Lincoln Electric PRO IM10031-A User's Manual
Contents
1. 1 K X y d Y AS N S D 02 TR KR L 3 EN VF LN 25 PRO LINCOLN A 7 INSTALLATION A 7 POWER SOURCE TO LN 25 PRO CABLE CONNECTION DIAGRAMS ACROSS THE ARC SET UPS CC Power Sources with Output Terminals Always Hot See Figure A 5 CC Power Source Classics Big Red s FIGURE A 5 Eagle 10 000 Plus Pipeliner 200D Without Wire Feed module SAE s Without CV Adapter _ TM SAE 400 with CV adapter Electrode LN 25 PRO Engine Driven welder with Wire Feed Module SR If the power source has Remote Local switch place the switch in the Local position K2613 1 LN 25 PRO 2613 2 LN 25 PRO Extra Torque Place the CV CC switch in the feeder in the CC posi KP1695 XX tion KP1696 XX Drive Roll Kit KP1697 XX See Magnum Literature Welding Gun Po CCC 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 LN 25 PRO DC 655 Electrode V450 Pro SAE 400 with CV adapter Engine Driven welder with Wire Feed Module Ranger 250 GXT Work clip SS FT 7 K2613 1 LN 25 PRO K2613 2 LN 25 PRO Extra Torque Place the power source Remote Local switch in the Local position KP1695 XX Place CV CC switch in the2. 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 Refer to http www lincolnelectric com safety for additional safety information LINCOLN SAFETY PR CAUTIONS DE S RET 6 Eloigner les mat riaux inflammables ou les recouvrir afin de 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 pinc
3. Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connec tion of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob lems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment LINCOLN vii vii for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product ses 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
4. CP RAC EXE AOT fr 5 ecu Xe JA uc ass AU HA e 5194 ASA HAS ous Quali y A 55 d Aa ALLY all daua Wile e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos CRAP TUEDOMTOBEFE LU TIS BW EKA e i 7 z VAM 15 BET FIST SS Aal ue Sa Ji ALI 3 gl e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use prote o para a vista ouvido e corpo 98 FHRUSEIRBRELTE SU CMRI 2 28 5 058 8 ez 79 Sol Sears Asis due Al y usu y i gal e s A 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 PROCEDURE
5. IM10031 A 1 25 TM pRO November 2010 For use with machines having Code Number 11620 11621 11716 11717 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 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 ISO 9001 og Y gt 7 gt 2 gt Ten the RvA Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requi CERTIFICATE NUMBER 30273 IP23 IEC 60974 5 OPERATOR S MANUAL Copyright Lincoln Global Inc LINCOLN go World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING M CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other repr
6. 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 5 d 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 be Read and understand the manufacturer s instructions for this 5 7 LINCOLN 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 641 SAFETY WELDING and CUTTING lt SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks 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
7. 2mm KP1696 1 040 1 0mm KP1696 2 030 035 0 8 0 9mm KP1697 035C 040 045 1 0 1 2mm KP1697 045C 052 1 4mm KP1697 052C Includes 2 Knurled 1 16 1 6mm KP1697 1 16C drive rolls and inner 068 072 1 7 1 8mm 1697 068 Wire guide 5 64 2 0mm KP1697 5 64 1697 3 32 035 0 9 KP1695 035A KP1695 040A Includes 2 polished 045 1 2mm Cored Wires Aluminum Wires KP1695 3 64A U groove drive rolls KP1695 1 16A outer wire guide and inner wire guide 1 6mm LN 25 PRO LINCOLN amp S ACCESSORIES C 2 K1796 xx AWG 1 0 Co Axial Power Cable Includes 1 0 Coaxial weld cable of length xx Ends of the weld cable have lug con nections Use for Pulse weld ing K2593 xx AWG 1 Coaxial Power Cable Includes AWG 1 Coaxial weld cable of length Ends of the weld cable have lug connections Use for Pulse or STT welding K1803 1 Work and Feeder Cables Package Includes Twist Mate to Lug 2 0 cable 14 1 2m long with Ground Clamp and Twist Mate to Lug 2 0 Cable 9 2 7m long K1840 xx Weld Power Cable Twist Mate to Includes 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 Includes 14 pin to 14 pin wire K1797 xx Control Cable fee
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9. CC representing the CC Wire Feed Speed setting where the above two lines cross See Figure B 1a arrow line for 450 Set the LN 25 Pro wire feed speed knob to this value Minimum Arc Volts Maximum WFS Maximum WFS dial setting desired WFS x 35 Standard Spin Extra Torque Arc Volts Gearing Gearing FIGURE B 1a Example 375 in min Horizontal Line x 35 29 Arc Volts Diagonal Line 452 5 Vertical Line See Figure B 1a Use 450 setting 5 ARC 650 wo A VOLTS 600 550 500 450 A constant voltage CV power 375 source is recommended for flux cored arc welding FCAW and 350 gas metal arc welding GMAW to 15 obtain code quality results 300 However this wire feeder may also 250 be used with a constant current 200 CC power source to obtain pass 150 able results for noncritical quality applications E 100 50 50 100 150 200 250 300 350 400 450 500 550 600 650 700 cc A WFS LN 25 PRO LINCOLN 5 OPERATION 3 5 PIN GUN TRIGGER CONNECTOR 4 WORK SENSE LEAD 5 THERMAL LED MOTOR OVERLOAD The thermal light illuminates when the wire drive motor draws too much current 10 If the thermal light illuminate
10. before installation or When inching with the gun trigger electrode and drive mechanism are hot to work and Do not operate with covers panels or guards removed or open The pressure arm controls the amount of force the changing drive rolls and or guides ground and could remain energized several sec e Only qualified personnel should perform mainte drive rolls exert on the wire Proper adjustment of the e ELECTRIC SHOCK can kill Do not touch electrically live parts onds after the gun trigger is released nance work pressure arm gives the best welding performance Set the pressure arm as follows 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 2 Do not wear gloves when threading wire 24 or changing wire spool e 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 a 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 t
11. 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 in min units A separate decal with m min units is included with these models wire feeder 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 Wire Feed Speed CC Operation When Across the Arc models are operated with CC power sources the wire feed 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 LN 25 Pro 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
12. 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 information 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 Carto
13. feeder in the CV position KP1696 XX Drive Roll Kit KP1697 XX See magnum Literature Welding Gun power Source K1803 1 Welding Cables LN 25 PRO LINCOLN A 8 INSTALLATION A 8 CV Power Sources with Stud Connectors and no Remote Local Switch See Figure A 7 Place CV CC switch in the feeder in the CV position FIGURE A 7 CV 400 DC 655 Ranger 250 250 LPG Ranger 305G 3050 Ranger 10 000 Ranger 3 Phase ecole Ranger 225GXT Ranger 225 Commander 300 Vantage 300 400 500 Air Vantage 500 KP1697 XX Welding Gun power Source K1803 1 Welding Cables CV Power Source with Twist Mate Connectors and Remote Local Switch See Figure A 8 FIGURE A 8 V350 Pro CV 305 Electrode Place CV CC switch in the feeder in the CV position Description K2613 1 LN 25 PRO K2613 2 LN 25 PRO Extra Torque KP1697 XX Welding Gun PC power Source K1841 Welding Cables LN 25 PRO LINCOLN 9 INSTALLATION A 9 CV Power Source with Twist Mate Connectors and no Remote Local Switch See Figure A 9 FIGURE A 9 Jumper Electrode Work clip Uo RL Dm 1 2613 1 25 PRO 2613 2 LN 25 PRO Extra Torque KP1697 XX a 1841 Place CV CC switch in the feeder in the CV position LN 25 PRO LINCOLN 5 1 OPERATION 5 1 SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON READ AND UNDERSTAND
14. 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 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 2 Dans le cas de travail au dessus du niveau du sol se proteger PRECAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES A SOUDER A ups TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc 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 pan talons sans revers et chaussures
15. meter 6 Verify that LN 25 PRO 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 LN 25 PRO volt meter Flow Meter Validation Tools required Flow meter reference standard Constant voltage DC welding power source DC 400 V 350 CV 400 or equivalent To verify the flow meter accuracy 1 Turn power OFF 2 Connect the LN 25 PRO to the constant voltage DC welding power source The work lead of the LN 25 PRO must be connected to the work ter minal of the power source 3 Connect a supply of CO2 to the wire feeder Do not exceed the maximum inlet pressure of the wire feeder 4 Disconnect the shielding gas hose that connects to the gun bushing 5 Connect the shielding gas hose to flow meter refer ence standard 6 Orient the LN 25 PRO in a vertical position 7 Turn power ON 8 Adjust the flow meter on the LN 25 PRO to 40 scfh while pressing the GAS PURGE button 9 Measure the gas flow with the calibrated flow meter while pressing the GAS PURGE button 10 The measured flow rate should be between 35 and 45 scfh LN 25 PRO LINCOLN amp D 2 The LN 25 PRO flow meter cannot be calibrated lf the flow meter reads incorrectly check for leaks or kinks in the gas hose Replace the flow meter if neces Sary Wire Feed Speed Validation See Figur
16. montantes 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 LINCOLN geri 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 possible 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 SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility 2004 108 EC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space
17. or spot welding EQUIPMENT LIMITATIONS The duty cycle of the wire feeder is 325A 100 and 450A 6096 Duty cycle is based upon the amount of welding performed in a 10 minute period The maximum spool size is 45 Ib 12 diameter 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 250 Ranger 3 Phase CV 300 Ranger 225 e CV 305 Ranger 225 GXT e CV 400 Ranger 250 CV 655 Ranger 250 GXT e DC 400 Ranger 305 e DC 600 SAE 400 DC 655 Pipeliner 2006 e Invertec V 350 PRO Classic 300 Invertec V 450 PRO e Multi Weld 350 Ranger 10 000 Vantage 300 Vantage 400 Vantage 500 Air Vantage 500 Big Red s Eagle 10 000 Plus Classic s LN 25 PRO LINCOLN B 3 OPERATION See Customer Assistance Policy in the front of this Instruction Manual CASE FRONT CONTROLS See Figure B 1 FIGURE B 1 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 LINCOLN B 3 B 4 OPERATION B 4 2 WIRE FEED SPEED KNOB The large
18. similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is compe tent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage
19. the flow rate while depressing the GAS PURGE switch by turning the valve at the bottom of the meter Most weld procedures require 25 40 scfh 11 8 18 9 lpm for sufficient shielding gas coverage Gun angle nozzle diameter joint configuration and wind conditions may effect the amount of shielding gas required When using a wire feeder with a flow meter adjust the regu lator at the shield gas bottle or supply to a flow rate that is higher than the flow rate indi cated on the feeder flow meter Note that most regula tors are calibrated based upon having low restrictions on the outlet The valve on the feeder flow meter creates a high restriction and may cause errors in the readings at the supply regulator Set the gas flow rate using the feeder flow meter reading and not the supply regulator reading OPERATION POWER UP SEQUENCE On 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 LINCOLN 1 ACCESSORIES 1 FACTORY INSTALLED EQUIPMENT K1500 2 Gun Receiver Bushing DRIVE ROLL KITS WIRE TYPE ELECTRODE SIZE KP KIT 023 030 0 6 0 8mm 035 0 9mm Steel Wires 1696 0305 1696 0358 1696 0454 Includes 2 V groove 052 1 4mm KP1696 052S drive rolls and inner 1 16 1 6mm 1696 1 165 wire guide 035 045 0 9 1
20. the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii TABLE OF CONTENTS Page AIO eec nn ea o Section A Besse ei 3c E EN T ETE A 1 Safety eg 2 82 dE A 2 BEE A 2 High Frequency e E e nM oU A 2 Weld Ree 2 Analog Control Cable EE Cable Connections and Control Cable Connector A 4 Shielding Gas Connection e T M A 4 Wire Re AON E TUE A 5 Changing The Gun Receiver Bushing sise A 5 Procedure to Install Drive Rolls and Wire Guides A 5 Pressure Arm AdJUSIMENI EE A 6 Loading Spools Of E A 6 EI ln e RE de E A 6 Power Source to LN 25 Pro Dual Power Cable Connection Diagrams A 7 thru A 9 Section B Safety e Mie B 1 Graphic Symbols that appear on this Machine or in this B 1 Definition of Welding EE B 2 General Descriptio Ee ee 5 2 Recommended Processes Equipment Limitations Recommended Power B 2 Case Front Controls ENNIO B 3 thru B 5 Jee TK lte E 5 6 Internal Controls Decription Se en nee B 7 Constant Current Wire W
21. 019 80 28s 219 E Bi ae 008 0 v60S szo 608 609 9608 N SN 91 918 LC AO NI NMOHS 9315 Z NI NMOHS u M n a i GU GU I ws o Las lo K za 3 99 3 4915 c Ig Ge 2608 2606 YOOTHSINI RK 9609 aeos 4399141 ER eS 15 Lor 421114 HOLON SOTVNV Odd SNISIM 2 12 x 16 ELLIPSE DIMENSION PRINT p 16 CIRCLE 7 LN 25 PRO LINCOLN F 2 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO SI Chinese e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e No toque las partes o los electrodos bajo carga con la piel o ropa moja da e Aislese del trabajo y de la tierra e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas elec trodos com a pele ou roupa molha da e Isole se da pe a e terra FPOaNKACMHEWUCE o HIHZHP rE NTUSRICL TFA e E BASURA DERE ER IER SFR
22. AC to feeder eserved JJ nused lectrode voltage from feeder 24 JJ used N ectrode voltage to power source m O m ol o a m JJ LN 25 PRO LINCOLN E A4 CABLE CONNECTIONS SHIELDING GAS CONNECTION MEM WARNING There is one circular connector for the gun trigger on the front of the LN 25 PRO CYLINDER may explode if damaged Keep cylinder upright and chained to support Not used Not used 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 electrical circuits e BUILD UP OF SHIELDING GAS MAY 3 HARM HEALTH OR KILL X 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 1 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 ex
23. AW e Flux Core Arc Welding GENERAL DESCRIPTION General Physical Description The LN 25 PRO is specially engineered to be the most rugged portable wire feeder available Several models of the LN 25 PRO are offered to best meet individual welder needs The Extra Torque model features additional torque gearing for reliable feeding of large diameter FCAW wires All of the mod els include a gas solenoid and flow meter for the flexi bility to run most wire processes 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 LN 25 PRO is the 2 roll MAX TRAC 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 The LN 25 PRO has only two p c boards that are designed to be simple reliable and easy to service General Functional Description The LN 25 PRO as designed is a simple robust feeder Standard features include a calibrated wire feed speed dial 2 step trigger interlock switch CV CC switch Gas Purge and Cold Feed RECOMMENDED PROCESSES GMAW FCAW PROCESS LIMITATIONS GMAW P procedures must be qualified by the cus tomer Across the Arc models are not recommended for stitch
24. E pa 18913 934 S108WAS 109 909 5 T 4 NOLLVINHOJNI 1VH3N35 S300 3080 1 VHLXZ NO 2 5804 OL VHLDGI LOINNOO OM SE Sec a 0902 HOLIMS 4O 3015 NOLLO3NNOO WOU NMOHS S3HOLIMS E N 13 308 02130 0 3 1317111131 e 3LIHM HLIM G37 40 3903 LW14 3HL IS38V3N jn DO oer 417 OO or SALON 2 vi O d 40 3916 LNINOdWOO DO poveNun 09 MO 1SOd 5 3ON3nO3S NIHIANWNN ALIAVO 682882621 IWNOLLdO UN YAWIL zb ly gt tv 0 2 osz 3 9 gt 2 3 99 0 99 312 29 EEN 2 NOLLO3NNOO 3790 NN CNN gz EE 2004193713 LN SE bb aize r 199 O 0199 1199 MET 8 9 CH Q D EH 3 9
25. ENTIRE SECTION THIS MACHINE OR IN THIS MANUAL BEFORE OPERATING MACHINE INPUT POWER e ELECTRIC SHOCK CAN KILL Unless using COLD FEED fea ON ture when feeding with gun trig ger the electrode and drive mechanism are always electri cally energized and could OFF remain energized several sec onds after the welding ceases Do not touch electrically live part or electrode WIRE FEEDER 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 e Use ventilation or exhaust to remove fumes from breathing zone e WELDING SPARKS can cause fire or explosion Keep flammable material away ARC RAYS can burn Wear eye ear and body protec tion SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL Orrsee LN 25 PRO LINCOLN POSITIVE OUTPUT NEGATIVE OUTPUT INPUT POWER DIRECT CURRENT OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION B 2 OPERATION B 2 DEFINITION OF WELDING TERMS WFS Wire Feed Speed CC e Constant Current CV Constant Voltage GMAW Gas Metal Arc welding SMAW e Shielded Metal Arc welding FC
26. LATION A 3 ANALOG CONTROL CABLE K1797 XX The control cable connecting the wire feeder to the power source is specially made for the welding envi ronment The wire feeder power requires overcurrent protec tion Connect the wire feeder only to power sources where the overcurrent protection is no more than 15 amps Do not use more than 100 ft 30 5 m of control cable between the wire feeder and power source Power Source Wire Feeder JO OA lO OKOB NO OL oMop Fo POWER SOURCE r D Q A unused hassis GND elding Output Control trigger from feeder elding Output Control trigger from feeder emote Voltage Control supply from power source emote Voltage Control ontrol signal from feeder or remote emote Voltage Control supply from power source ork connection to feeder 2 VAC to feeder eserved eserved eserved elding Output Control trigger to power source elding Output Control trigger to power source emote Voltage Control supply from power source emote Voltage Control ontrol signal from feeder or remote emote Voltage Control supply from power source ork connection from power source 2 VAC to feeder eserved QUE D 2 gt gt JJ JJ Ho D J gt _ 41111 2 VAC to feeder eserved PN 2 V
27. S 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 e Use ventilation or exhaust to remove fumes from breathing zone e Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o 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 fuma a e Use ventilac o e exhaust o para remover fumo da zona respirat ria VE E EE KE UE 9 51 e RAR BEES e 1 FUR E fE i JL EX BE 8 82 e Y22374 SA7ISE HAMAL gye 837 8 amp HAHI Ssh 17 1 1 OF ad ore ghali bis Je d ni e e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig 0 nen Maschine anhalten e N o opere com as tampas removidas e Desligue a cor
28. arc rays 4 c 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 8 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b 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 5 c Do not weld in locations near chlorinated hydrocarbon vapors
29. aring Wire Feed Speed Standard Speed 400 in min Extra Torque 150 in min 5 Connect the LN 25 PRO to the constant voltage DC welding power source The work lead of the LN 25 PRO must be connected to the work terminal of the power source 6 Turn power ON 7 Insert the shorting plug into connector J3 on the Control P C Board The shorting plug shorts pins 4 amp 8 8 Remove the shorting plug 9 Turn power OFF 10 Replace the cover and secure with the screws FIGURE D 2 LN 25 PRO LINCOLN ef TROUBLESHOOTING zi HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate 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 l
30. ble with Miller amp guns and hex key wrench Includes Gun receiver bushing Gun Receiver Bushing compatible with hose nipple 4 guide tubes with Oxo guns set screw and hex key wrench Gun Receiver Bushing for Lincoln Includes Gun receiver bushing Fast Mate guns with trigger connector opindle Adapter for mounting 14 Includes Spindle Adapter made Ib 6 4 kg Innershield Coils on 2 from 2 coil retainers Electrode in 51 mm spindles not included opindle Adapter for mounting 8in Includes 2 Spindle Adapters 203mm diameter spools on 2 in one for 2 wide spools and the 51 mm spindles other for 3 wide spools Includes 2 hoses with female quick connectors at each end 2 male connectors for 3 16 ID hose 2 male connectors for ID hose and mounting hardware Water Connection Kit for European and Control cable mod els only Includes Deluxe Gas Regulator for Mixed Gases Adapter for CO2 and 10 3 0m Hose Deluxe Adjustable Gas Regulator LN 25 PRO LINCOLN amp 5 ACCESSORIES 6 5 INSTALLATION OF THE K590 6 WATER COOLING KIT A WARNING ELECTRIC SHOCK can kill Turn the input power OFF at dis connect switch before working on this equipment Do not touch electrically hot parts Only qualified personnel should install use or service this equipment The K590 6 components are rated up to 70 psi 5 bar and 158 F 70 C Use a coolant fluid tha
31. bushing and tighten the thumb screw PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES A WARNING e Turn the input power OFF at the welding power source before instal lation or changing drive rolls and or Do not touch electrically live parts guides e 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 1 Turn power off at the welding power source 2 Release the idle 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 UNLOCKED POSITION LOCKED 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 LINCOLN A 6 INSTALLATION A 6 PRESSURE ARM ADJUSTMENT Turn the input power OFF at the weld ing power source
32. c voltage is regulated by the power source by adjusting the arc current cv E 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 neither the power source nor the gas solenoid will be energized Adjust the speed of cold feeding by rotat ing the WFS knob Cold feed ing or cold inching the elec trode is useful for threading the electrode through the gun olo LN 25 PRO LINCOLN 5 5 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 For co
33. d is suitable for outdoor use The handle of the LN 25 PRO 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 HIGH FREQUENCY PROTECTION CAUTION Locate the LN 25 PRO away from radio controlled machinery The normal operation of the LN 25 PRO may adversely affect the operation of RF con trolled equipment which may result in bodily injury or damage to the equipment 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 A 1 RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 167 F or 75 C AMPERES PERCENT to 50Ft 0 to15m O1 2 1 1 1 2 2 1 2 2 1 3 2 1 3 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 0 CABLE SIZES FOR COMBINED LENGTHS OF 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 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 LINCOLN A 3 INSTAL
34. der to power source control cable Includes 14 pin circular con nector with jumper for leads 2 K484 Jumper Plug Kit 4 For use in power sources for turning the weld terminals ON at all times K1798 requires Adapter Cable for Control Cable to Includes 14 circular connector remote control Terminal Strip Power Sources with leads to connect to a ter kit minal strip LN 25 PRO LINCOLN amp 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 LINCOLN amp K1500 4 K1500 5 K489 7 K435 K468 K590 6 K586 1 d I ACCESSORIES Gun Receiver Bushing for Includes Gun receiver bush with K466 3 Lincoln gun connec ing with hose nipple set screw tors compati
35. e D 1 Calibration of the LN 25 PRO 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 Constant voltage DC welding power source DC 400 V 350 CV 400 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 Model gearing Wire Feed Speed Acceptable Range Standard Speed 400 in min Extra Torque 150 in min 25 31 rpm 3 Remove the plastic cover from the lower portion of the wire drive with a 7 16 wrench A Connect the LN 25 PRO to the constant voltage DC welding power source The work lead of the LN 25 PRO 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 MOTOR SHAFT MAINTENANCE D 2 To change the wire feed speed calibration See Figure D 2 Tools required 5 16 nut driver RPM meter Shorting plug The shorting plug shorts pins 4 8 8 of connector J3 on the Control P C Board J3 is a 8 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 ge
36. e 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 precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 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
37. elding sisi B 8 Real ee qiie RR NEN T 94 9 GaS EE 10 FOW E 5 10 Power Up Sequence RN ane 9 3 299 5 10 EE Section C metes Ee e le PEE DO C 1 Drive Roll Kits on se tan eme ee ee C 1 Accessories Used nes mn ne si due C 2 thru C 5 Installation or Water Cooling RES 6 C 6 Olai Le Section D Safety Precautions a D 1 Routine Maintenance ERE T T D 1 Beie lee elc NUR ENT mE D 1 Calibration Specification ken D 1 D 2 e SO Te de ERE E E D E EET Section E How to Use Troubleshooting Guide 56 e uma NUR RU E 1 Troubleshooting Guide M E 2 E 3 Wiring Diagram amp Dimension Prints essere eee rese Section F PATES PAGS M P 630 Series viii 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS LN 25 PRO 2613 1 K2613 2 INPUT VOLTAGE and CURRENT INPUT VOLTAGE 10 RATED OUTPUT 104 F 40 C 60 rating GEARING WIRE FEED SPEED RANGE WIRE SIZE e Extra torque 30 400 ipm 023 1 16 30 400 ipm 030 3 32 K2613 2 0 6 10 1 0 6 1 6m m 0 8 10 1m m
38. elding 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 8 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located e 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 PL 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
39. ently oper ates at the wrong value The speed changes when the wire feed speed knob is adjusted The wire feed speed stuck at 200 11 300 in min and there is no change when the wire feed speed knob is 2 adjusted Variable or hunting arc Poor arc starts with sticking 1 blast offs weld porosity narrow and ropy looking bead Output Problems the drive rolls The spindle brake is too tight Worn drive roll speed extra torque is connected improperly The wrong gear is installed in the wire drive The brushes on the motor are worn The tachometer is connected 1 improperly The tachometer has failed Wrong size worn and or melted contact tip Worn work cable or poor work 2 connection Wrong polarity The gas nozzle is extended 4 beyond the contact tip or the wire stickout is too long Poor gas shielding on 5 requiring gas Improper procedures or tech 1 Replace 7 Incorrect tension arm pressure 7 Adjust the tension arm per the Instruction Manual Most elec trodes feed well at a tension arm setting of 3 Verify the spool of wire moves with minimal effort Replace the drive rolls if worn or filled with dirt Properly connect the normal speed extra torque jumper Install the proper pinion gear in the wire drive the motor gearbox assembly Verify all of the tachometer leads are prope
40. he 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 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 Do not operate with covers panels or guards removed or open e Only qualified personnel should perform mainte nance work The LN 25 PRO comes with a K1500 2 gun adapter installed See Figure A 4 To install 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 A THUMB SCREW GUN
41. he 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 after the gun trigger is released Do not operate with covers panels or guards removed or open e Only qualified personnel should perform main tenance work 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 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 LN 25 PRO to the constant voltage DC welding power source The work lead of the LN 25 PRO must be connected to the work ter minal of the power source 3 Connect the reference voltmeter between the brass block of the LN 25 PRO and the work lead 4 Turn power ON 5 Energize the output circuit of the power source Adjust the power source output to 20x1 VDC as measured on the reference
42. in 10 3 2 4mm Standard Speed 50 700 ipm 023 1 16 50 700 ipm 030 5 64 K2613 1 1 3 17 7m min 0 6 1 6m m 1 3 17 7m min 0 8 2 0mm PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 14 8 Inches 8 7 Inches 22 2 Inches 376 mm 221 mm 589 mm Handle folded down TEMPERATURE RANGE OPERATION 40 F to 104 F 40 C to 40 C STORAGE 40 F to 185 F 40 C to 85 C LN 25 PRO LINCOLN A 2 INSTALLATION A 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL e 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 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 LN 25 PRO 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 LN 25 PRO The LN 25 PRO is rated IP23 an
43. irect response to the trigger Trigger Interlock operation allows welding to continue when the trig ger is released for comfort on long welds Place the toggle switch in the DOWN position for 2 otep operation or in the UP position for Trigger Interlock operation 2 Step Trigger 2 Step trigger operation is the most common When the gun trigger is pulled the welding power source energizes the electrode output and the wire feeder feeds wire for welding The power source and wire feeder continue welding until the trigger is released Trigger Interlock Trigger Interlock operation provides for operator com fort when making long welds When the gun trigger is first pulled the welding power source energizes the output and the wire feeder feeds wire for welding The gun trigger is then released while the weld is made To stop welding the gun trigger is pulled again and when it is released the welding power source output turns off and the wire feeder stops feed ing wire CAUTION If the arc goes out while welding with trigger interlock operation the elec trode output from the welding power source remains energized and the wire feeder will continue to feed wire until the gun trigger is again pulled and then released 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 ar
44. isting 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 Hecommended Course of Action safely contact your local Lincoln 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 after 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 If for any reason you 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 LINCOLN amp E 2 TROUBLESHOOTING E 2 Observe a
45. ll Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION The feeder does power up no dis play no cold feed is no output when the trigger is and the drive rolls turn No shielding gas feeding but drive rolls turning The wire feeder power up but there 1 pulled The shielding gas is flowing 2 Inconsistent wire feeding or wire 0111 Output Problems The work sense lead is discon 4 Connect the work sense lead to nected or is a poor electrical con nection Across the arc models The power source is OFF The circuit breaker for wire 3 feeder on power source have tripped control cable models The control cable may be loose or 4 damaged control cable models The contactor coil connections are loose The contactor has failed The gas supply is OFF or empty The gas hose is cut or crushed The flow meter valve is closed Dirt or debris is in the solenoid There is a loose solenoid connec tion The solenoid has failed The gun cable is kinked twisted The wire is jammed in the gun 2 cable The gun liner is dirty or worn The electrode is rusty or dirty The contact tip is partially melted 5 or has spatter Improper gun liner tip drive rolls 6 and or inner wire guide the work in a location free of di
46. lowing equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 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 material to protect your skin and that of your helpers from the
47. n 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 warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where
48. nstant 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 difficul
49. oductive 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 Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 4 1h To avoid scalding do not remove the Ql opis radiator pressure cap when the engine is powered equipment ANA 8 cm i 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes QA outdoors 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 con
50. plosive 3 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 4 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 5 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 wrench 6 Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released 7 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 8 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 LINCOLN 5 INSTALLATION 5 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 g
51. ply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components
52. re as appropriate LINCOLN amp effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 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 2 d 3 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 8 The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 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 fol
53. rente antes de fazer servico e N o toque as partes el tricas nuas FHR E ZC PERLE e Er TE ES Lie Aj d i Ada gl jui aba e e Do not operate with panel open or guards off e No operar con panel abierto o guardas quitadas e 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 setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas e IL HI ZRI t EE THRHIRIFE OARRA XS ARE X Sel P EX OM AIS Yi cils UI gall Jedi y e Aale Gel All dl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO 2 Chinese Korean LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR ESRR LEHO 2 lt lt ETHRUCTSUS CL CRHOKRESRMEK HTP SU nu ET MD DE RU A da RH BA L XE SEO 0 SSE ei AAP Sie asl veel Catia Al 4 Aal oig v i aat LINCOLN World s Leader in Welding and Cutting Product
54. rly connected Replace the motor and tachome ter assembly the contact tip Verify all work and electrode con nections are tight and that the cables are in good condition Clean replace as necessary Adjust polarity to the recommend ed procedure Adjust the gas nozzle and shorten the stickout to 3 8 to 1 2 inches Check gas flow and mixture Remove or block sources of drafts See Gas Metal Arc Welding Guide GS 100 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 LINCOLN Jequunu epoo 1ueuudinbe eu 1ueujeoe doi e 10 931495 9 109 si eui sjeued aui JO euo uo oU episui paysed si 1e norued 40 out siy Aq peJeAoo 404 eq jou Ajuo JO S siu 310N LL 8955 SS3NUVH NO 09d OL d 2 8 8 E ce An CE NE
55. rt rust and paint Turn ON the power source Reset the circuit breakers Tighten repair or replace the con trol cable Verify the contactor coil connec tions Replace the contactor Verify the gas supply is ON and flowing Route the gas hose so it avoids sharp corners and make sure nothing is on top of it Repair or replace damaged hoses Open the flow meter valve Apply filtered shop at 80psi to the solenoid to remove dirt Remove the cover and check that all connections are in good condi tion Keep the gun cable as straight as possible Avoid sharp corners or bends in the cable Remove the gun from the wire feeder and pull the jammed wire out of the gun and cable Blow dirt out of the liner with low pressure 40psi or less Replace the liner if worn Use only clean electrode Use quality electrode like L 50 or L 56 from Lincoln Electric the contact tip Verify the proper parts are installed 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 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Wire feed speed consist
56. s 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
57. s 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 feeder is connected e POLARITY for positive polarity e POLARDAD Use the polarity LED to verify the wire feeder is connected for the proper polarity 8 POLARIT LN 25 PRO LINCOLN B 6 OPERATION INTERNAL CONTROLS 12 FIGURE B 2 DESCRIPTION 2 Step Trigger Interlock Switch CV CC Switch 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 LINCOLN B 6 7 OPERATION B 7 INTERNAL CONTROLS DESCRIPTION See Figure B 2 2 Step Trigger Interlock Switch The 2 Step Trigger Interlock switch changes the function of the gun trigger 2 Step trigger opera tion turns welding on and off in d
58. t is compati ble with the water cooler and the gun Tools required 3 8 wrench 5 16 nut driver e medium flat bladed screw driver cutting tool 1 Turn power off at the welding power source 2 Remove the screws securing the case to the inner module using a 3 8 wrench V 3 Remove the module from the case by lifting the front of the module approximately 25 6 mm and then sliding forward 4 Use a 5 16 nut driver to remove the screws holding the water cooling cover on the case front of the inner module and on the rear of the case Ke Tee Or 7 Ge D WE 229 H YS 4 5 Install the fitting and hose assembly to case front Route the hoses along the bottom of the inner module and out through the cutout of the cover Slide the module back into the case 6 Secure the module to the case with the screws Shown in Step 2 7 Install the fitting assembly to the rear of the case ALUMINUM CASE PLASTIC CASE 8 Slide the hose clamps on to the hoses Trim the hoses to length so that they lay flat on the case bot tom Slide hose clamps on the hose Slide the hoses on to the fittings on the case rear and secure with the hose clamps LN 25 PRO LINCOLN amp D i MAINTENANCE 0 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Turn t
59. t 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 Wire T Feeder CTWD Constant Current p WFS N Power Source A rm LN 25 PRO LINCOLN 8 9 OPERATION B 9 REAR CONTROLS uu Ewe XW Y V CY Git S CU c uU N 527 wu MI ITEM DESCRIPTION Gas Purge Pushbutton Flow Meter Ball Flow Meter Valve Shielding Gas Inlet 5 Electrode Lead 6 Optional Water cooled gun connections LN 25 PRO LINCOLN 53 10 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 FLOW METER The flowmeter shows the flow rate of shielding gas and has a valve to adjust the flow The flow meter is scaled for Ar and Ar CO blends The middle of the ball indicates the flow rate of shielding gas Adjust
60. tact 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 ELECTRIC AND MAGNETIC FIELDS may be dangerous 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 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 In some cases it may be necessary to remove safety 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 1 f Do not put your hands near the engine fan CS Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 1 0 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 wi
61. the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out LINCOLN SAFETY vi Electromagnetic Compatibility EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains sup
62. touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase 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 follow NFPA 51B Standard for Fire Prevention During W
63. un 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 Tools required 1 4 hex key wrench Note Some gun bushings do not require the use of the thumb screw Turn power off at the welding power source Remove the welding wire from the wire drive Hemove the thumb screw from the wire drive Hemove the welding gun from the wire drive Loosen the socket head cap screw that holds the connector bar against 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 ROM THUMB SCREW CONNECTOR BLOCK SOCKET HEAD N CAP SCREW LOOSEN TIGHTEN OUTER WIRE GUIDE 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
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