Lincoln Electric IM10084 User's Manual
Contents
1. il 110 YOLWINOD ais LOS N DLL SA LL 8ld LLI 292 LE 9L DSL eil s SSINYVH No Div Y 169 804 gt 6 V80Z 8Lf OL LOANNOO oc LLS 8 6 GION310S 9 5 gt L V9L5 giz O ef SYD SLS gt 9 6 yizo e 069 9 LOL v 9 5 55 szs ZZS L69 5 109 8178 cu de a az A CC 6 6 Les 285 os 069 be 419 Wizz vz 9 GE SE za bi i Z E SS SC F Je ES SS oos Z vo0s 931411038 O 8e LEE _ EE 8 O 6 S DN pr 8 99 ZN A Da zridie BL OS FETL ELICPETI 2 lt s lt 200020000 254 2 22 22 DAD D 6 3 055 85 M SSS Ss kE per El S 2 a J See Les el 9 lt lt S lt 9 lt y ESCH vf sf i ves Ge LO aN a aid LES tele ps n Era i om 8 lt TA 2 Fot K Z gt ON gt oe SSANHYH NO SCH q YLL a clo i Lg OCf 0Td HONTE 5 ur OL SLOANNOO HDLIMS WC gm Ltd _ MOL NOLLNGHSNd 4 4 KE gt gt b 708 115028 LIA gt gt 108 3DYNd SYD na mr CE JOULNOD SLO3NNO9 gt L 508 5 SSS Ole zag y HOLOW 846 0394 20 ege S 109 lt 8 lt HOWL O INDIOL 8 809 LA o r 999 E ECH SE CH VOS Dd IOHLN2. LN 25 RONWORKER For use with machines having Code Number 11752 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 i k ANSI RAB gt 1 S HI 2 d Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requiremen 5 CERTIFICATE NUMBER 30273 IP23 IEC 60974 5 OPERATOR S MANUAL Copyright Lincoln Global Inc LINCOLN amp e 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 SAFETY A WARNING Y CALIFORNIA PROPOSITION 65 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 WELDIN
3. 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 gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located e Away from areas where they may be struck or subjected to physical damage eA 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 8 8 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 Electrica
4. y e FUMES AND GASSES can be a dangerous E GN e Keep your head out of fumes 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 OPERATION B 1 GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL O ojo DD 5 A LN 25 IRONWORKER LINCOLN 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 B 2 OPERATION B 2 DEFINITION OF WELDING TERMS WFS e Wire Feed Speed CC e Constant Current CV e 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 LN 25 IRONWORKER is specially engineered to be the most rugged portable wire feeder available and meets the individual welder needs 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 IRONWORKE
5. READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS 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 piracion Mantenga la cabeza fuera de los humos Utilice ventilacion o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 7 4 6 598 2 6 80770 9 0 i Ae eS FO E fE Fh E 5 AR e 575 97 e yczy 8 M6 A4 2241412114 SDE ASSHALRZ gs ye lye dul su 0 Jl all his juas yl 4948 Jaia
6. 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 e Turn the input power OFF at the 0 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 e Do not operate with covers panels or guards removed or open e Only qualified personnel should perform mainte nance work Turn power off at the welding power source Release the idle roll pressure arm Remove the outer wire guide by turning the knurled thumbscrews counter clockwise to unscrew them from the feed plate SEL 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
7. 151656 del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces 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 e electro dos com a pele ou roupa molhada e Isole se da peca e terra 0000 18 5 E Let 860 6 61 07 2 5 84068 NTUBRELTFA40 ORKRAKDY 5 8 8 ST TIET OAT SHES as FY qe AU HSA ofa 0212 HHE HYSA OAR A gat il el all Quali 8 A aall alag 39 0 yl giil ell Aal ey Jaall DUA Aas ple Yjle 6 elj e Keep flammable materials away e Mantenga el material combustible fuera del area de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos SRA CTU SOOMTCOBRETFR 4 6 MICL THEY EPA eiT Hnt ELL EE FT ed A Ju ALU AA es Sc AIX 0M2 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 Use protec o para a vista ouvido e corpo SP HAUSHIRBRELTE ez 194 20 78 IES HAZ dal y due de 4 dat cil yal kg Di A
8. Ranger 3 Phase e CV 400 e Ranger 225 e CV 655 e Ranger 225 GXT 0 e Ranger 250 0 Ranger 305 e DC 655 e SAE 400 e Invertec V 350 Pipeliner 200G e FlexTec 450 e Classic 300 e Multi Weld 350 e Ranger 10 000 e Vantage 0 e Vantage 0 e Vantage 500 LN 25 IRONWORKER LINCOLN B 3 OPERATION B 3 See Customer Assistance Policy in the front of this WIRE FEED SPEED KNOB Instruction Manual Wire Feed Speed CV Operation CASE FRONT CONTROLS See Figure B 1 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 FIGURE B 1 83 Wire Feed Speed The 83 wire feed speed reduces the wire feed speed to 83 of the original set value when activated For example if the original wfs 200 in min the feed er will regulate to 0 83 x 200 166 in min The 83 trigger requires a gun with a dual procedure switch This feature is often useful when welding pipe and a cooler procedure is required on the bottom portion Minimum Arc Volts Maximum WFS Gearing 340 520 rv GIA VW HU GIA co DA ITEM DESCRIPTION Wire Feed Speed Amperage Display 7 Wire Feed Speed LED Amperage LED 4 Wire Feed Speed Knob 5 5 pin gun trigger connector e Work Clip Connection Thermal LED ECH Voltage Display 9 V
9. 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 Replace the contact tip Verify the proper parts are installed CAUTION 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 IRONWORKER LINCOLN E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Wire feed speed consistently oper ates at the wrong value The speed changes when
10. 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 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
11. 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 Vil Vil for selecting a QUALITY product by Lincoln Electric We want you T hank 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 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 Li
12. 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 not 1 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Output Problems 1 The work sense lead is discon 1 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 1 3 feeder on power source have tripped control cable models The control cable may be loose orl4 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 and or twisted The wire is jammed in the gun and 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 rollsi6 and or inner wire guide E 3 the work in a location free of dirt rust and paint Turn ON the power source Reset the circuit breakers
13. power source before disconnecting the work clip from the work e Only use on power sources with open circuit voltages less than 110 VDC LOCATION For best wire feeding performance place the LN 25 IRONWORKER 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 IRONWORKER The LN 25 IRONWORKER is rated IP23 and is suitable for outdoor use The handle of the LN 25 IRONWORKER 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 IRONWORKER away from radio controlled machinery The normal operation of the LN 25 IRONWORKER may adversely affect the operation of RF controlled 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 O to 50Ft 0 to15m D oO 5 D D 2 1 1 1 2 2 1 2 2 1 3 2
14. repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A 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 e 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 CAUTION for any reason you do not understan
15. 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 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
16. to enter the WFS calibration menu WFS CALIBRATION Measurements for adjusting the WFS calibration must be made before entering the set up menu lf no changes are being made to the calibration then press the set up button to enter WFS Knob Range While in the set up menu adjust the calibration factor as follows Actual WFS 405 Calibration Factor Example 1 01 Set WFS 400 Press the set up button when calibration factor is set LN 25 IRONWORKER LINCOLN B 6 OPERATION B 6 LEFT DISPLAY SELECTION The left display can show either amperage or actual WEG during welding Note that actual WEG is not the same as preset WFS For example the preset WFS may be set to 400 ipm but the arc voltage is only 15V The actual WFS will be approximately 280 ipm because there is not enough arc voltage to run at 400 lpm To change the left display reading Rotate the WFS knob to the left to display amperage current Rotate the WFS knob to the right to display actual WES Then rotate the knob to the 12 o clock position Press the set up button SS A OA OV dii SP 1 FEEld OA V LN 25 IRONWORKER LN 25 IRONWORKER nd __ 010 WFS __
17. 00 WFS WFS KNOB RANGE For wire feeders equipped with standard torque gear ing the WFS range can be changed to provide better knob sensitivity at low wire feed speeds This is often useful when welding with Innershield wires To change the WFS knob range Rotate the WEG knob to the left for the low wire feed speed range of 40 405 ipm Rotate the WFS knob to the right for the high wire feed speed range of 40 715 ipm Then rotate the knob to the 12 o clock position See ai AA SPd illo CSP HII OA olo a KA KA LN 25 IRONWORKER LN 25 IRONWORKER A 6 OIOWFS e ___ OIO WFS Press the set up button Power Source Amperage AMPERAGE CALIBRATION Measurements for adjusting the Amperage calibration must be made before entering the set up menu If no changes are being made to the calibration then press the set up button to enter Display Hold While in the set up menu adjust the calibration factor as follows 200 Calibration Factor Example 5 210 Feeder Amperage Press the set up button again to enter the Amperage Calibration Rotate the knob to the 12 o clock position then press the set up button to enter Display Hold DISPLAY HOLD Af
18. 1 3 2 1 3 2 1 2 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 IRONWORKER LINCOLN A3 3 INSTALLATION AS CABLE CONNECTIONS SHIELDING GAS CONNECTION WARNING CYLINDER may explode if damaged There is one circular connector for the gun trigger on the front of the LN 25 IRONWORKER e Keep cylinder upright and chained to support Keep cylinder away from areas where it may be 5 volt supply D 83 WES switch 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 S HARM HEALTH OR KILL Me 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 5 volt supply 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 cylin
19. G CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard 249 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 UN FOR ENGINE E d 1 h ee scalding la the powered equipment AE ge gt Si or pressure cap when the engine is 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 8 2 ELECTRIC AND MAGNETIC FIELDS 1 0 Do not add the fuel near an open flame GC may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz localized Electric and Magnetic Fields EMF Welding ing on contact wit
20. 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 Gun Receiver Bushing for guns Includes Gun receiver bush with K613 7 Lincoln gun connec ing with hose nipple set screw tors Magnum 550 guns and com and hex key wrench patible with Tweco 5 LN 25 IRONWORKER LINCOLN d w K1500 4 K1500 5 K435 K468 K586 1 K283 ACCESSORIES Gun Receiver Bushing for gun with K466 3 Lincoln gun connec tors compatible with Miller guns Gun Receiver Bushing compatible with Oxo guns Spindle Adapter for mounting 14 Ib 6 4 kg Innershield Coils on 2 in 51 mm spindles Spindle Adapter for mounting 8in 203mm 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 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 Wire Feed Sp
21. N See Figure A 2 CHANGING THE GUN RECEIVER BUSHING WARNING ELECTRIC SHOCK can kill e 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 s 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 Remove the thumb screw from the wire drive Remove 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 2 te D 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
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23. OD 09 31Vld L ir of N gr y lt 09d 0333 508 y Se lt E lt v Gay Fe d A dl dd 8605 0 Gg GERVA QLSLPLELZLLLOLE8 LI 5 HETIL 08 E io it 0168 229 5 5 YYYY UN 7 SE el TT TJ ER SE 1 1 0 S y lt 1 voes yoess e 1 33 d Doi ae ee BEES 05 y Els lt Es VETS 3605 e 52 LOL SLOINNOD 08 D d L3S3Ud NO 185 Ze 6 8f OL ML 79 019 80 285 09 a N ES D Era ge mz 005 zoz Weos ezs 6 os 605 2605 N aN 5 9Lf 9Ld 0 0 8 0 0 0 0 4 l von 08 29 zo8 y lt 4 em gel bzoz Lo8 E III yom oC J al S 4315 Z NI NMOHS LAL AAAAAAA JA Li Ja 0 0 0 0 0 0 aN 6 TL 9LSIPLEIZLILO 16 BLOGS FETT 06 BLOSHTETL veze yes Lo TITT EE ADA 3 za H 99 i 63156 1D La bag 05 3605 1YDO NANNI 6r UU guvos 24 13saud EH 1 LLL 1 05 7 7 7 7 7 0 7 oes 61 ve TL LS 1 MARA zor Lor GUVOS D d YILT YOLOW UTHHOMNOEI Odd wiSe N1T NVESVIC F 1 F 2 DIMENSION PRINT LN 25 IRONWORKER LINCOLN F 2 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO 7 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
24. QAUAMNE elt FA AA 98 55 EPA sHC asl all Gl dl cial Al laata Qu Aal y land 03 Sall Glebe ap y ai LA LINCOLN E e 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
25. R 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 The LN 25 IRONWORKER with a 450 amp 60 duty cycle rating is ready for heavy duty welding General Functional Description The LN 25 IRONWORKER have adjustable WFS range for improving the knob sensitivity The low range is great for critical welds with Innershield wires and the upper range is suitable for general purpose welding Selection of the WEG range is by a rocker switch or through the set up menu on meters with digi tal displays RECOMMENDED PROCESSES GMAW e FCAW PROCESS LIMITATIONS GMAW P procedures must be qualified by the cus tomer e Across the Arc models are not recommended for stitch or spot welding EQUIPMENT LIMITATIONS The duty cycle of the wire feeder is 450A 60 Duty cycle is based upon the amount of welding performed in a 10 minute period e The maximum spool size is 45 lb 12 diameter e Maximum FCAW gun length is 15 ft e Maximum GMAW gun length is 25 ft e K2330 1 Timer Kits do not work with the feeder Use K2330 2 kits e Push pull guns do not work with the LN 25 PRO The digital displays do not show preset voltage e Not compatible with K489 7 Euro connector RECOMMENDED POWER SOURCES e CV 305 e
26. S knob to LL the right to use meters minute for the EUirjo OA O LN 25 IRONWORKER wire feed speed units d 6 Then rotate the WFS knob ON to the 12 o clock position OJO WFS Press the set up button again to enter the Run In menu RUN IN Run in refers to the wire feed speed during the time from when the trigger is pulled to when an arc is struck When Run in is ON the wire feed speed is reduced until an arc is struck Factory setting is Run In OFF Model _ Run in Wire Feed Speed Extra Torque Models Standard Speed Models When Run in is OFF the wire feed speed is the same as the welding wire feed speed Turn Run In OFF for fast crisp starts especially when running with 035 or 045 0 9 or 1 2mm solid steel wires at high wire feed speeds To change the Run in setting Rotate the WFS knob to Ioe the left to turn Run In OFF d Rotate the WFS knob to eg the right to turn Run In l ON 005 Irun n Then rotate the WFS knob d to the 12 o clock position LN 25 IRONWORKER EN mil OJO WFS Press the set up button again
27. aitier LINCOLN ES Relier a la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece a souder doit tre branche a une bonne mise a 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 507616 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 similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical
28. d 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 IRONWORKER LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION ERROR CODES 1 Check that the electrode slides easily through the gun and cable Remove tight bends from the gun and cable Check that the spindle brake is Err 81 Motor overload long term 11 The wire drive motor has over heated 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 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 locked 2 Verify that the gears are free of rotor state debris and dirt Err 82 Motor overload short term CAUTION 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 IRONWORKER LINCOLN E 3 The feeder does power up no dis play no cold feed is no output when the trigger
29. der 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 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 IRONWORKER LINCOLN A 4 INSTALLATION A 4 WIRE DRIVE CONFIGURATIO
30. e feeder is connected for electrode negative welding then the voltage display shows a minus sign After Welding The display continues to hold the value of the amper age or WFS and arc voltage for five seconds after welding stops The amperage or WFS and voltage displays flash Set Up Menu Before entering the set up menu Set the display to the desired wire feed speed exam ple 400 inches per minute Measure the actual wire feed speed example 405 inches per minute Place the WFS knob in the 12 o clock position To enter the set up menu use paper clip to press the small button located on the case front Calibration of Amperage Connect the feeder to a power source and grid Adjust the power source and grid to the desired amperage example 220 Amps Record the amperage display on the wire feeder example 210 amps To enter the set up menu use paper clip to press the small button located on the case front LN 25 IRONWORKER LINCOLN B 5 OPERATION B 5 Wire Feed Speed Units To change the wire feed speed units Rotate the WFS knob to a the left to use inches minute for the wire feed speed units L US b g LN 25 ee d ___ 010 WFS Rotate the WF
31. eed Meter Includes A wire feed speed meter with digital display LN 25 IRONWORKER LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill e Turn the input power OFF at the 9 welding power source before installation or changing drive rolls and or guides Do not touch electrically live parts e 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 mainte nance work ROUTINE MAINTENANCE e Check weld cables control cables and gas hoses for cuts e Clean and tighten all weld terminals PERIODIC MAINTENANCE e Clean drive rolls and inner wire guide and replace if worn e Blow out or vacuum the inside of the feeder LN 25 IRONWORKER LINCOLN E 1 TROUBLESHOOTING E 1 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
32. ent 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 prot ger PRECAUTIONS DE SURETE 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 SES TRANSFORMATEUR ET A Un coup d arc peut tre plus s vere 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 proteger 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 proteger 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 montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le l
33. er 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 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 or guides Do not touch electrically live parts 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 e Do not operate with covers panels or guards removed or open e Only qualified personnel should perform mainte nance work The LN 25 IRONWORKER 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
34. erial 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information m
35. h hot engine parts and current creates EMF fields around welding cables and igniting Do not spill fuel when filling tank If welding machines fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and l welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 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 qe 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the
36. he tachometer leads are properly connected Replace the motor and tachome ter assembly Replace 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 strike out to 3 8 to 1 2 inches Check gas flow and mixture Remove or block sources of drafts Use the set up Push button to turn Run in OFF Guide GS 100 CAUTION 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 IRONWORKER LINCOLN tld T Jaquinu po juaudinba oun BAIN e 10 juauedag a911198 eu 0 SIUM s uesbelp eu Sjoued ainsojous y JO suo aulyoeul LL y pajsed s 2p09 e Jo WelBeip oyI9eds yenueW siy Aq saulyoeu IS 10 ayenooe aq jou ew y AjUO a9uaJaja JO SI SIUL ALO
37. her simultan ment les parties sous tension des porte lectrodes connect s a deux machines a souder parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Si on utilise la machine a 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 du aux tincelles Quand on ne soude pas poser la pince a une endroit isol de la masse Un court circuit accidental peut provoquer un echauffement 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 cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu a 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 d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuv
38. ically 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 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
39. ill 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 LN 25 IRONWORKER LINCOLN 1 ACCESSORIES FACTORY INSTALLED EQUIPMENT e K1500 2 Gun Receiver Bushing DRIVE ROLL KITS See Parts Pages K1803 1 Work and Feeder Cables Package K1840 xx Weld Power Cable Twist Mate to Lug K1842 xx Weld Power Cable Lug to Lug Jumper Plug Kit Timer Kit Plastic Case 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 Includes Twist Mate to Lug 1 0 cable of length xx Includes Lug to Lug 3 0 Cable of length xx for lengths up to 60 18 3m Lug to Lug 4 0 Cable of length xx for lengths greater than 60 18 3m Includes 14 pin circular con nector with jumper for leads 2 4 For use in power sources for turning the weld terminals ON at all times Includes Panel and harness for adjusting preflow burnback and postflow times Includes a complete engi neered plastic case LN 25 IRONWORKER LINCOLN C 1 C 2 ACCESSORIES C 2 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
40. l i A A ye il e 2 gdalstdAle Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig offnen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas ASTA RH EXE PERICO vw Fe 234 4 o 8 e 280 HS 6 Sila J AS Jl al Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgehause oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas eill DRALL EEE 0761015 5 LEWC PSU CHART EEE gt AHH ero Bel See 43l OFM Ala 25 cals 13 al la Jada Ye Ale ail Gl dl AA Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO te BIA Chinese 5 LEIA COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR LE 5 HERO 1 gt 8 1 lt 8077306 2 an et MEARE MEM MAU AD A RIRH EE ECKE AJ A DS o Ao SSE ZA
41. l 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 iv SAFETY iv PRECAUTIONS DE SURETE 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 Les circuits l lectrode et a la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vetements mouilles 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 couche pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine a souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais touc
42. lled 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 the arc goes out while welding with trigger interlock operation the elec 0 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 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 ener gized Adjust the speed of cold feeding by rotating the WFS knob Cold feeding or cold inching the electrode is useful for threading the electrode through the gun LN 25 IRONWORKER LINCOLN B 9 OPERATION B 9 REAR CONTROLS La ITEM DESCRIPTION Gas Purge Pushbutton Shielding Gas Inlet Electrode Lead GAS PURGE PUSHBUTTON The gas solenoid valve w
43. ncoln 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 Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for mat
44. nsion Prints EEN Section F E P 672 Series vill A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS LN 25 IRONWORKER K2614 9 INPUT VOLTAGE and CURRENT INPUT VOLTAGE 10 RATED OUTPUT 104 F 40 C GEARING WIRE FEED SPEED RANGE WIRE SIZE GMAW FCAW Standard Speed 50 700 ipm 023 1 16 50 700 ipm 030 5 64 K2614 5 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 376 mm 8 7 Inches 23 2 Inches 221 mm 589 mm Handle folded down TEMPERATURE RANGE OPERATION 40 F to 104 F 40 C to 40 C STORAGE 40 F to 122 F 40 C to 50 C Thermal tests have been performed at ambient temperature The Duty Cycle duty factor 40 C 104 F has been determined by simulation LN 25 IRONWORKER 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 LN 25 IRONWORKER 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
45. oltage LED Set up Push Button LN 25 IRONWORKER LINCOLN B 4 OPERATION B 4 THERMAL LED MOTOR OVERLOAD The thermal light illuminates when the wire drive 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 POWER UP SEQUENCE All of the LED s will briefly illuminate during power up the gun trigger is activated during power up the feeder will not operate until the gun trigger is released WIRE FEED SPEED AMPERAGE DISPLAY Idle The left display shows the preset wire feed speed The right display shows OCV The wire feed speed LED is lit Welding The value in the left display will be either amps or actual wire feed speed depending upon the selection chosen in the set up menu The corresponding LED below the display will light Note that actual WFS may not match preset WES if welding at low voltages with high wire feed speeds The right display shows the arc voltage If the wir
46. omatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 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 287 standards 4 0 Use suitable clothing made from durable flame resistant if LINCOLN material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to
47. other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b 64 SAFETY WELDING and CUTTING gt 5 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 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
48. ter welding the LN 25 IRONWORKER will hold the last values from welding on the display The values will continue to be displayed until the hold period is finished the trigger is pulled again or the cold feed gas purge switch is activated To change the Display Hold time Rotate the WFS knob to the left for 5 seconds Hold Rotate the WFS knob to the right for 300 seconds Hold Press the set up button to exit the set up menu LN 25 IRONWORKER LINCOLN 7 OPERATION INTERNAL CONTROLS FIGURE B 2 DESCRIPTION 2 Step Trigger Interlock Switch Pressure Adjustment Arm Optional Timer Kit See Accessories Section Spool Retainer 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 IRONWORKER LINCOLN B 7 B 8 OPERATION 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 direct 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 Step 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 pu
49. the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and 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 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
50. 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 LN Sy X i E Ww q o TR a 3 ZEN D CN AVE LN 25 IRONWORKER LINCOLN A 6 INSTALLATION A 6 POWER SOURCE TO LN 25 IRONWORKER CABLE CONNECTION DIAGRAMS CV Power Sources with Stud Connectors and Remote Local Switch See Figure A 6 FIGURE A 6 CV 400 CV 655 DC 400 DC 600 DC 655 V450 Pro Electrode SAE 400 with CV adapter Engine Driven welder with Wire Feed Module Ranger 250 GXT 9 LN 25 IRONWORKER Drive Roll Kit Welding Gun CV power Source RS K1803 1 Welding Cables Place the power source Remote Local switch in the Local position Place CV CC switch in the feeder in the CV position 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 Ranger 250 250 LPG Ranger 305G 305D Ranger 10 000 Ranger 3 Phase Ranger 225GXT LN 25 IRONWORKER Ranger 225 Electrode Commander 300 Vantage 300 400 500 Air Vantage 500 PL Peon 261 9 KP1697 XX Welding Gun P CV power Source H Power Source has a 14 Pin Cable connector and no O
51. 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 manufacturers recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivalent Shielding should be electr
52. the wire feed speed knob is adjusted The wire feed speed stuck at 200 1 300 in min and there is no change when the wire feed speed 2 adjusted Variable or hunting arc blast offs weld porosity narrow and ropy looking bead When the trigger is pulled the wire The Run In switch is ON 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 1 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 processesi5 requiring gas Poor arc starts with sticking ott Improper procedures or tech 1 See Gas Metal Arc Welding Replace 7 Incorrect tension arm pressure on 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 t
53. ust be followed to avoid minor personal injury or damage to this equipment vill TABLE OF CONTENTS Page JE d e E Section A Technical SpecificatonS EN A 1 SEET EE A 2 a ne A 2 High Frequency EE A 2 Weld Kee A 2 Cable Connections Shielding Gas Connection ss A 3 Wire Drive Configuration porn A 4 Changing The Gun Receiver Bushing actions A 4 Procedure to Install Drive Rolls and Wire Guides cccccseseeeeeeseeeeeeseeeeeeeaaeeeeeeeeseeeeaas A 4 Pressure Arm Adjustment uk A 5 Loading Spools EE A 5 GUN CONNECTIONS een ee A 5 Power Source to LN 25 lronworker Connection Diagrams 0occccccccnoccccnconcnnnncccncnnnnnas A 6 A 7 OD SF E Section B ED A A D dc die ee B 1 Graphic Symbols that appear on this Machine or in this 8 8 B 1 Definition of Welding BN Kn E B 2 General Re de de Ir EE B 2 Recommended Processes Process amp Equipment Limitations Recommended Power Sources B 2 Gase FONOS ee EE B 3 B 4 WFS Calibration with Digital Meters ss B 5 B 6 taaan 0 7 8 Kee ut E B 9 Gas Purge SMO OI EEN B 9 ACCES SOUICS 2 Section C Factory Installed C 1 Dive Roll KIS AS RE NO ee En C 1 Accessories Used sise C 2 thru C 3 o nn Section D d e DEE D 1 Routine Maintenance D 1 Periodic Eege e D 1 Troubleshooting ee Section How to Use Troubleshooting Guide sise E 1 e 2 ele dt ue EE e E E 3 4 Wiring Diagram amp Dime
54. utput Terminal switch LN 25 IRONWORKER Jumper Plug Kit LN 25 IRONWORKER LINCOLN A 7 INSTALLATION A 7 CV Power Source with Twist Mate Connectors and Remote Local Switch See Figure A 8 FIGURE A 8 CV 305 LN 25 IRONWORKER V350 Pro Electrode Place CV CC switch in the feeder in the CV position K2614 9 LN 25 IRONWORKER Drive Roll Kit See Magnum Literature Welding Gun AAA CV power Source K1841 Welding Cables CV Power Source with Twist Mate Connectors and no Remote Local Switch See Figure A 9 FIGURE A 9 Jumper LN 25 IRONWORKER Electrode z Description Place CV CC switch in the feeder in the CV position E K2614 9 LN 25 IRONWORKER KP1695 XX KP1696 XX Drive Roll Kit KP1697 XX K1841 LN 25 IRONWORKER LINCOLN B 1 SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE 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 8
55. 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 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 3 0 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 e DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or aut
56. 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 IRONWORKER LINCOLN A 5 INSTALLATION A 5 PRESSURE ARM ADJUSTMENT Turn the input power OFF at the weld ing power source before installation or e 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 changing drive rolls and or guides ground and could remain energized several sec e Only qualified personnel should perform mainte o ELECTRIC SHOCK can kill C Do not touch electrically live parts onds after the gun trigger is released 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 follows See Figure A 3 Aluminum wires Cored wires Steel Stainless wires between 1 and 2 between 2 and 3 between 3 and 5 FIGURE A 3 ALUMINUM WIRES CORED WIRES STEEL STAINLESS WIRES LOADING SPOOLS OF WIRE A WARNING Keep hands hair clothing and tools away from rotating equipment Do not wear gloves when threading wire or changing wire spool Only qualified personnel should install use or service this equipment Loading 10 to 15 lb 4 5 6 8kg Spools A K468 spindle adapt
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