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IM10092
February, 2011
LN-25™ PIPE
For use with machines having Code Number: 11779
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.
OPERATOR’SꢀMANUAL
Copyright © Lincoln Global Inc.
• 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 WEBꢀSITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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. I standards.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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.
5.e. 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.
5.f. Also see item 1.b.
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
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.
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. 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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. 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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. 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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. 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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. 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.
6.j. Do not use a welding power source for pipe thawing.
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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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 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 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.
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SAFETY
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
supply. 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.
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
1.
applications
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of 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.
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty 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 WEbꢀSITE 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 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.
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TAbLE OF CONTENTS
Page
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Location................................................................................................................................A-2
High Frequency Protection...................................................................................................A-2
Weld cable Sizes..................................................................................................................A-2
Analog Control Cable ...........................................................................................................A-3
Cable Connections and Control Cable Connector ...............................................................A-4
Shielding Gas Connection....................................................................................................A-4
Wire Drive Configuration ......................................................................................................A-5
Changing The Gun Receiver Bushing................................................................................A-5
Procedure to Install Drive Rolls and Wire Guides ..............................................................A-5
Pressure Arm Adjustment ....................................................................................................A-5
Loading Spools of Wire ........................................................................................................A-5
Gun Connections..................................................................................................................A-5
Power Source to LN-25™ PIPE Connection Diagrams..............................................A-6, A-7
________________________________________________________________________________
Operation.........................................................................................................................Section b
Safety Precautions ...............................................................................................................B-1
Graphic Symbols that appear on this Machine or in this Manual .........................................B-1
Definition of Welding Terms .................................................................................................B-2
General Description..............................................................................................................B-2
Recommended Processes, Equipment Limitations, Recommended Power Sources..........B-2
Case Front Controls ...............................................................................................B-3 thru B-6
Internal Controls...................................................................................................................B-7
Internal Controls Decription..................................................................................................B-8
Rear Controls .......................................................................................................................B-9
________________________________________________________________________________
Accessories ....................................................................................................................Section C
Factory Installed Equipment.................................................................................................C-1
Drive Roll Kits used..............................................................................................................C-1
Accessories Used ..................................................................................................C-2 thru C-4
________________________________________________________________________________
Maintenance....................................................................................................................Section D
Safety Precautions...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
________________________________________________________________________________
Troubleshooting .............................................................................................................Section E
How to Use Troubleshooting Guide .....................................................................................E-1
Error Codes..........................................................................................................................E-2
Troubleshooting Guide .................................................................................................E-3, E-4
________________________________________________________________________________
Wiring Diagram & Dimension Prints .............................................................................Section F
________________________________________________________________________________
Parts Pages ................................................................................................................P-679 Series
_______________________________________________________________________________
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A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – LN-25™ PIPE (K2614-10)
A-1
INPUT VOLTAGE and CURRENT
INPUT VOLTAGE ± 10%
INPUT AMPERES
40 VDC
4A
RATED OUTPUT @ 104°F (40°C)
DUTY CYCLE
INPUT AMPERES
60% rating
450
325
100% rating
GEARING - WIRE FEED SPEED RANGE-WIRE SIzE
GMAW
FCAW
GEARING
WIRE SIzES
WFS RANGE
WFS RANGE
WIRE SIzES
K2614-10
.023 – 1/16"
(0.6 – 1.6mm)
50 – 700 ipm
(1.3 – 17.7m/min)
50 – 700 ipm
(1.3 – 17.7m/min)
.030 - 5/64
(0.8 - 2.0mm)
PHYSICAL DIMENSIONS
WIDTH
HEIGHT
DEPTH
WEIGHT
14.8 Inches
(376 mm)
Handle folded down
8.7 Inches
( 221 mm)
22.2 Inches
(589 mm)
41 lbs
(18.6 kg)
TEMPERATURE RANGE
OPERATION:
STORAGE:
-40°F to 104°F (-40°C to 40°C)
-40°F to 185°F (-40°C to 85°C)
LN-25™ PIPE
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A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
The LN-25™ PIPE is rated IP23 and is suitable for
outdoor use.
WARNING
The handle of the LN-25™ PIPE is intended for
moving the wire feeder about the work place only.
ELECTRICꢀSHOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box
When suspending a wire feeder, insulate the
hanging device from the wire feeder enclosure.
before attempting to connect or
disconnect input power lines, out-
put cables or control cables.
• Only qualified personnel should
HIGH FREQUENCY PROTECTION
perform this installation.
CAUTION
• Do not touch metal portions of the LN-25™ PIPE
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.
Locate the LN-25™ PIPE away from radio con-
trolled machinery. The normal operation of the LN-
25™ PIPE may adversely affect the operation of RF
controlled equipment, which may result in bodily
injury or damage to the equipment.
------------------------------------------------------------------------
• Only use on power sources with open circuit
voltages less than 110 VDC.
WELD CAbLE SIzE
------------------------------------------------------------------------
LOCATION
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.
For best wire feeding performance, place the LN-
25™ PIPE 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™ PIPE.
TAbLE A.1
RECOMMENDED CAbLE SIzES (RUbbER COVERED COPPER - RATED 167°F or 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES PERCENT
DUTY
CYCLE
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
2
2
3
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
2
2
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
200
200
225
225
250
250
250
250
300
325
350
400
400
500
60
100
20
40 & 30
30
40
60
100
60
100
60
60
100
60
2
2
1
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).
LN-25™ PIPE
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A-3
A-3
INSTALLATION
SHIELDING GAS CONNECTION
CAbLE CONNECTIONS
WARNING
There is one circular connector for the gun trigger on
the front of the LN-25™ PIPE .
CYLINDER may explode if
damaged.
• Keep cylinder upright and
chained to support.
Function
Wiring
Pin
• 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.
5-pin trigger
connector for
push-guns
only.
5 volt supply
Not used
Trigger
83% WFS switch
5 volt supply
A
B
C
D
E
• bUILD UP OF SHIELDING GAS MAY
HARM HEALTH OR KILL.
• Shut off shielding gas supply when not
in use.
• See American National Standard z-49.1, "Safety
in Welding and Cutting” Published by the
American Welding Society.
C
B
A
------------------------------------------------------------------------
Maximum inlet pressure is 100 psi. (6.9 bar.)
E
D
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 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
2
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.
2
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™ PIPE
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A-4
A-4
INSTALLATION
WIRE DRIVE CONFIGURATION
(See Figure A.2)
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.
CHANGING THE GUN RECEIVER
bUSHING
WARNING
11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
Tools required:
• 1/4" hex key wrench.
WARNING
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
Note: Some gun bushings do not require the use of
the thumb screw.
• Only qualified personnel should perform mainte-
nance work.
1. Turn power off at the welding power source.
2. Remove the welding wire from the wire drive.
3. Remove the thumb screw from the wire drive.
4. Remove the welding gun from the wire drive.
5. Loosen the socket head cap screw that holds the
connector bar 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.
------------------------------------------------------------------------
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.
7. Disconnect the shielding gas hose from the gun
bushing, if required.
FIGURE A.2
THUMB SCREW
GUN RECEIVER BUSHING
5. Remove the inner wire guide.
OUTER WIRE GUIDE
6. 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.
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN
TIGHTEN
LN-25™ PIPE
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A-5
A-5
INSTALLATION
1. Squeeze the release bar on the retaining collar and
remove it from the spindle.
PRESSURE ARM ADJUSTMENT
WARNING
2. Place the spindle adapter on the spindle, aligning
the spindle brake pin with the hole in the adapter.
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.
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.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
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.
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.
Set the pressure arm as follows:
(See Figure A.3)
Aluminum wires
Cored wires
Steel, Stainless wires between 3 and 5
between 1 and 2
between 2 and 3
• 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.
FIGURE A.3
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
The LN-25™ PIPE comes with a K1500-2 gun
adapter installed. (See Figure A.4)
ALUMINUM WIRES
Al
Fe, CrNi
CORED WIRES
Fe, CrNi
STEEL, STAINLESS WIRES
6
To install a gun,
1. Turn power OFF.
2. Remove the thumb screw.
3. Push the gun the completely into the gun bushing.
4. Secure the gun in place with the thumb screw.
5. Connect the trigger cable from the gun to the trigger
connector on the front of the feeder.
LOADING SPOOLS OF WIRE
WARNING
• Keep hands, hair, clothing and tools
away from rotating equipment.
• Do not wear gloves when threading wire
or changing wire spool.
Note: Not all gun bushings require the use of the
thumb screw.
• Only qualified personnel should install,
use or service this equipment.
------------------------------------------------------------------------
Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.
FIGURE A.4
THUMB
SCREW
GUN
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.
LN-25™ PIPE
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A-6
A-6
INSTALLATION
POWER SOURCE TO LN-25™ PIPE
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
LN-25™ PIPE
Electrode
(Across the Arc)
SAE 400 with CV adapter
Engine Driven welder with
Work clip
Wire Feed Module
Ranger 250 GXT
Work
K#
Description
Place the power source Remote/Local switch in the
Local position.
K2614-10
KP1695-XX
KP1696-XX
LN-25™ PIPE
Drive Roll Kit
Place CV/CC switch in the feeder in the "CV" position.
KP1697-XX
See magnum Literature
Welding Gun
CV power Source
Welding Cables
K1803-1
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
Jumper
Ranger 3 Phase
Ranger 225GXT
Ranger 225
Commander 300
Vantage 300, 400, 500
Air Vantage 500
LN-25™ PIPE
Electrode
Work
Work clip
K#
Description
K2614-10
K484*
KP1695-XX
LN-25™ PIPE
Jumper Plug Kit
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CV power Source
Welding Cables
K1803-1
*If Power Source has a 14-Pin Cable connector and no
“Output Terminal” switch.
LN-25™ PIPE
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A-7
A-7
INSTALLATION
CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.8)
FIGURE A.8
LN-25™ PIPE
Electrode
CV-305
V350-Pro
Work clip
Work
K#
Description
Place CV/CC switch in the feeder in the "CV" position.
K2614-10
KP1695-XX
KP1696-XX
LN-25™ PIPE
Drive Roll Kit
KP1697-XX
See Magnum Literature
Welding Gun
CV power Source
Welding Cables
K1841
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.9)
FIGURE A.9
Jumper
CV-250
CV-300
LN-25™ PIPE
Electrode
Work clip
Work
K#
Description
Place CV/CC switch in the feeder in the "CV" position.
K2614-10
KP1695-XX
KP1696-XX
LN-25™ PIPE
Drive Roll Kit
KP1697-XX
See Magnum Literature
Welding Gun
CV power Source
Welding Cables
K1841-
K852-95
K484
Twist-Mate Cable Plug
Jumper Plug kit
LN-25™ PIPE
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b-1
b-1
OPERATION
GRAPHIC SYMbOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
bEFORE OPERATING MACHINE.
INPUT POWER
ON
WARNING
• 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.
---------------------------------------------------------------------
• FUMES AND GASSES can be
dangerous.
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
INPUT POWER
---------------------------------------------------------------------
• WELDING SPARKS can cause
fire or explosion.
DIRECT CURRENT
• Keep flammable material away.
OPEN CIRCUIT
VOLTAGE
U
0
---------------------------------------------------------------------
ARCꢀRAYS can burn.
• Wear eye, ear and body protec-
tion.
U
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
1
2
---------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MAN-
UAL.
U
---------------------------------------------------------------------
I
1
I
OUTPUT CURRENT
2
PROTECTIVE
GROUND
WARNING OR
CAUTION
LN-25™ PIPE
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b-2
b-2
OPERATION
General Functional Description
DEFINITION OF WELDING TERMS
The LN-25™ PIPE as designed is a simple, robust
feeder. Standard features include a calibrated wire
feed speed dial, 2 step/trigger interlock switch, Gas
Purge and Cold Feed.
WFS
• Wire Feed Speed
CC
• Constant Current
RECOMMENDED PROCESSES
• GMAW
• FCAW
CV
• Constant Voltage
PROCESS LIMITATIONS
GMAW
• Gas Metal Arc welding
• GMAW-P procedures must be qualified by the cus-
tomer.
SMAW
• Shielded Metal Arc welding
• Across-the-Arc models are not recommended for
stitch or spot welding.
FCAW
• Flux Core Arc Welding
EQUIPMENT LIMITATIONS
• The duty cycle of the wire feeder is 450A, 60%;
325A, 100%. Duty cycle is based upon the amount
of welding performed in a 10 minute period.
• The maximum spool size is 45 lb, 12" diameter.
• Maximum FCAW gun length is 15 ft.
GENERAL DESCRIPTION
General Physical Description
The LN-25™ PIPE is specially engineered to be the
most rugged portable wire feeder available and meets
the individual welder needs. This model includes a
gas solenoid for flexibility to run most wire processes.
• Maximum GMAW gun length is 25 ft.
• K2330-1 Timer Kits do not work with the feeder.
Use K2330-2 kits.
• Push-pull guns do not work with the wire feeder.
• The digital displays do not show preset voltage.
• Does not include an electrode cable.
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.
RECOMMENDED POWER SOURCES
The heart of the LN-25™ PIPE 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.
• CV-250
• CV-300
• CV-305
• CV-400
• CV-655
• DC-400
• DC-600
• DC-655
• Invertec V-350 PRO
• Invertec V-450 PRO
• Multi-Weld 350
• Ranger 10,000
• Ranger 3 Phase
• Ranger 225
• Ranger 225 GXT
• Ranger 250
• Ranger 250 GXT
• Ranger 305
• SAE-400
The LN-25™ PIPE has only two p.c. boards that are
designed to be simple, reliable and easy to service.
• Pipeliner 200G
• Classic 300
• Vantage 300
• Vantage 400
• Vantage 500
• Air Vantage 500
Big Red’s
Eagle 10,000 Plus
Classic’s
LN-25™ PIPE
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b-3
b-3
OPERATION
(See Customer Assistance Policy in the front of this
Instruction Manual)
WIRE FEED SPEED KNOb
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.
CASE FRONT CONTROLS (See Figure b.1)
FIGURE b.1
7
1
83% Wire Feed Speed
8
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.
2
9
10
The 83% trigger requires a gun with a dual procedure
switch.
3
This feature is often useful when welding pipe, and a
“cooler” procedure is required on the bottom portion.
4
5
CV OPERATION
Minimum Arc Volts
Maximum WFS
6
15 V
17 V
21 V
24 V
27 V
280
340
440
520
600
THERMAL LED, MOTOR
OVERLOAD
ITEM
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
Wire Feed Speed/Amperage Display
Wire Feed Speed LED
Amperage LED
The thermal light illuminates when the wire drive
motor draws too much current. If the thermal light illu-
minates, 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.
Wire Feed Speed Knob
5 pin gun trigger connector
Work Clip Connection
Thermal LED
Voltage Display
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.
Voltage LED
Set-up Push Button
LN-25™ PIPE
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b-4
b-4
OPERATION
POWER-UP SEQUENCE
SET-UP MENU
All of the LED’s will briefly illuminate during power-up.
If the gun trigger is activated during power up, the
feeder will not operate until the gun trigger is released.
Preparation for WFS Calibration:
• Place the CV/CC switch in CV.
• Set the display to the desired wire feed speed
(example: 400 inches per minute)
WIRE FEED SPEED/AMPERAGE DISPLAY
Idle
• Measure the actual wire feed speed (example: 405
inches per minute)
The left display shows the preset wire feed speed.
The right display shows OCV. The wire feed speed
LED is lit.
W
F
S
A
T
E
N
• Place the WFS knob in the 12 o’clock position.
WFS
A
V
E
R
TI S
S
E
M
E
N
T
Preparation for Amperage Calibration:
Connect the feeder to a power source and grid.
Adjust the power source and grid to the desired
amperage. (example: 220 Amps)
A
V
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 WFS, if welding at low voltages with
high wire feed speeds. The right display shows the arc
voltage. If the wire feeder is connected for electrode
negative welding, then the voltage display shows a
minus sign.
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.
A
V
A
M
P
S
V
O
T
E
T
BUTTON
VOLTAGE
AMPS
A
V
E
R
T IS
M
E
N
T
A
V
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.
LN-25™ PIPE
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b-5
b-5
OPERATION
WIRE FEED SPEED UNITS
To change the wire feed speed units:
WFS CALIbRATION WITH DIGITAL
METERS
Rotate the WFS knob to the left
to use “inches/minute” for the
wire feed speed units.
To calibrate the wire feed speed, before entering the
set-up menu. When first entering WFS Calibration,
the calibration factor displayed is based upon the
position of the knob and does not reflect the actual
calibration factor stored in memory.
US
O
O
V
A
LN-25™
PIPE, C
CC
O O WFS
Set the display to the desired wire feed speed
(example: 400 inches per minute)
Rotate the WFS knob to the
right to use “meters/minute”
for the wire feed speed units.
E
U
r
o
Measure the actual wire feed speed (example: 405
inches per minute)
O
O
V
A
LN-25™
PIPE, C
CC
Then rotate the WFS knob to
the 12 o’clock position.
While in the set-up menu, adjust the calibration factor
as follows:
O O WFS
Press the set-up button again to enter the Run-In
menu.
Actual WFS
Set WFS
405
400
=
Calibration Factor Example
=1.01
RUN-IN
Press the set-up button.
“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
LN-25™ PIPE
Run-in Wire Feed Speed
50 in/min
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 the
left to turn Run-In OFF.
u n
r
FF
O
O
O
V
A
LN-25™
PIPE,
CCC
O O WFS
Rotate the WFS knob to the
right to turn Run-In ON.
u n
n
r
O
O
O
V
A
LN-25™
PIPE, C
CC
Then rotate the WFS knob to
the 12 o’clock position.
O O WFS
Press the set-up button again to enter the WFS cali-
bration menu.
LN-25™ PIPE
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b-6
b-6
OPERATION
LEFT DISPLAY SELECTION
AMPERAGE CALIbRATION
The left display can show either amperage or actual
WFS during welding. Note that actual WFS 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
ipm.
Measurements for adjusting the Amperage calibration
must be made before entering the set-up menu.
When first entering Amperage Calibration, the calibra-
tion factor displayed is the value in memory. If the
knob is rotated, the calibration factor changes based
upon the position of the knob.
To change the left display reading:
If no changes are being made to the calibration, then
press the set-up button to enter Display Hold.
Rotate the WFS knob to the left to display amperage
(current).
While in the set-up menu, adjust the calibration factor
as follows:
Rotate the WFS knob to the right to display actual
WFS.
Power Source Amperage
Feeder Amperage
220
210
=
1.01
=Calibration Factor Example:
Then rotate the knob to the 12 o’clock position.
Press the set-up button.
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.
I
SP
FEEd
I
SP
c u
r
d
d
r
O
O
V
O
O
A
V
A
LN-25
™ PIP
E, CC
C
LN-25
™ PIP
E, CC
C
DISPLAY HOLD
After welding, the LN-25 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 acti-
vated.
O O WFS
O O 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 Display Hold time:
Rotate the WFS knob to the left for 5 seconds Hold.
To change the WFS knob range:
Rotate the WFS knob to the right for 300 seconds
Hold
Rotate the WFS knob to the left for the low wire feed
speed range of 40 – 405 ipm
Press the set-up button to exit the set-up menu.
Rotate the WFS knob to the right for the high wire
feed speed range of 40 – 715 ipm.
d
SP
O
H I
d
P
I o
S
O
O
O
V
A
V
A
LN-25
™ PIP
LN-25
™ PIP
E, CC
E, CC
C
C
O O WFS
O O WFS
Then rotate the knob to the 12 o’clock position.
Press the set-up button.
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b-7
b-7
OPERATION
INTERNAL CONTROLS
FIGURE b.2
1
I
e
F
e
u
e
t
I
8
7
9
10
1
6
1
2
3
4
5
4
5
3
2
1
6
7
10
11
9
8
ITEM
DESCRIPTION
1
2
3
2 Step Trigger Interlock Switch
Pressure Adjustment Arm
Optional Timer Kit (See Accessories Section)
4
5
6
7
8
Spool Retainer
Spindle Brake
Gun Bushing
Thumb Screw for securing the welding Gun
Socket Head Cap Screw for securing the Gun Bushing
Drive Hubs
9
10
11
Inlet Wire Guide
Cold Feed Pushbutton
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b-8
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 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.
COLD FEED PUSHbUTTON
(See Figure B.2)
When cold feeding, the wire
drive will feed electrode but nei-
ther the power source nor the
gas solenoid will be energized.
Adjust the speed of cold feed-
ing by rotating the WFS knob.
Cold feeding, or "cold inching"
the electrode is useful for
threading the electrode through
the gun.
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b-9
b-9
OPERATION
REAR CONTROLS:
I
3
2
1
1
2
3
ITEM
DESCRIPTION
1
2
3
Gas Purge Pushbutton
Shielding Gas Inlet
Electrode Lead
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.
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C-1
C-1
ACCESSORIES
FACTORY INSTALLED EQUIPMENT
• K1500-2 Gun Receiver Bushing.
DRIVE ROLL KITS (See Parts Pages)
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
K1842-xx
K484
Weld Power Cable, Twist-Mate to
Lug.
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).
Weld Power Cable, Lug to Lug.
Jumper Plug Kit.
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.
Timer Kit
Includes: Panel and harness
for adjusting preflow, burnback
and postflow times
K2330-2
K2596-2
Plastic Case
Includes: a complete engi-
neered plastic case.
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C-2
C-2
ACCESSORIES
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
with K466-1 Lincoln gun connec-
tors; Innershield and Subarc guns)
Includes: Gun receiver bush-
ing, set screw and hex key
wrench.
K1500-1
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
K1500-2
guns and compatible with Tweco®
#2-#4)
and hex key wrench.
Gun Receiver Bushing (for guns Includes: Gun receiver bush-
with K613-7 Lincoln gun connec- ing with hose nipple, set screw
K1500-3
tors; Magnum 550 guns and com-
patible with Tweco® #5)
and hex key wrench.
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C-3
C-3
ACCESSORIES
Gun Receiver Bushing (for gun Includes: Gun receiver bush-
with K466-3 Lincoln gun connec- ing with hose nipple, set screw
K1500-4
K1500-5
tors; compatible with Miller® 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.
K435
K468
Spindle Adapter, for mounting 14 Includes: Spindle Adapter made
lb. (6.4 kg) Innershield Coils on 2
in (51 mm) spindles.
from 2 coil retainers. (Electrode
not included.)
Spindle Adapter, for mounting 8in
(203mm) diameter spools on 2 in
(51 mm) spindles.
Includes: 2 Spindle Adapters,
one for 2" wide spools and the
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)
K590-6
Includes: Deluxe Gas Regulator
for Mixed Gases, Adapter for
CO2 and 10' (3.0m) Hose.
K586-1
K283
Deluxe Adjustable Gas Regulator
Wire Feed Speed Meter
Includes: A wire feed speed
meter with digital display.
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
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.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance 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.
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E-1
E-1
TROUbLESHOOTING
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 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.
Step 1. LOCATE PROBLEMꢀ(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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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.
• Only qualified personnel should perform maintenance work.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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E-2
E-2
TROUbLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAUSE
RECOMMENDED
COURSE OF ACTION
ERROR CODES
1. Check that the electrode slides
easily through the gun and cable.
2. Remove tight bends from the gun
and cable.
Err 81 Motor overload, long term.
1. The wire drive motor has over-
heated.
3. Check that the spindle brake is
not too tight.
4. Verify a high quality electrode is
being used.
5. Wait for the error to reset and the
motor to cool (approximately 1
minute).
1. Check that motor can turn freely
when idle arm is open.
2. Verify that the gears are free of
debris and dirt.
Err 82 Motor overload, short term. 1. The wire drive motor current draw
has exceeded limits, usually
because the motor is in a locked
rotor state.
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.
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E-3
E-3
TROUbLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Output Problems
The feeder does power up - no dis- 1. The work sense lead is discon-
1. Connect the work sense lead to
the work in a location free of dirt,
rust and paint.
2. Turn ON the power source.
3. Reset the circuit breakers.
play, no cold feed.
nected or is a poor electrical con-
nection. (Across the arc models)
2. The power source is OFF.
3. The circuit breaker for the wire
feeder on power source have
tripped. (control cable models)
4. The control cable may be loose or
damaged. (control cable models)
4. Tighten, repair or replace the con-
trol cable.
The wire feeder power up but there 1. The contactor coil connections are
is no output when the trigger is loose.
pulled. The shielding gas is flowing 2. The contactor has failed.
and the drive rolls turn.
1. Verify the contactor coil connec-
tions.
2. Replace the contactor.
No shielding gas.
1. The gas supply is OFF or empty.
2. The gas hose is cut or crushed.
1. Verify the gas supply is ON and
flowing.
2. Route the gas hose so it avoids
sharp corners and make sure
nothing is on top of it. Repair or
replace damaged hoses.
3. The flow meter valve is closed.
4. Dirt or debris is in the solenoid.
3. Open the flow meter valve.
4. Apply filtered shop at 80psi to the
solenoid to remove dirt.
5. There is a loose solenoid connec-
tion.
5. Remove the cover and check that
all connections are in good condi-
tion.
6. The solenoid has failed.
Inconsistent wire feeding or wire not 1. The gun cable is kinked and/or
feeding but drive rolls turning.
1. Keep the gun cable as straight as
possible. Avoid sharp corners or
bends in the cable.
twisted.
2. The wire is jammed in the gun and
cable.
2. Remove the gun from the wire
feeder and pull the jammed wire
out of the gun and cable.
3. The gun liner is dirty or worn.
4. The electrode is rusty or dirty.
3. Blow dirt out of the liner with low
pressure (40psi or less). Replace
the liner if worn.
4. Use only clean electrode. Use
quality electrode, like L-50 or L-56
from Lincoln Electric.
5. The contact tip is partially melted
or has spatter.
5. Replace the contact tip.
6. Improper gun liner, tip, drive rolls
and/or inner wire guide.
6. 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.
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E-4
E-4
TROUbLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Output Problems
7. Incorrect tension arm pressure on 7. Adjust the tension arm per the
the drive rolls.
Instruction Manual. Most elec-
trodes feed well at a tension arm
setting of "3".
8. The spindle brake is too tight.
9. Worn drive roll.
8. Verify the spool of wire moves
with minimal effort.
9. Replace the drive rolls if worn or
filled with dirt.
Wire feed speed consistently oper-
ates at the wrong value. The speed
changes when the wire feed speed
knob is adjusted.
1. The jumper lead for normal 1. Properly connect the normal
speed/extra torque is connected
improperly.
2. The wrong gear is installed in the the wire drive.
speed/extra torque jumper.
2. Install the proper pinion gear in
wire drive.
3. Replace the motor/gearbox
3. The brushes on the motor are assembly.
worn.
The wire feed speed stuck at 200-
300 in/min and there is no change
when the wire feed speed knob is
adjusted.
1. The tachometer is connected 1. Verify all of the tachometer leads
improperly.
2. The tachometer has failed.
are properly connected.
2. Replace the motor and tachome-
ter assembly.
Variable or "hunting" arc.
1. Wrong size, worn and/or melted 1. Replace the contact tip.
contact tip.
2. Worn work cable or poor work 2. Verify all work and electrode con-
connection.
nections are tight and that the
cables are in good condition.
Clean/replace as necessary.
3. Adjust polarity to the recommend-
ed procedure.
3. Wrong polarity.
4. The gas nozzle is extended 4. Adjust the gas nozzle and shorten
beyond the contact tip or the wire the stickout to 3/8 to 1/2 inches.
stickout is too long.
5. Poor gas shielding on processes 5. Check gas flow and mixture.
requiring gas.
Remove or block sources of
drafts.
When the trigger is pulled, the wire
feeds slowly.
The Run-In switch is “ON”
Use the set-up Push-button to turn
Run-in OFF.
Poor arc starts with sticking or
"blast-offs", weld porosity, narrow
and ropy looking bead.
1. Improper procedures or tech- 1. See "Gas Metal Arc Welding
niques. 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.
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F-1
F-1
DIAGRAMS
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F-2
F-2
DIMENSION PRINT
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•
•
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
•
•
Keep flammable materials away.
•
•
Wear eye, ear and body protection.
WARNING
Spanish
•
No toque las partes o los electrodos
bajo carga con la piel o ropa moja-
da.
Mantenga el material combustible
fuera del área de trabajo.
Protéjase los ojos, los oídos y el
cuerpo.
AVISO DE
PRECAUCION
French
•
•
Aislese del trabajo y de la tierra.
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
Isolez-vous du travail et de la terre.
•
•
Gardez à l’écart de tout matériel
inflammable.
•
•
Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
•
•
German
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Entfernen Sie brennbarres Material!
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
•
Elektroden und dem Erdboden!
Portuguese
•
•
Não toque partes elétricas e electro-
dos com a pele ou roupa molhada.
Isole-se da peça e terra.
•
Mantenha inflamáveis bem guarda-
dos.
•
Use proteção para a vista, ouvido e
corpo.
ATENÇÃO
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOWYOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEERY ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPOY 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
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•
•
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
•
•
Turn power off before servicing.
•
•
Do not operate with panel open or
guards off.
WARNING
Spanish
•
•
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
•
•
Débranchez le courant avant l’entre-
tien.
•
•
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
•
•
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ATTENTION
German
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
•
•
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
•
•
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
•
•
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
•
•
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
•
Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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 WEBꢀSITE: www.lincolnelectric.com
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