectors and Remote Local Switch See Figure A 8 FIGURE A 8 LN25 PRO EXTREME Across the Arc V350 Pro Electrode pm nemis Place CV CC switch in the feeder in the CV positio
21. 3 9 i ies z 09 9 HL ISINAN N NM d MEE GENE HEN ss vio u SN NY AGONY SN31 937 40 3903 1V14 3HL 1S3HV3N Nid 4 0 N ul SALON HOLOVINOS 20 ae Weed 9 E 199 9 99 le 2 gt gt Z gt woos Vol V9 S LLC MI a rin 20 T v VELG vus NOILOANNOO 318VO E J i ae 330 NMOHS No 2004193173 INdNI x gt INTEN cy V V NE SS3NHVH NO 4 Y 2 9 z NED ale 3 OL SLO3NNOO le 0 NNH 1V1S03HE 1V1SO03Hu 3 9 1109 HOLOYLNOO lt qiz g 8l b gt Y 4208 cs L 8 6 209 w Lld 252 108 Ou1NOO q33dS 5 e en 310 33 Q334 N gt 3 n d UE M 10H1NOO NO 7 I Lf OL SLO3NNOO X314 6 5 59 CT u lt 9 8 29 al vv 02 gt s gt i _ i B ZS 8 9 4 6 169 169 ale v 229 b v amp z go 802 10112 29 vos 208 am u _ sus ves zes 206 069 Joss X9 Wiel Ve 199 _ u E pal 202 108 Ul ger 8 a 008 2 gt A 5 i VIELE L gt 9ISIPLELC IDR LOS PES 068219S8 2zl DG VEEL gay 8 NED qae qot Cote MU ee 4 2110168 LI SHE 21 sLasrez lt MOVIE 9 lt P 4 A 2 wa 099 8 M OLf quvO8g 24 l3S3ud Y Y 199 9 si mM get Sf 1 9 ASVO NO d 1
22. For constant current operation the power source is set to deliver the specified current The power source regulates this current regardless of changes in the welding circuit including cable length electrode diam eter wire feed speed contact tip to work distance etc Changes in the wire feed speed WFS or contact tip to work distance CTWD affect the arc voltage when constant current power sources are used Lowering the wire feed speed raises the voltage raising the wire feed speed lowers the voltage Lengthening the contact tip to work distance raises the voltage short ening the contact tip to work distance lowers the volt age If the contact tip to work distance is properly main tained a satisfactory operating voltage range may be achieved and a sound weld may result However when a welder uses a longer contact tip to work dis tance an arc sensing wire feeder compensates by increasing the wire feed speed to regulate the voltage Even if the voltage and current remain unchanged the increased wire feed speed may result in a deposition rate well beyond the specified range of the electrode Under these conditions the specified weld metal prop erties may not be achieved Constant voltage power sources deliver large current surges to stabilize the arc when the electrode is short ed or the arc length is very short However a constant current power source does not provide such a response to stabilize the arc It may be diffi
23. IM939 A March 2008 LN 25 EXTREME Red D Arc Welderentals OPERATOR S MANUAL Red D Arc Spec Built Welding Equipment This RED D ARC welder is built to RED D ARC Extreme Duty design specifications by Lincoln Electric Safety Depends on You This welder is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful 1 800 245 3660 North America s Largest Fleet of Welding Equipment SAFETY WARNING CALFORNIAPROPOSITIONGS WARNINGS 1 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 reproductive 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 Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of S
24. L Turn the input power OFF at the disconnect switch or fuse box before attempting to connect or disconnect input power lines out put cables or control cables e Only qualified personnel should perform this installation Do not touch metal portions of the LN25 PRO EXTREME work clip when the welding power source is on Do not attach the work clip to the wire feeder Connect the work clip directly to the work as close as possible to the welding arc Turn power off at the welding power source before disconnecting the work clip from the work Only use on power sources with open circuit voltages less than 110 VDC LOCATION For best wire feeding performance place the LN25 PRO EXTREME on a stable and dry surface Keep the wire feeder in a vertical position Do not operate the wire feeder on an angled surface of more than 15 degrees Do not submerge the LN25 PRO EXTREME The LN25 PRO EXTREME is rated IP23 and is suitable for outdoor use The handle of the LN25 PRO EXTREME is intended for moving the wire feeder about the work place only When suspending a wire feeder insulate the hanging device from the wire feeder enclosure CAUTION HIGH FREQUENCY PROTECTION Locate the LN25 PRO EXTREME away from radio controlled machinery The normal operation of the LN25 PRO EXTREME may adversely affect the oper ation of RF controlled equipment which may result in bodily injury or damage to the equipm
25. LIZAR 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 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaga e Use ventilac o e exhaust o para remover fumo da zona respirat ria tsr LPSOMTRTLAICLT e s PHHEC Topal U C TEL OTD RAE e EOF UR E fE FH uf LS BEL APR TS e EH2IAB WaHe e S TASERE 2 HAPI A4 2F2 38 242 L1 s7E amp g ABSHHA R gaal ge Jaye dal e Qu all me Jue sl e se Sl power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes iniciar cualquier servicio D
26. Routine Maintenance a ara dots D 1 Periodic Maintenancoe rasa risa risa ese sir D 1 Calibration 5 r 1 0 2 TroUDIESNOOLUNG a a ae naasa Section E How to Use Troubleshooting Guide hisser E 1 Digital Display Models Error Codes E 2 Troubleshooting Guide RN Um T TT UU T E 3 E 4 Wiring Diagram amp Dimension Prints T Section F Parts l P 562 Series vi 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS LN25 PRO 2613 3 INPUT VOLTAGE and CURRENT INPUT VOLTAGE 10 RATED OUTPUT 104 40 100 rating GEARING WIRE FEED SPEED RANGE WIRE SIZE GMAW FCAW Normal Speed 50 700 ipm 023 1 16 50 700 ipm 5 64 1 3 17 7m min 0 6 1 6mm 1 3 17 7m min 0 8 2 0mm PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 14 8 Inches 8 7 Inches 22 2 Inches 876 mm 221 mm 589 mm Handle folded down TEMPERATURE RANGE OPERATION 40 F to 104 40 to 40 STORAGE 40 F to 185 40 to 85 LN 25 PRO EXTREME Red D Arc Welderentals 2 INSTALLATION A 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK KIL
27. SS3NHVH 9 X VIc9 6 a 4 or FT 9 19 NO 094 OL 8 19 Vico giz 66995 3LIHM M Ver yov a a ver vir 6 TERR 3 4 s at vat 91 r lt gt G gt il lt Hier OO air gir Lip ONICO HO OO l lt 109 909 gr 9609 LE 9 9 v 99 590 lt A i 21919 STOSWAS 1v2IH12313 312 dlg K 9 lt 809 S09 109 NO 8 99 N voos tld NOLLVIAHOJNI TVH3N3 ld 121 OL SLO3NNOO Wie p O d 40 ACIS IN3NOdWOO CAMINA 9 ay qe 8706 Iz Veeg e v lt ONIHAENINN ALIAVO y ex TITTET T lt YOLOANNOO vir 2 kk Meist ger EN 9128 IDYNOS HIMOd OL ae T MOTH LSOd x z HOLO3NNOO HVINOHIO GEEN en 7 xL u pv 814 HEEL STHQO TIY NO LNASSHd LON TN PL OL SLOANNOO d NOD Nid tL TWNOILdO UIWIL 9 4 H3l41193H AT NO ST3qON 3008011 VHLX NO ANOHOL OL VH1X3 LO3NNOO P INOud 3SVO NO NEEN N 2 39949 LIANNOO ar KINO STAGON 3HL SSOHOY IN3S3Hd O N a 82 rt SI SS OLSLOANNOD gt s10annoo d We aly ili KINO STAGON 318V2 10H1NOO NO INAS3Hd ON LL zoo 21 yo B 8 L VS HOLIMS 40 306 NOLLO3NNOO NMOHS S3HO LIMS 319901 gt N tp vz
28. afety 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 d 1h To avoid scalding do not remove the 0022 radiator pressure cap when the engine is powered equipment ANA oe i 1 Turn the engine off before troubleshooting and maintenance 3 work unless the maintenance work requires it to be running 1 6 engines open well ventilated areas engine exhaust fumes outdoors 2 ELECTRIC AND MAGNETIC FIELDS EN may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields Welding current creates EMF fields around welding cables and welding machines 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 vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some
29. ainst the gun bushing Important Do not attempt to completely remove the socket head cap screw 6 Remove the outer wire guide and push the gun bushing out of the wire drive Because of the pre cision fit light tapping may be required to remove the gun bushing 7 Disconnect the shielding gas hose from the gun bushing if required FIGURE A 2 THUMB SCREW CONNECTOR BLOCK SOCKET HEAD S CAP SCREW LOOSEN TIGHTEN OUTER WIRE GUIDE A 4 8 Connect the shielding gas hose to the new gun bushing if required 9 Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned 10 Tighten the socket head cap screw 11 Insert the welding gun into the gun bushing and tighten the thumb screw PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES A WARNING Turn the input power OFF at the welding power source before instal lation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released Do not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work 1 Turn power off at the welding power source 2 Release the idle
30. anty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life 4 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page SOA nnee Section Technical NS CMC een ee 1 CN NDS uu u uuu l ee een A 2 m ee ee 2 High Frequency dad Ke Ieren eg 2 A 2 Gable CONC OS E Shielding Gas Connection a sn Wire Drive COANOUE IGN MER EE o de ee 4 Changing The Gun Receiver Bushing
31. ation or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 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 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 warr
32. autions 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 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 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 lev age 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 Ne pas souder en pr sence de vapeurs de chlore provenant
33. b 6 4 kg Innershield Coils on 2 in 51 mm spindles Spindle Adapter for mounting 8in 208mm diameter spools on 2 in 51 mm spindles Deluxe Adjustable Gas Regulator Includes Gun receiver bush ing with hose nipple set screw and hex key wrench Includes Gun receiver bushing with hose nipple 4 guide tubes set screw and hex key wrench Includes Gun receiver bushing with trigger connector Includes Spindle Adapter made from 2 coil retainers Electrode not included Includes 2 Spindle Adapters one for 2 wide spools and the other for 3 wide spools Includes Deluxe Gas Regulator for Mixed Gases Adapter for CO2 and 10 3 0m Hose LN 25 PRO EXTREME Red D Arc Welderentals D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS AWARNING 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 Check weld cables control cables and gas hoses for cuts Clean and tighten all weld terminals PERIODIC MAINTENANCE Clean drive rolls and inner wire guide and replace if worn Blow out or vacuum the inside of the feeder CALIBRATION SPECIFICATION The voltmeter and flow m
34. branchez le courant avant l entretien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e THA HEAR te EPRRAT vy Fe FEU eo HNE nij mm HAS 404 J Lit SM alll Do not operate with panel open or guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enleves Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas e PAIS RR tJ ES LUT Pal e HRT 8 ES AT AAF D Edo del EA Gils 1 y e Al Aia Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG EE Chinese LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR WSRHTEHNI D DETERL BA amp TL TRHOKRSRE ET F vv SA DE N FE AB ME t HE EL EX t FH A SB MIT NA BI 0 SSE HYE SSA HAI AUX L L ETSA src anal
35. c trodes feed well at a tension arm setting of 3 The spindle brake is too tight Verify the spool of wire moves with minimal effort Worn drive roll Replace the drive rolls if worn or filled with dirt 4 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 25 PRO EXTREME Red D Arc Welderentals E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Output Problems 1 The jumper lead for normal 1 Properly connect the normal speed extra torque is connected speed extra torque jumper improperly Install the proper pinion gear in The wrong gear is installed in the the wire drive wire drive Replace the motor gearbox The brushes on the motor are assembly worn Wire feed speed consistently oper ates at the wrong value The speed changes when the wire feed speed knob is adjusted The wire feed speed is fast 1 The tachometer is connected 1 Verify all of the tachometer leads mum and there is no change when improperly are properly connected the wire feed speed knob is adjust 2 The tachometer has failed Replace the motor and tachome ed ter assembly Variable or hunting arc Wrong size
36. ch Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released Standing to one side open the cylinder valve slowly a fraction of a turn When the cylinder pressure gage stops moving open the valve fully The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making a weld LN 25 PRO EXTREME Red D Arc Welderentals 4 INSTALLATION WIRE DRIVE CONFIGURATION See Figure A 2 CHANGING THE GUN RECEIVER BUSHING WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before instal lation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released e Do not operate with covers panels or guards removed or open e Only qualified personnel should perform mainte nance work Tools required 1 4 hex key wrench Note Some gun bushings do not require the use of the thumb screw 1 Turn power off at the welding power source 2 Remove the welding wire from the wire drive 3 Remove the thumb screw from the wire drive 4 Remove the welding gun from the wire drive 5 Loosen the socket head cap screw that holds the connector bar ag
37. cult to achieve required weld metal properties or to achieve the required quality of welds needed to pass nonde structive tests when such welds are made under con stant current operation For these reasons Lincoln Electric does NOT recom mend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality requirements FIGURE B 3 Current gt Wire T Feeder CTWD Constant Current y WFS NN Power Source dF LN 25 PRO EXTREME Red D Arc Welderentals 9 OPERATION B 9 REAR CONTROLS DESCRIPTION Gas Purge Pushbutton Shielding Gas Inlet Control Cable Input standard on K2414 xx Electrode Lead Optional Water cooled gun connections GAS PURGE PUSHBUTTON The gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on The Gas Purge switch is useful for setting the proper flow rate of shielding gas Flow meters should always be adjusted while the shielding gas is flowing POWER UP SEQUENCE For feeders with analog voltmeters the thermal LED will briefly light during power up If the gun trigger is activated during power up the feeder will not operate until the gun trigger is released LN 25 PRO EXTREME Red D Arc Welderentals C 1 e K1500 2 Gun Receiver Bushing DRIVE ROLL KITS ELECTRODE SIZE KP KIT 023 030 0 6 0 8
38. e l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LN 25 PRO EXTREME Red D Arc Welderentals V V Yi for selecting a QUALITY product We want you to take pride in nk operating this product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of inform
39. ed to be simple reliable and easy to service The p c board is mounted with Lincoln s leading envi ronmental design protection by mounting the board in a plastic tray and potting it with epoxy General Functional Description The LN25 PRO EXTREME as designed is a simple robust feeder Standard features include a calibrated wire feed speed dial CV CC switch Gas Purge and Cold Feed RECOMMENDED PROCESSES GMAW e FCAW PROCESS LIMITATIONS e GMAW P procedures must be qualified by the cus tomer Across the Arc models are not recommended for stitch or spot welding EQUIPMENT LIMITATIONS The duty cycle of the wire feeder is 325A 100 and 450A 60 Duty cycle is based upon the amount of welding performed in a 10 minute period The maximum spool size is 45 Ib 12 diameter e Maximum FCAW gun length is 15 ft e Maximum GMAW gun length is 25 ft Push pull guns do not work with the wire feeder RECOMMENDED POWER SOURCES e CV 305 e CV 400 e CV 655 e DC 400 e DC 600 e DC 655 Invertec V 350 PRO Invertec V 450 PRO e Multi Weld 350 Ranger 10 000 Ranger Phase e Ranger GXT Ranger 250 Ranger 305 e SAE 400 Pipeliner 200G e Classic 300 Vantage 300 Vantage 400 Vantage 500 LN 25 PRO EXTREME Red D Arc Welderentals 3 OPERATION See Customer Assistance Policy in the front of this Instruction Manual CASE FRONT CONTROLS See Figure B 1 FIGURE B
40. eed speed changes as the arc voltage changes When the arc voltage increases the wire feed speed will increase and when the arc voltage decreases the wire feed speed will decrease To preset the wire feed speed on CC power sources 1 Set the Wire Feed Mode switch inside the LN25 PRO EXTREME to CC 2 Refer to the Figure B 1a graph for the setting for the wire feed speed knob setting Select the hori zontal line representing the Desired Wire Feed Speed See Figure B 1a arrow for 375 in min 3 Select the diagonal line representing the Arc Volts See Figure B 1a for 29 volts 4 Determine the vertical line representing the CC representing the CC Wire Feed Speed setting where the above two lines cross See Figure B 1a arrow line for 450 Set the LN25 PRO 15V EXTREME wire feed speed knob to this value 440 CC WFS dial setting desired WFS x 35 520 ArVols See Figure B 1a FIGURE 1 700 35 V 650 9s 31 600 29 550 37 500 25 28 250 200 150 100 50 50 100 150 200 250 300 350 400 450 500 550 600 650 700 C WFS LN 25 PRO EXTREME Red D Arc Welderentals OPERATION 3 5 PIN GUN TRIGGER CONNECTOR 4 WORK SENSE LEAD 5 THERMAL LED MOTOR OVERLOAD The thermal light illuminates when the wire dr
41. eing 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 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 4 b Use suitable clothing made from durable flame resistant 51 AUG 06 material protect your skin 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 t
42. ent WELD CABLE SIZE Table A 1 located below are copper cable sizes rec ommended for different currents and duty cycles Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop TABLE 1 RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 167 F or 75 AMPERES PERCENT to 50Ft 0 to15m O1 2 1 1 1 CABLE SIZES FOR COMBINED LENGTHS ELECTRODE AND WORK CABLES 50 to 100Ft 100 to 150 Ft 150 to 200 Ft 200 to 250 Ft 15 to 30m 30 to 46m 46 to 61m 61 to 76m 2 2 1 2 2 1 3 2 1 3 2 1 3 2 1 2 1 1 1 1 1 1 1 1 1 1 1 0 Tabled values are for operation at ambient temperatures of 104 F 40 C and below Applications above 104 F 40 C may require cables larger than recommended or cables rated higher than 167 F 75 C LN 25 PRO EXTREME Red D Arc Welderentals A 3 CABLE CONNECTIONS INSTALLATION A 3 SHIELDING GAS CONNECTION There is one circular connector for the gun trigger on the front of the LN25 PRO EXTREME BE Not used Not used AWARNING CYLINDER may explode if damaged e Keep 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 Ke
43. ep cylinder away from welding or other live electrical circuits e BUILD UP OF SHIELDING GAS MAY HEALTH OR KILL X e Shut off shielding gas supply when not in use e See American National Standard Z 49 1 Safety in Welding and Cutting Published by the American Welding Society Maximum inlet pressure is 100 psi 6 9 bar Install the shielding gas supply as follows Secure the cylinder to prevent it from falling 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve out let Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench Note if connecting to 100 CO cylinder insert regulator adapter between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seated for connection to the CO cylinder Attach one end of the inlet hose to the outlet fitting of the flow regulator Attach the other end to the welding system shielding gas inlet Tighten the union nuts with a wren
44. eter are not calibrated and are for reference purposes only Voltmeter Validation Across the Arc Analog Meter Models Tools required DC voltmeter reference standard Constant voltage DC welding power source with adjustable no load voltage DC 400 V 350 CV 400 or equivalent To verify the analog voltmeter accuracy 1 Turn power OFF 2 Connect the LN25 PRO EXTREME to the constant voltage DC welding power source The work lead of the LN25 PRO EXTREME must be connected to the work terminal of the power source 3 Connect the reference voltmeter between the brass block of the LN25 PRO EXTREME and the work lead 4 Turn power ON 5 Energize the output circuit of the power source Adjust the power source output to 20 1 VDC as measured on the reference meter 6 Verify that LN25 PRO EXTREME voltmeter reads between 19 and 21 volts If the voltmeter reading is out of range check for loose connections or replace the voltmeter There is no calibration adjustment for the LN25 PRO EXTREME voltmeter LN 25 PRO EXTREME Red D Arc Welderentals D 2 MAINTENANCE D 2 Wire Feed Speed Validation See Figure D 1 Calibration of the LN25 PRO EXTREME may be required when the p c board wire feed speed potentiometer or motor is replaced or serviced Calibration matches the scale on the name plate to the actual wire feed speed Tools required RPM meter e Constant voltage DC welding power source DC 400 V 350 CV 4
45. he 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 9 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 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 under
46. ive motor draws too much current If the thermal light illuminates the wire drive will automatically shutdown for up to 30 seconds to allow the motor to cool To start welding again release the gun trigger inspect the gun cable liner and conduit Clean and make repairs as necessary Start welding again when the problem has been safely resolved For best results keep the gun cable and conduit as straight as possible Perform regular maintenance and cleaning on the gun liner conduit and gun Always use quality electrode such as L 50 or L 56 from Lincoln Electric 6 POLARITY LED The Polarity LED lights when the wire gt feeder is connected POLARITY for positive polarity POLARDAD Use the polarity LED to verify the wire feeder is connected for the proper polarity POLARIT LN 25 PRO EXTREME Red D Arc Welderentals 6 OPERATION INTERNAL CONTROLS FIGURE B 2 Pressure Adjustment Arm Optional Timer Kit See Accessories Section Spool Retainer Spindle Brake Gun Bushing Thumb Screw for securing the welding Gun Socket Head Cap Screw for securing the Gun Bushing Drive Hubs Inlet Wire Guide Cold Feed Pushbutton LN 25 PRO EXTREME Red D Arc Welderentals B 6 7 OPERATION CV CC SWITCH See Figure B 2 The CV CC switch sets the wire feed speed control method for the wire feeder In the CV position the wire feed speed remains constant during welding steady a
47. le brake is not too tight Verify a high quality electrode is being used Wait for the error to reset and the motor to cool approximately 1 minute Err 82 Motor overload short term 1 The wire drive motor current draw 1 Check that motor can turn freely has exceeded limits usually when idle arm is open because the motor is in a 2 Verify that the gears are free of rotor state debris and dirt CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 25 PRO EXTREME Red D Arc Welderentals E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Output Problems The feeder does power up dis 1 The work sense lead is 1 11 Connect the work sense lead to play no cold feed nected or is a poor electrical con the work in a location free of dirt nection Across the arc models rust and paint The power source is OFF Turn ON the power source The circuit breaker for the wire 3 Reset the circuit breakers feeder on power source have tripped control cable models The control cable may be loose orf4 Tighten repair or replace the con damaged control cable models trol cable No shielding
48. n K2613 3 LN25 PRO EXTREME KP1695 XX KP1696 XX Drive Roll Kit KP1697 XX See Magnum Literature Welding Gun CC power Source K1841 Welding Cables LN 25 PRO EXTREME Red D Arc Welderentals 8 INSTALLATION A 8 CV Power Source with Twist Mate Connectors and no Remote Local Switch See Figure A 9 FIGURE A 9 Electrode Place CV CC switch in the feeder in the CV position K2613 3 LN25 PRO EXTREME Drive Roll Kit S CV power Source K1841 Welding Cables K484 Jumper Plug kit LN 25 PRO EXTREME Red D Arc Welderentals 1 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE A WARNING e ELECTRIC SHOCK CAN KILL Unless using COLD FEED fea ture when feeding with gun trig ger the electrode and drive mechanism are always electri cally energized and could remain energized several sec onds after the welding ceases Do not touch electrically live part or electrode with skin or wet clothing insulate yourself from work and ground Always wear dry insulating gloves Do not operate with covers panels or guards removed or open e FUMES AND GASSES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away ARC RAYS ca
49. n Lr OL S193NNO9 an ig s ai i4 bond 390412913 nn A 3 9 049 y x x Y YADNGSNVYL m ar ec0 4 T XN MAOL MMOL SSANYVH NO Y Ao V x V IN344ND uc ML gt t b y LP OL SLOANNOO leL0 NNY 1V1SO4Hu 1VISO3HH 3 9 aic ge dl 5 b gt Y 3708 39VL1OA 1OHLNOD OD 3012402 8 6 OS 4 ben Lld 082 108 JOY LNOD 03345 0 M 294 gt bb D gt 08 31OW3H 334 3UIM ISL POD gt 2 08 804 26 gt zr 4 i 10H1NOO NO HE i gt gt xau s s gt 9 gt u u u 101 S gt 948 VES BLS S 169 LSS 169 ALZ wW r gt 844 994 804 104 1 lt Z9 708 TO8 S S Hes zes 106 069 bss 419 Vizz 99 Je zoz sog j zoz Log Ul dr glr m er i E J ses 00 Z gt Jod an A d dou kc 5 VL L gt 016 BASE PELI 06 81 9 DD 8 A de A JN J KLE ZLLLOL6E8ZL9SVETL lt Dv18 ge CNE NN NE NE NE wa OSS 8 M 24 135334 8f er 2 Sc Y Y 3 LSS 4 8 ind xc amp sr S1 x 3599 NO Zd 3SV2 AVTdSId 1VLIDIQ vf ves S OL SLOSNNOO WE lt LES tan L 3 9 4 v1z9 lt lt gt G gt lt lt 169 gt E gt 99
50. n burn Wear eye ear and body protec tion SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL B 1 THIS MACHINE OR IN THIS MANUAL 0 0 6 LN 25 EXTREME Red D Arc Welderentals INPUT POWER ON OFF WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT INPUT POWER DIRECT CURRENT OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION 2 OPERATION B 2 DEFINITION OF WELDING TERMS WFS e Wire Feed Speed e Constant Current CV Constant Voltage GMAW e Gas Metal Arc welding SMAW e Shielded Metal Arc welding FCAW e Flux Core Arc Welding GENERAL DESCRIPTION General Physical Description The LN25 PRO EXTREME is specially engineered to be the most rugged portable wire feeder available The plastic case is molded from a high impact flame retardant plastic for durability and low weight The patent pending design keeps the internal components protected and dry The heart of the LN25 PRO EXTREME is the 2 roll MAXTRAC drive The patented features on the wire drive offer tool less changing of the drive rolls and wire guides for quick spool changes A tachometer controlled motor powers the patent pending drive rolls for smooth steady feeding without slippage With only one p c board the LN25 PRO EXTREME is design
51. ollows See Figure A 3 Aluminum wires Cored wires Steel Stainless wires between 1 and 3 between 3 and 4 between 4 and 6 FIGURE A 3 ALUMINUM WIRES CORED WIRES STEEL STAINLESS WIRES LOADING SPOOLS OF WIRE WARNING Keep hands hair clothing and tools away from rotating equipment Do not wear gloves when threading wire gt f or changing wire spool Only qualified personnel should install use or service this equipment Loading 10 to 15 Ib 4 5 6 8kg Spools A K468 spindle adapter is required for loading 2 51mm wide spools on 2 51mm spindles Use K468 spindle adapter for loading 2 1 2 64mm wide spools 1 Squeeze the release bar on the retaining collar and remove it from the spindle 2 Place the spindle adapter on the spindle aligning the spindle brake pin with the hole in the adapter 3 Place the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool An indicator mark on the end of the spindle shows the orientation of the brake tab Be certain the wire feeds off of the spool in the proper direction 4 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle GUN CONNECTION A WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the weld ing power source before installation or changing drive rolls and
52. pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 In some cases it may be necessary to remove safety iis oo 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 en Do not attempt to override the governor or 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right while the engine is running side the work cable should also be on your right side ar Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines
53. rc voltage is regulated by the power source by adjusting the arc current In the CC position the wire feed speed varies during welding The arc length is maintained by chang ing the wire feed speed COLD FEED PUSHBUTTON See Figure B 2 When cold feeding the wire drive will feed electrode but nei ther the power source nor the gas solenoid will be energized Adjust the speed of cold feed ing by rotating the WFS knob Cold feeding or cold inching the electrode is useful for threading the electrode through the gun LN 25 PRO EXTREME Red D Arc Welderentals cv E B 7 8 OPERATION B 8 CONSTANT CURRENT WIRE WELDING See Figure B 3 Most semiautomatic welding processes perform better using constant voltage power sources Welding codes usually do not address the power source selection or specifically whether the welding process is to be operated in the constant voltage or constant current mode Instead codes typically speci fy limitations on the current voltage heat input and preheat temperature based on the material to be welded The intention is to assure that proper weld material properties will develop Welding is sometimes performed using constant cur rent power sources The operation can be more con venient because it may allow the use of an existing stick SMAW power source and the power source can be placed at a distant location without any provi sion for adjusting the output settings
54. rchase 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and folllow 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 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the ga
55. roceed LN 25 PRO EXTREME Red D Arc Welderentals Y epoo 1u uudinb y SAIN juowe9edel e 104 4 s9IMSS eu SHM qIB III s ou J sjoued y euo uo y 18955 19 SSINUYH 9 3 19 r Hx TM T nu ley BE n o n MHOM OL 29989889 ouer 838889 m BESS ALIHM M TOIT 4 za c T 8 9 5 air MOv18 8 t Ver n vir s 2 gt li 431411533 a TEE oor er sr er weer 29 air our Lr ONIAOI
56. s 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 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 LN 25 PRO
57. s e elec trodos com a pele ou roupa molha da e Isole se da pe a e terra Nite JPN TMN ETE Ha T 337 x ATWSHICLT FEU e E BR EIC A n ERR BS PE Ht ets B Mm MIER Xe SM SS sup HE 9 x HE Gill el jad Gaal y e g pull ala 2 4 gl sl all DA daas Keep flammable materials away Mantenga el material combustible fuera del de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos Pra xp m T g S kE ESE EEA e EE mn HRE T elses ZHE 7 hang ihe NE Wear eye ear and protection e Prot jase los ojos los o dos y el Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido corpo e H HAUSHERMRELTTF ez 72 Bo Sete due 4413 oaa y algal pis uaa 3 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 UTI
58. stand 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 LN 25 PRO EXTREME Red D Arc Welderentals 6 j SAFETY WELDING SPARKS can lt 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 249 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 pu
59. u e ae NEN SVO veze 7 gen 85 S m Me rs loo UL MEHL CMS GAIN 60S q tS 15 L Js MOTIAA 35 2 AV ISI DOTVNV 911 3002 Odd SENT IWVH9SVIG SNISIA F 2 LN 25 PRO EXTREME Red D Arc Welderentals F 3 DIMENSION PRINT F 3 23 17 RED D ARC 14 81 12 x 18 ELLIPSE bw 17 19 LN 25 PRO EXTREME Red D Arc Welderentals NOTES LN 25 PRO EXTREME Red D Arc Welderentals NOTES LN 25 PRO EXTREME Red D Arc Welderentals Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese EE JH Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel moja da Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouilles entrer en contact avec des pieces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el trica

Lincoln Electric 11389 Welder User Manual

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