IM939-A
March, 2008
LN-25 PRO EXTREME
For use with machines having Code Numbers:
11389, 11523
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OPERATOR’S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
1-800-245-3660
North America’s Largest Fleet of Welding Equipment
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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
• AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
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 manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
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SAFETY
WELDING SPARKS can
CYLINDER may explode
if damaged.
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
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.
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.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
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.
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.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.I. Read and folllow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
Jan, 07
6.j. Do not use a welding power source for pipe thawing.
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SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
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:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
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 dʼincendie.
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler 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.
d.Ne jamais plonger le porte-électrode dans lʼeau 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.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
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.
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 nʼimporte quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
LN-25 PRO EXTREME
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for selecting a QUALITY product. We want you to take pride in
operating this 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 customerʼs 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 WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where 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
Cable Connections...............................................................................................................A-3
Shielding Gas Connection....................................................................................................A-3
Wire Drive Configuration ......................................................................................................A-4
Changing The Gun Receiver Bushing................................................................................A-4
Procedure to Install Drive Rolls and Wire Guides ..............................................................A-4
Pressure Arm Adjustment ....................................................................................................A-5
Loading Spools of Wire ........................................................................................................A-5
Gun Connections..................................................................................................................A-5
Power Source to LN25 PRO EXTREME Cable Connection Diagrams ..................A-6 thru A-8
________________________________________________________________________________
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-5
Internal Controls...................................................................................................................B-6
Internal Controls Decription..................................................................................................B-7
Constant Current Wire Welding............................................................................................B-8
Rear Controls .......................................................................................................................B-9
Gas Purge Pushbutton.........................................................................................................B-9
Power-Up Sequence ............................................................................................................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
Calibration Specification................................................................................................D-1,D-2
________________________________________________________________________________
Troubleshooting .............................................................................................................Section E
How to Use Troubleshooting Guide .....................................................................................E-1
Digital Display Models Error Codes......................................................................................E-2
Troubleshooting Guide .................................................................................................E-3, E-4
________________________________________________________________________________
Wiring Diagram & Dimension Prints .............................................................................Section F
________________________________________________________________________________
Parts Pages ................................................................................................................P-562 Series
_______________________________________________________________________________
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – LN25 PRO (K2613-3)
INPUT VOLTAGE and CURRENT
INPUT VOLTAGE 10%
INPUT AMPERES
15-110 VDC
4A
RATED OUTPUT @ 104°F (40°C)
DUTY CYCLE
INPUT AMPERES
60% rating
100% rating
450
325
GEARING - WIRE FEED SPEED RANGE-WIRE SIZE
GMAW
FCAW
GEARING
WFS RANGE
WIRE SIZES
WFS RANGE
WIRE SIZES
Normal Speed
50 – 700 ipm
.023 – 1/16"
50 – 700 ipm
.030 - 5/64
(1.3 – 17.7m/min) (0.6 – 1.6mm)
(1.3 – 17.7m/min)
(0.8 - 2.0mm)
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
14.8 Inches
(376 mm)
8.7 Inches
( 221 mm)
22.2 Inches
(589 mm)
36 lbs
(16 kg)
Handle folded down
TEMPERATURE RANGE
OPERATION:
STORAGE:
-40°F to 104°F (-40°C to 40°C)
-40°F to 185°F (-40°C to 85°C)
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A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
The LN25 PRO EXTREME is rated IP23 and is
suitable for outdoor use.
WARNING
The handle of the LN25 PRO EXTREME is intended
for moving the wire feeder about the work place
only.
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box
before attempting to connect or
When suspending a wire feeder, insulate the
hanging device from the wire feeder enclosure.
disconnect input power lines, out-
put cables or control cables.
• Only qualified personnel should
perform this installation.
CAUTION
• Do not touch metal portions of the LN25 PRO
EXTREME work clip when the welding power
source is on.
HIGH FREQUENCY PROTECTION
• 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 LN25 PRO EXTREME away from radio
controlled machinery. The normal operation of the
LN25 PRO EXTREME may adversely affect the oper-
ation of RF controlled equipment, which may result
in bodily injury or damage to the 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 LN25
PRO EXTREME on a stable and dry surface. Keep
the wire feeder in a vertical position. Do not operate
the wire feeder on an angled surface of more than
15 degrees.
Do not submerge the LN25 PRO EXTREME.
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
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)
DUTY
CYCLE
2
2
2
2
200
200
225
225
250
250
250
250
300
325
350
400
400
500
60
100
20
2
2
1
1
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
3
2
4 or 5
3
1
3
2
40 & 30
30
1
3
2
3
1
2
1
40
2
1
1
1
60
1
1
1
1
100
60
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
2/0
1/0
2/0
3/0
2/0
2/0
2/0
2/0
3/0
3/0
100
60
2/0
1/0
2/0
3/0
2/0
60
100
60
** 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).
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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 LN25 PRO EXTREME.
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.
5-pin trigger
connector for
push-guns
only.
Trigger
Not used
Common
Not used
Not used
A
B
C
D
E
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live
electrical circuits.
• 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
------------------------------------------------------------------------
Maximum inlet pressure is 100 psi. (6.9 bar.)
E
A
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.
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A-4
A-4
INSTALLATION
WIRE DRIVE CONFIGURATION
8. Connect the shielding gas hose to the new gun
bushing, if required.
(See Figure A.2)
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.
WARNING
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
Tools required:
• 1/4" hex key wrench.
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
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A-5
A-5
INSTALLATION
1. Squeeze the release bar on the retaining collar and
PRESSURE ARM ADJUSTMENT
remove it from the spindle.
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-
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.
ing power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
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.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
GUN CONNECTION
------------------------------------------------------------------------
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.
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
between 1 and 3
between 3 and 4
• 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.
Steel, Stainless wires between 4 and 6
FIGURE A.3
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
The LN25 PRO EXTREME comes with a K1500-2 gun
adapter installed. (See Figure A.4)
ALUMINUM WIRES
Al
CORED WIRES
Fe, CrNi
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.
FIGURE A.4
• Only qualified personnel should install,
use or service this equipment.
------------------------------------------------------------------------
Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.
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.
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A-6
A-6
INSTALLATION
POWER SOURCE TO LN25 PRO EXTREME
CABLE CONNECTION DIAGRAMS
ACROSS THE ARC SET-UPS
CC Power Sources with Output Terminals Always
Hot (See Figure A.5)
FIGURE A.5
K#
Description
If the power source has a Remote/Local switch, place
the switch in the Local position.
K2613-3
KP1695-XX
LN25 PRO EXTREME
Drive Roll Kit
Place the CV/CC switch in the feeder in the "CC" posi-
tion.
KP1696-XX
KP1697-XX
See Magnum Literature
Welding Gun
CC power Source
Welding Cables
K1803-1
CV Power Sources with Stud Connectors and
Remote/Local Switch (See Figure A.6)
FIGURE A.6
K#
Description
LN25 PRO EXTREME
Drive Roll Kit
Place the power source Remote/Local switch in the
Local position.
K2613-3
KP1695-XX
KP1696-XX
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
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A-7
A-7
INSTALLATION
CV Power Sources with Stud Connectors and no
Remote/Local Switch. (See Figure A.7)
FIGURE A.7
K#
Description
Place CV/CC switch in the feeder in the "CV" position.
K2613-3
KP484
LN25 PRO EXTREME
Jumper Plug Kit
KP1695-XX
KP1696-XX
Drive Roll Kit
KP1697-XX
See Magnum Literature
Welding Gun
CC power Source
Welding Cables
K1803-1
CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.8)
FIGURE A.8
K#
Description
LN25 PRO EXTREME
Drive Roll Kit
Place CV/CC switch in the feeder in the "CV" position.
K2613-3
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum Literature
Welding Gun
CC power Source
Welding Cables
K1841
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A-8
A-8
INSTALLATION
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.9)
FIGURE A.9
Place CV/CC switch in the feeder in the "CV" position.
K#
Description
LN25 PRO EXTREME
Drive Roll Kit
K2613-3
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum Literature
Welding Gun
CV power Source
Welding Cables
Jumper Plug kit
K1841
K484
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B-1
B-1
OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
THIS MACHINE OR IN THIS MANUAL
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.
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
• 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.
• 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
U
0
----------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear and body protec-
tion.
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
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B-2
B-2
OPERATION
RECOMMENDED PROCESSES
DEFINITION OF WELDING TERMS
• GMAW
• FCAW
WFS
• Wire Feed Speed
PROCESS LIMITATIONS
CC
• Constant Current
• GMAW-P procedures must be qualified by the cus-
tomer.
CV
• Across-the-Arc models are not recommended for
stitch or spot welding.
• Constant Voltage
GMAW
EQUIPMENT LIMITATIONS
• Gas Metal Arc welding
• The duty cycle of the wire feeder is 325A, 100% and
450A, 60%. Duty cycle is based upon the amount of
welding performed in a 10 minute period.
SMAW
• Shielded Metal Arc welding
• The maximum spool size is 45 lb, 12" diameter.
• Maximum FCAW gun length is 15 ft.
FCAW
• Maximum GMAW gun length is 25 ft.
• Flux Core Arc Welding
• Push-pull guns do not work with the wire feeder.
GENERAL DESCRIPTION
RECOMMENDED POWER SOURCES
General Physical Description
• Ranger 3 Phase
• Ranger GXT
• Ranger 250
• Ranger 305
• SAE-400
• CV-305
The LN25 PRO EXTREME is specially engineered to
be the most rugged portable wire feeder available.
• CV-400
• CV-655
• DC-400
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.
• DC-600
• Pipeliner 200G
• Classic 300
• Vantage 300
• Vantage 400
• Vantage 500
• DC-655
• Invertec V-350 PRO
• Invertec V-450 PRO
• Multi-Weld 350
• Ranger 10,000
The heart of the LN25 PRO EXTREME is the 2 roll
MAXTRAC™ drive. The patented features on the wire
drive offer tool-less changing of the drive rolls and
wire guides for quick spool changes. A tachometer
controlled motor powers the patent pending drive rolls
for smooth, steady feeding without slippage.
With only one p.c. board, the LN25 PRO EXTREME is
designed to be simple, reliable and easy to service.
The p.c. board is mounted with Lincolnʼs leading envi-
ronmental design protection by mounting the board in
a plastic tray and potting it with epoxy.
General Functional Description
The LN25 PRO EXTREME as designed is a simple,
robust feeder. Standard features include a calibrated
wire feed speed dial, CV-CC switch, Gas Purge and
Cold Feed.
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B-3
B-3
OPERATION
(See Customer Assistance Policy in the front of this
Instruction Manual)
CASE FRONT CONTROLS (See Figure B.1)
FIGURE B.1
1
5
6
2
3
4
ITEM
DESCRIPTION
1
2
3
4
5
6
Analog Voltmeter
Wire Feed Speed Knob
5-pin gun trigger connector
Work sense lead
Thermal LED, MOTOR OVERLOAD
Polarity LED
1. ANALOG VOLTMETER
The analog voltmeter shows the voltage between
electrode and work. On across the arc models, the
voltmeter shows open circuit voltage when the wire
feeder is not welding. The voltmeter is polarity
insensitive and the range is 0 – 40VDC.
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B-4
B-4
OPERATION
Wire Feed Speed, CC Operation
2. WIRE FEED SPEED KNOB
The large, calibrated wire feed speed knob makes
for easy and accurate adjustment of the wire feed
speed. The knob rotates 3/4 turn. Turn the knob
clockwise to increase the wire feed speed, and
counter clockwise to reduce the wire feed speed.
When Across the Arc models are operated with CC
power sources, the wire feed speed changes as the
arc voltage changes. When the arc voltage increases,
the wire feed speed will increase; and when the arc
voltage decreases, the wire feed speed will decrease.
Models with analog voltmeters have a calibrated
scale printed around the wire feed speed knob
using "in/min" units. A separate decal with "m/min"
units is included with these models wire feeder.
To preset the wire feed speed on CC power sources:
1. Set the Wire Feed Mode switch inside the LN25
PRO EXTREME to "CC".
Models with digital displays show the wire feed
speed on the display.
2. Refer to the Figure B.1a graph for the setting for
the wire feed speed knob setting. Select the hori-
zontal line representing the Desired Wire Feed
Speed. (See Figure B.1a arrow for 375 in/min.)
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.
3. Select the diagonal line representing the Arc
Volts. (See Figure B.1a for 29 volts.)
4. Determine the vertical line representing the CC
representing the CC Wire Feed Speed setting
where the above two lines cross. (See Figure
B.1a arrow line for 450.) Set the LN25 PRO
EXTREME wire feed speed knob to this value.
CV Operation
Maximum WFS
Minimum Arc Volts
280
340
440
520
600
15 V
17 V
21 V
24 V
27 V
CC WFS dial setting = desired WFS x 35
Arc Volts
(See Figure B.1a)
FIGURE B.1a
35
700
650
600
550
500
450
400
350
300
250
200
150
100
50
33 V
31
29
27
25
23
21
19
17
15
50 100 150 200 250 300 350 400 450 500 550 600 650 700
CC
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B-5
B-5
OPERATION
3. 5-PIN GUN TRIGGER CONNECTOR
4. WORK SENSE LEAD
5. THERMAL LED, MOTOR OVERLOAD
The thermal light illuminates when the
wire drive motor draws too much current.
If the thermal light illuminates, the wire
drive will automatically shutdown for up to
30 seconds to allow the motor to cool. To
start welding again, release the gun trigger, inspect
the gun cable, liner (and conduit). Clean and make
repairs as necessary. Start welding again when the
problem has been safely resolved.
For best results, keep the gun cable and conduit as
straight as possible. Perform regular maintenance
and cleaning on the gun liner, conduit and gun.
Always use quality electrode, such as L-50 or L-56
from Lincoln Electric.
6. POLARITY LED
The Polarity LED
lights when the wire
+ POLARITY
POLARDAD
- POLARITÉ
feeder is connected
for positive polarity.
Use the polarity
LED to verify the
wire feeder is connected for the proper polarity.
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B-6
B-6
OPERATION
INTERNAL CONTROLS
FIGURE B.2
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B-7
B-7
OPERATION
CV/CC SWITCH
(See Figure B.2)
The CV/CC switch sets the wire
feed speed control method for the
wire feeder.
CC
CV
In the CV position, the wire feed
speed remains constant during
welding. A steady arc voltage is
regulated by the power source by
adjusting the arc current.
In the CC position, the wire feed
speed varies during welding. The
arc length is maintained by chang-
ing the wire feed speed.
COLD FEED PUSHBUTTON
(See Figure B.2)
When cold feeding, the wire
drive will feed electrode but nei-
ther the power source nor the
gas solenoid will be energized.
Adjust the speed of cold feed-
ing by rotating the WFS knob.
Cold feeding, or "cold inching"
the electrode is useful for
threading the electrode through
the gun.
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B-8
B-8
OPERATION
CONSTANT CURRENT WIRE WELDING
If the contact tip to work distance is properly main-
tained, a satisfactory operating voltage range may be
achieved, and a sound weld may result. However,
when a welder uses a longer contact tip to work dis-
tance, an arc-sensing wire feeder compensates by
increasing the wire feed speed to regulate the voltage.
Even if the voltage and current remain unchanged, the
increased wire feed speed may result in a deposition
rate well beyond the specified range of the electrode.
Under these conditions, the specified weld metal prop-
erties may not be achieved.
(See Figure B.3)
Most semiautomatic welding processes perform better
using constant voltage power sources.
Welding codes usually do not address the power
source selection or specifically, whether the welding
process is to be operated in the constant voltage or
constant current mode. Instead, codes typically speci-
fy limitations on the current, voltage, heat input and
preheat temperature based on the material to be
welded. The intention is to assure that proper weld
material properties will develop.
Constant voltage power sources deliver large current
surges to stabilize the arc when the electrode is short-
ed or the arc length is very short. However, a constant
current power source does not provide such a
response to stabilize the arc. It may be difficult to
achieve required weld metal properties, or to achieve
the required quality of welds needed to pass nonde-
structive tests, when such welds are made under con-
stant current operation.
Welding is sometimes performed using constant cur-
rent power sources. The operation can be more con-
venient because it may allow the use of an existing
stick (SMAW) power source and the power source
can be placed at a distant location without any provi-
sion for adjusting the output settings.
For constant current operation, the power source is
set to deliver the specified current. The power source
regulates this current regardless of changes in the
welding circuit, including cable length, electrode diam-
eter, wire feed speed, contact tip to work distance,
etc.
For these reasons, Lincoln Electric does NOT recom-
mend constant current semiautomatic welding for
applications which need to meet specified weld metal
chemical or mechanical property requirements or weld
quality requirements.
Changes in the wire feed speed (WFS) or contact tip
to work distance (CTWD) affect the arc voltage when
constant current power sources are used. Lowering
the wire feed speed raises the voltage, raising the
wire feed speed lowers the voltage. Lengthening the
contact tip to work distance raises the voltage, short-
ening the contact tip to work distance lowers the volt-
age.
FIGURE B-3
Current
Current
Wire
+
-
Feeder
CTWD
WFS
Constant Current
Power Source
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B-9
B-9
OPERATION
REAR CONTROLS:
GAS PURGE PUSHBUTTON
The gas solenoid valve will energize but neither the
power source output nor the drive motor will be turned
on. The Gas Purge switch is useful for setting the
proper flow rate of shielding gas. Flow meters should
always be adjusted while the shielding gas is flowing.
POWER-UP SEQUENCE
For feeders with analog voltmeters, the thermal LED
will briefly light during power-up.
If the gun trigger is activated during power up, the
feeder will not operate until the gun trigger is released.
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C-1
C-1
ACCESSORIES
FACTORY INSTALLED EQUIPMENT
• K1500-2 Gun Receiver Bushing.
DRIVE ROLL KITS
KP KIT
WIRE TYPE
ELECTRODE SIZE
.023-.030 (0.6-0.8mm)
.035 (0.9mm)
KP1696-030S
KP1696-035S
KP1696-045S
KP1696-052S
Steel Wires:
Includes: 2 V groove
drive rolls and inner
.045 (1.2mm)
.052 (1.4mm)
1/16 (1.6mm)
KP1696-1/16S wire guide.
KP1696-1
.035,.045 (0.9, 1.2mm)
.040 (1.0mm)
KP1696-2
.030-.035" (0.8-0.9mm) KP1697-035C
.040-.045" (1.0-1.2mm)
.052" (1.4mm)
KP1697-045C
KP1697-052C
KP1697-1/16C
KP1697-068
Cored Wires:
Includes: 2 Knurled
drive rolls and inner
wire guide.
1/16" (1.6mm)
.068-.072" (1.7-1.8mm)
5/64" (2.0mm)
KP1697-5/64
KP1697-3/32
KP1695-035A
KP1695-040A
KP1695-3/64A
KP1695-1/16A
3/32” (2.4mm)
.035" (0.9 mm)
.040" (1.0mm)
Includes: 2 polished
U groove drive rolls,
outer wire guide and
inner wire guide.
Aluminum Wires:
3/64" (1.2mm)
1/16" (1.6mm)
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C-2
C-2
ACCESSORIES
Includes: 1/0 Coaxial weld
cable of length "xx". Ends of
the weld cable have lug con-
nections. Use for Pulse weld-
ing.
K1796-xx
AWG 1/0 Co-Axial Power Cable
AWG #1 Coaxial Power Cable
Work and Feeder Cables Package
Includes: AWG #1 Coaxial
weld cable of length "xx".
Ends of the weld cable have
lug connections. Use for
Pulse or STT™ welding.
K2593-xx
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.
K1803-1
K1840-xx
Weld Power Cable, Twist-Mate to
Lug
Includes: Twist-Mate to Lug,
1/0 cable of length "xx".
IIncludes: 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).
K1842-xx
Weld Power Cable, Lug to Lug
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C-3
C-3
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
K1500-3
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
tors; Magnum 550 guns and com-
patible with Tweco® #5)
and hex key wrench.
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C-4
C-4
ACCESSORIES
Gun Receiver Bushing (for gun
Includes: Gun receiver bush-
K1500-4
K1500-5
K489-7
with K466-3 Lincoln gun connec- ing with hose nipple, set screw
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.
Gun Receiver Bushing (for Lincoln Includes: Gun receiver bushing
Fast-Mate guns.) with trigger connector.
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: Deluxe Gas Regulator
for Mixed Gases, Adapter for
CO2 and 10' (3.0m) Hose.
K586-1
Deluxe Adjustable Gas Regulator
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
4. Turn power ON.
5. Energize the output circuit of the power source.
Adjust the power source output to 20 1 VDC as
measured on the reference meter.
ELECTRIC SHOCK can kill.
• Do not operate with covers
removed.
6. Verify that LN25 PRO EXTREME voltmeter reads
between 19 and 21 volts.
• Turn off power source before
installing or servicing.
• Do not touch electrically hot
parts.
If the voltmeter reading is out of range, check for
loose connections or replace the voltmeter. There is
no calibration adjustment for the LN25 PRO
EXTREME voltmeter.
• Turn the input power to the welding power
source off at the fuse box before working in the
terminal strip.
• Only qualified personnel should install, use or
service this equipment.
----------------------------------------------------------------------
ROUTINE MAINTENANCE
• Check weld cables, control cables and gas hoses
for cuts.
• Clean and tighten all weld terminals.
PERIODIC MAINTENANCE
• Clean drive rolls and inner wire guide and replace if
worn.
• Blow out or vacuum the inside of the feeder.
CALIBRATION SPECIFICATION
The voltmeter and flow meter are not calibrated and
are for reference purposes only.
Voltmeter Validation, Across the Arc Analog Meter
Models
Tools required:
• DC voltmeter reference standard
• Constant voltage DC welding power source with
adjustable no-load voltage (DC-400, V-350, CV-400
or equivalent).
To verify the analog voltmeter accuracy:
1. Turn power OFF.
2. Connect the LN25 PRO EXTREME to the constant
voltage DC welding power source. The work lead
of the LN25 PRO EXTREME must be connected to
the work terminal of the power source.
3. Connect the reference voltmeter between the
brass block of the LN25 PRO EXTREME and the
work lead.
LN-25 PRO EXTREME
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D-2
D-2
MAINTENANCE
Wire Feed Speed Validation
To change the wire feed speed calibration:
(See Figure D.1)
(See Figure D.2)
Tools required:
Calibration of the LN25 PRO EXTREME may be required
when the p.c. board, wire feed speed potentiometer or
motor is replaced or serviced. Calibration matches the
scale on the name plate to the actual wire feed speed.
• 5/16" nut driver
• RPM meter
• Shorting plug. The shorting plug shorts pins 1 & 5 of
connector J2 on the p.c. board. J2 is a 6 pin molex
connector.
Tools required:
• RPM meter
• Constant voltage DC welding power source (DC-400,
V-350, CV-400 or equivalent)
• 7/16" open end wrench
1. Turn power OFF.
2. Remove the 4 screws holding the rear cover inside
the feeder and remove the cover.
To verify if calibration is necessary:
1. Turn power OFF.
3. Open the idle arm.
4. Set the wire feed speed per the table.
2. Set the wire feed speed per the table.
Model gearing Wire Feed Speed Acceptable Range
Model gearing Wire Feed Speed
Normal Speed 400 in/min
Normal Speed 400 in/min
69 - 77 rpm
5. Connect the LN25 PRO EXTREME to the constant
voltage DC welding power source. The work lead of
the LN25 PRO EXTREME must be connected to the
work terminal of the power source.
3. Remove the plastic cover from the lower portion of the
wire drive with a 7/16" wrench.
4. Connect the LN25 PRO EXTREME to the constant
voltage DC welding power source. The work lead of
the LN25 PRO EXTREME must be connected to the
work terminal of the power source.
6. Turn power ON.
7. Insert the shorting plug into connector J2 on the p.c.
board. The shorting plug shorts pins 1 & 5.
5. Turn power ON.
8. Remove the shorting plug.
6. Measure the motor rpm when the COLD FEED button
is pressed.
9. Turn power OFF.
7. Verify the rpm is within the acceptable range.
10. Replace the cover and secure with the screws.
FIGURE D.2
COVER
FIGURE D.1
MOTOR
SHAFT
COVER
P.C. BOARD
LN-25 PRO EXTREME
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will
invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all
safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Authorized Field Service Facility.
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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local 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.
LN-25 PRO EXTREME
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
Digital Display Models Error Codes
Description
Possible Adjustments
Fault Code
1. The wire drive motor has over- 1. Check that the electrode slides
Err 81 Motor overload, long term.
heated.
easily through the gun and cable.
2. Remove tight bends from the gun
and cable.
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. The wire drive motor current draw 1. Check that motor can turn freely
has exceeded limits, usually when idle arm is open.
Err 82 Motor overload, short term.
because the motor is in a locked 2. Verify that the gears are free of
rotor state.
debris and dirt.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
LN-25 PRO EXTREME
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
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.
play, no cold feed.
nected or is a poor electrical con-
nection. (Across the arc models)
2. The power source is OFF.
2. Turn ON the power source.
3. Reset the circuit breakers.
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.
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
1. Keep the gun cable as straight as
possible. Avoid sharp corners or
feeding but drive rolls turning.
twisted
bends in the cable.
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.
3. Blow dirt out of the liner with low
pressure (40psi or less). Replace
the liner if worn.
4. The electrode is rusty or dirty.
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.
7. Incorrect tension arm pressure on
the drive rolls.
7. Adjust the tension arm per the
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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
LN-25 PRO EXTREME
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
Output Problems
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.
speed/extra torque jumper.
2. Install the proper pinion gear in
2. The wrong gear is installed in the the wire drive.
wire drive.
3. Replace the motor/gearbox
3. The brushes on the motor are assembly.
worn.
The wire feed speed is fast (maxi-
mum) and there is no change when
the wire feed speed knob is adjust-
ed.
1. The tachometer is connected 1. Verify all of the tachometer leads
improperly.
are properly connected.
2. Replace the motor and tachome-
ter assembly.
2. The tachometer has failed.
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.
(Digital display models)
When the trigger is pulled, the wire
feeds slowly.
1. The Run-In switch is "ON"
1. Place the Run-In switch to the
"OFF" position.
(Digital display models)
1. The preset voltage calibration in 1. Use the set-up menu to change
the feeder has been selected for a the preset voltage calibration in
The preset voltage does not match
the power source voltage.
different power source.
the feeder to match the power
source.
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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
LN-25 PRO EXTREME
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F-1
F-1
DIAGRAMS
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F-2
F-2
DIAGRAMS
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F-3
F-3
DIMENSION PRINT
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NOTES
LN-25 PRO EXTREME
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NOTES
LN-25 PRO EXTREME
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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 ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
cuerpo.
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
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 elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE 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’entretien.
● 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 öff-
nen; 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 WEB SITE: www.lincolnelectric.com
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