Lincoln Electric Welder IM359 G User Manual

IM359-G  
LN-25 PORTABLE CV/CC  
February, 1998  
SEMIAUTOMATIC WIRE FEEDER  
For use with machines having Code Number 10231  
10232  
10233  
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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 thought-  
ful 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.  
OPERATING MANUAL  
World's Leader in Welding and Cutting Products  
Premier Manufacturer of Industrial Motors  
• 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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ii  
ii  
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  
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.  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
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.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
• DC Manual (Stick) Welder.  
• 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.  
5.b. 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  
products.  
3.f. Maintain the electrode holder, work clamp, welding cable  
and welding machine in good, safe operating condition.  
Replace damaged insulation.  
3.g. Never dip the electrode in water for cooling.  
5.c. 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.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because volt-  
age between the two can be the total of the open circuit volt-  
age of both welders.  
5.d. 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  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
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.  
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.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
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  
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.  
(see address above).  
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 circuits. 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.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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iv  
iv  
SAFETY  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
PRÉCAUTIONS DE SÛRETÉ  
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 échauf-  
fement et un risque d’incendie.  
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 levage,  
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.  
Sûreté Pour Soudage A L’Arc  
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 met-  
allique 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 defonc-  
tionnement.  
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.  
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.  
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.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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.  
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 rayon-  
nement 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.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la debrancher  
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.  
Mar. ‘93  
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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  
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 com-  
pany 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.  
Model Name & Number _____________________________________  
Code & Serial Number _____________________________________  
Date of Purchase _____________________________________  
Whenever you request replacement parts for or information on this equipment always supply the infor-  
mation you have recorded above.  
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 dam-  
age to this equipment.  
LN-25  
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TABLE OF CONTENTS  
SAFETY ...............................................................................................................................................i-iv  
INSTALLATION .......................................................................................................................SECTION A  
Technical Specifications.....................................................................................................................A-1  
Safety Precautions .............................................................................................................................A-2  
Power Source Connections................................................................................................................A-2  
Gun Cable Connection to Feeder ......................................................................................................A-3  
Weld Cable Connection......................................................................................................................A-4  
Electrode Cable Connection ..........................................................................................................A-4  
Work Cable Connection .................................................................................................................A-4  
Wire Feed Drive Roll and Guide Tube Kits........................................................................................A-4  
OPERATION ............................................................................................................................SECTION B  
Safety Precautions .............................................................................................................................B-1  
General Description............................................................................................................................B-1  
Recommended Processes and Equipment ........................................................................................B-1  
Welding Capability .............................................................................................................................B-1  
Controls and Settings.........................................................................................................................B-2  
Sequence of Operation ......................................................................................................................B-4  
Loading Electrode ..........................................................................................................................B-4  
Loading Wire Drive ........................................................................................................................B-5  
Idle Roll Pressure Setting ..............................................................................................................B-5  
Presetting Wire Feed Speed..........................................................................................................B-6  
Making a Weld ...............................................................................................................................B-7  
Procedure at End of Coil....................................................................................................................B-8  
Automatic Protection Shutdown .........................................................................................................B-8  
ACCESSORIES........................................................................................................................SECTION C  
LN-25 Option Chart............................................................................................................................C-1  
Options and Accessories ...................................................................................................................C-2  
K430-1 Gas Solenoid Kit ...............................................................................................................C-2  
K434-1 Gas Flow Timer Kit............................................................................................................C-2  
K460-1 Pulse Power Adapter Kit ...................................................................................................C-3  
K461 Pulse Power Control Cable Assembly..................................................................................C-3  
K443-1 LN-25 Contactor Kit...........................................................................................................C-3  
Remote Output Control Options and Control Cable Assemblies........................................................C-3  
K431-1 Remote Output Control Kit ................................................................................................C-3  
K433 Power Source Remote Box ..................................................................................................C-3  
K432 Remote Control Cable Assembly..........................................................................................C-4  
K439 Remote Extension Cable Assembly .....................................................................................C-4  
K624-1 42V Remote Output Control Module .................................................................................C-4  
K625, K626, K626 Remote Control Cable Assembly.....................................................................C-4  
K444, K444-1 or K444-2 Remote Voltage Control Kit....................................................................C-5  
K557-1 Rear Handle Kit.................................................................................................................C-5  
MAINTENANCE .......................................................................................................................SECTION D  
Safety Precautions.............................................................................................................................D-1  
Routine Maintenance .........................................................................................................................D-1  
Circuit Protection and Automatic Shutdown.......................................................................................D-1  
Adjusting Speed Sensor Module........................................................................................................D-1  
Calibration of the LN-25 Wire Speed Dial..........................................................................................D-2  
TROUBLESHOOTING GUIDE .................................................................................................SECTION E  
How to Use the Troubleshooting Guide .............................................................................................E-1  
Troubleshooting Guide.......................................................................................................................E-2  
WIRING DIAGRAM...................................................................................................................SECTION F  
PHYSICAL DIMENSIONS ........................................................................................................SECTION F  
PARTS MANUAL..................................................................................................................P175 SERIES  
LN-25  
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INSTALLATION  
A-1  
TECHNICAL SPECIFICATIONS – LN-25  
VOLTAGE  
Constant Voltage (CV)  
or  
15-40 VDC (110VDC Maximum OCV)  
Constant Current (CC)  
RATED CURRENT  
Rated current without contactor  
Rated current with contactor  
500 Amps 60% Duty Cycle  
300 Amps 60% Duty Cycle  
WIRE FEED SPEED  
50 – 700 Inches Per Minute (IPM)  
WIRE DIAMETERS  
1
.023” to 16”  
SOLID STEEL WIRE  
CORED WIRE  
ALUMINUM WIRE  
5
.045” to 64”  
1
.035” to 16”  
PHYSICALDIMENSIONS  
HEIGHT  
(Handle Down)  
WIDTH  
DEPTH  
WEIGHT  
w/o Options  
14 Inches  
(354 mm)  
7.4 Inches  
(187 mm)  
21 Inches  
(531 mm)  
28 lbs  
(13 kg)  
TEMPERATURE RANGE  
o
o
o
o
OPERATION:  
STORAGE:  
- 40 C to +40 C (- 40 F to +104 F)  
o
o
o
o
- 40 C to +85 C (- 40 F to +185 F)  
ENVIRONMENTAL RATING  
IP23 (IEC529)  
MAR97  
LN-25  
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INSTALLATION  
A-2  
SAFETY PRECAUTIONS  
WARNING  
WARNING  
ELECTRIC SHOCK can kill.  
Unless an optional output control or contactor is used  
with the LN-25, the electrode circuit (including welding  
wire, wire drive and welding gun) is electrically hot  
when the welding power source is on. The gun trigger  
controls wire feed only.  
• Do not operate with covers  
removed.  
• Turn off power source before  
installing or servicing.  
Disconnect or shut off welding power source before  
making connections or installations to the LN-25.  
• Do not touch electrically  
hot parts.  
Welding gun should be stored in the insulated  
gun holder, located near the rear on the top of the  
LN-25 case, to avoid accidental arcing.  
• Turn the input power to the  
welding power source off at the  
fuse box before working in the  
terminal strip.  
The LN-25 should be positioned upright on a  
horizontal surface.  
• Only qualified personnel should  
install, use or service this  
equipment.  
WARNING  
ELECTRIC SHOCK can kill.  
DC-250  
• Do not touch metal portions  
of the LN-25 lead clip when  
welding power source is on.  
a. Connect a jumper from 2 to 4 on the power source  
terminal strip so the output will be energized when  
the DC-250 is turned on.  
POWER SOURCE CONNECTION  
b. Connect electrode cable to the “Innershield/  
GMAW” output terminal of polarity required by  
electrode. Connect work lead to other  
“Innershield/GMAW” output terminal.  
The LN-25 can be used with any DC welding power  
source. A constant voltage power source is  
recommended; however, the LN-25 can also be used  
with a constant current power source as long as the  
open circuit voltage is less than 110V DC.  
c. Place “Set to CV Electrode Cable Polarity” switch  
at appropriate position.  
d. Place power source toggle switch in “Output  
Control at DC-250” position, unless a Remote  
Control is connected to 75, 76 and 77 on the DC-  
250 terminal strip.  
CAUTION  
Do not use LN-25 models below Code 9200 with any  
TIG or Square Wave welding power sources. Do not  
use LN-25 models equipped with internal contactors  
with non- Lincoln TIG or Square Wave welding power  
sources. Damage to the LN-25 circuit can occur as a  
result of the high output inductance typically  
associated with these power sources. TIG high  
frequency power should never be applied to the LN-25.  
e. Place mode switch in “Innershield GMAW (CV)”  
position. Set CV arc control to “2” (or “NORMAL”  
on some machines). Initially set the output  
control on “7”.  
DC-400 AND CV-400  
a. Connect a jumper from 2 to 4 on the power  
source terminal strip so the output will be  
energized when the power source is turned on.  
If not using an LN-25 Remote Output Control option  
(See Remote Output Control Options and Cable  
Assemblies Section), the power source output must  
be electrically “hot” at all times when the power  
source is turned on.  
NOTE: DC-400 machines above Code 9200 have  
an output toggle switch to perform this function.  
See the power source instruction manual for proper  
power source connections and setting required.  
b. Connect the electrode cable to the output  
terminal of polarity required by electrode.  
Connect work lead to other output terminal.  
MAR97  
LN-25  
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INSTALLATION  
A-3  
c. Place “Set to Same Polarity As Electrode Cable  
Connection” switch at appropriate position.  
c. Set ELECTRODE POLARITY switch to constant  
voltage polarity required by electrode.  
d. Place power source toggle switch in “Output  
Control at DC(CV) -400” position, unless a  
remote control is connected to 75, 76 and 77 on  
the power source terminal strip.  
d. Set toggle switch to “Constant Voltage” and set  
the Constant Voltage Control on welder and the  
portable field control on #5 for initial start.  
SA-200, —250 OR SAE-300, —400 (WITH  
CV ADAPTER)  
e. If power source has a mode switch, set switch to  
Constant Voltage Innershield. Initially set the  
output control on “6”.  
a. For electrode negative welding, connect the  
electrode lead from the LN-25 to the output  
terminal on the CV Adapter, and the work lead to  
the power source output terminal labeled  
“POSITIVE”. For electrode positive welding,  
interchange the above lead connections so the  
LN-25 electrode lead is then connected to the  
positive power source terminal.  
DC-600  
a. Connect a jumper from 2 to 4 on the power  
source terminal strip so the output will be  
energized when the DC-600 is turned on. (For  
DC-600 below Code 8200, also jumper N to S.)  
b. Connect the electrode cable to the output  
terminal of polarity required by electrode.  
Connect work lead to other output terminal.  
b. Place both switches on the CV Adapter to the CV  
INNERSHIELD position and make appropriate  
power source settings per the CV Adapter instruc-  
tions provided for the power source being used.  
c. Place “Set to Same Polarity As Electrode Cable  
Connection” switch at appropriate position.  
c. The output voltage is set with the voltage control  
on the CV Adapter.  
d. Place power source toggle switch in “Output  
Control at DC-600” position, unless a remote  
control is connected to 75, 76 and 77 on the DC-  
600 terminal strip.  
NOTE: Refer to the Instruction Manual provided with  
the machine for details on connection and operation  
of the LN-25 with the power source.  
e. Set mode switch to Constant Voltage Innershield.  
Initially set output control on “4”.  
INVERTEC, CV300 AND OTHER NEWER  
LINCOLN POWER SOURCES  
R3S-325  
Refer to the instruction manual provided with the  
power source for details on connection and operation  
of the LN-25 with these newer machines.  
a. Connect a jumper from 4 to 32 on the power  
source terminal strip so that the output will be  
energized when the R3S-325 is turned on.  
b. Connect the electrode cable to the output  
terminal of polarity required by electrode.  
Connect work lead to other output terminal.  
GUN CABLE CONNECTION  
TO FEEDER  
c. Set power source per its instruction manual.  
Lay the cable out straight. Insert the connector on the  
welding conductor cable into the brass conductor  
block on the front of the wire drive unit. Make sure it is  
all the way in and tighten the hand wheel clamp. Keep  
this connection clean and bright. Connect the control  
cable polarized amphenol plug into the mating 5-cavity  
receptacle on the front panel of the wire feeder case.  
NOTE: Use of the optional Line Voltage  
Compensator available for the R3S-325 is  
recommended if input line voltage variation  
exceeds 3%.  
SAM-400, —650  
FOR GMA GUN AND CABLES:  
a. Connect a jumper from 2 to C4 on the power  
source terminal strip so the output will be  
engergized when the SAM power source is on.  
Requires installation of K430-1 Gas Solenoid Kit  
(factory installed on K446 and K449 models).  
b. Connect work lead to WORK stud. Connect  
electrode to AUTO EQUIPMENT stud. Connect  
SAM-650 “Tap” lead to the Innershield stud  
desired.  
See K430-1 Gas Solenoid Kit Section (in Accessories  
Section) for gas solenoid operation and gas supply  
connection.  
LN-25  
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INSTALLATION  
A-4  
5
Install the barbed fitting and union nut to the 8-18  
WIRE FEED DRIVE ROLL AND  
GUIDE TUBE KITS  
female inert gas fitting on the front panel of the  
LN-25 case. Connect the 16” I.D. gas hose from the  
3
gun cable to the barbed fitting.  
WARNING  
When the gun is to be removed, this fitting can be  
easily detached by loosening the union nut.  
Turn off power source before installing or changing  
drive roll and/or guide tubes.  
WELD CABLE CONNECTION  
The size of the electrode cable and work cable must  
be sufficient for the maximum weld current and total  
cable length to be used. Refer to table A.1.  
NOTE: The maximum wire sizes the LN-25 will  
5
1
satisfactorily feed are 64” cored and 16” solid  
electrodes.  
TABLE A.1  
The electrode sizes that can be fed with each roll and  
(1)  
guide tube are stencilled on each part. Check the kit  
Total Cable Length  
Weld Current  
for proper components. See the instructions, included  
with the drive roll kit, to install these parts on new  
machines or replace them on used machines. Refer  
to table A.2.  
60% Duty Cycle  
50’-100’ 100’-150’ 150’-200’ 200’-250’  
200Amps  
300Amps  
400Amps  
500Amps  
2 AWG 2 AWG  
1 AWG 1 AWG  
1 AWG  
1/0  
1/0  
2/0  
3/0  
4/0  
2/0  
2/0  
2/0  
3/0  
3/0  
3/0  
TABLE A.2  
ELECTRODE CABLE CONNECTION  
Kit  
Instructions  
On units without an internal contactor route the  
electrode cable through the oval hole in the LN-25  
rear panel, then along the case floor behind the reel  
support and around the door side of the wire drive.  
Steel Wire Sizes:  
5
3
.068- ⁄64 Cored  
KP653- ⁄32  
L9932  
1
1
16  
(.062) Cored or Solid  
- ⁄16  
Steel  
(Can also be used for .052)  
.045 and .052 Solid Steel  
.045 and .052 Cored  
.035 Solid Steel  
.035 Cored  
-.052  
Connect the electrode cable to the LN-25 using the  
-.052C  
-.035S  
-.035C  
-.030S  
-.025S  
1
2” bolt on the front of the wire drive.  
On units with an internal contactor connect the  
electrode cable to the LN-25 electrode input cable  
with the nut and bolt provided. Tape the bolted  
connection.  
.030 Solid Steel  
.025 Solid Steel  
Aluminum Wire Sizes:  
16  
KP654-116A  
L9932  
1
3
3
64  
- ⁄64A  
WORK CABLE CONNECTION  
.035  
-.035A  
(1)  
Drive rolls for only cored electrode sizes are stencilled with a  
Connect a work lead of sufficient size between  
the proper output stud on the power source and  
the work. Be sure the connection to the work  
makes tight metal-to-metal electrical contact.  
Poor work lead connections can result in poor  
welding performance.  
“C” suffix to the wire sizes.  
Drive rolls for only solid electrode sizes are stencilled with an  
“S” suffix to the wire sizes.  
Drive rolls for aluminum wire sizes are stencilled with an “A” suffix  
to the wire sizes.  
LN-25  
4/96  
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OPERATION  
B-1  
GENERAL DESCRIPTION  
SAFETY PRECAUTIONS  
The LN-25 is a lightweight portable semiautomatic  
wire feeder designed for “across-the-arc” operation  
without a control cable on most any DC welding  
power source. Simply connect the LN-25 to the  
electrode cable, clip it to Work and it is ready to weld,  
using up to 30 lb. coils or spools.  
READ AND UNDERSTAND ENTIRE SECTION  
BEFORE OPERATING MACHINE  
WARNING  
The wire drive, controls and wire reel are fully  
enclosed in a rugged molded plastic case providing  
a compact and versatile welding package ideally  
suited to “on-the-go” field welding applications in  
virtually any environment.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live  
part or electrode with skin or  
wet clothing.  
• Insulate yourself from work  
and ground.  
RECOMMENDED PROCESSES  
AND EQUIPMENT  
• Always wear dry insulating  
gloves.  
When combined with the quality drive roll kits and  
accessories available for use with the LN-25, a  
versatile portable welding system can be provided to  
meet the specific needs of Innershield, submerged  
arc or gas metal arc welding applications within the  
wire feed capabilities of the LN-25.  
FUMES AND GASSES can be  
dangerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes trom breathing  
zone.  
The LN-25 provides constant wire feed speed for use  
with constant voltage (CV) power sources, and arc-  
sensing wire feed speed for use with constant current  
(CC) (formerly variable voltage) power sources. Wire  
speed is presettable on a dual-range calibrated dial.  
WELDING SPARKS can cause  
fire or explosion.  
The power sources recommended for use with the  
LN-25 include the DC-250, -400, -600, CV-400 and  
R3S type transformer machines, and the SAM-400,  
-650 engine welders, as well as the SA-200, -250 or  
SAE-300, -400 with CV Adapter and Pulse Power  
500 with K460-1 LN-25 Kit.  
• Keep flammable material  
away.  
ARC RAYS can burn.  
• Wear eye, ear and body pro-  
tection.  
WELDING CAPABILITY  
The LN-25 will handle up to 500 Amp 60% duty cycle  
welding currents. However, when equipped with a  
K443-1 Contactor, the LN-25 will handle up to 300  
Amp 60% duty cycle.  
LN-25  
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OPERATION  
B-2  
NOTE:  
LN-25 INSTRUMENTS AND  
CONTROLS  
1. The Voltmeter will read zero if the LN-25 work  
clip lead is not connected to work, even if the  
electrode is electrically “hot” to work.  
Refer to Figure B.1 for control locations.  
REMOTE  
ARC VOLTAGE  
CONTROL  
2. The Voltmeter will read below zero if the LN-25  
polarity switch is not set to the same polarity as  
the electrode.  
WIRE SPEED  
DIAL RANGE  
SWITCH  
(OPTIONAL)  
3. The Voltmeter will read power source open  
circuit voltage when the gun trigger is open, even  
if the LN-25 is equipped with the internal  
contactor.  
WIRE  
SPEED  
DIAL  
VOLT  
METER  
“ELECTRODE POLARITY” SWITCH  
GAS POST/  
PRE FLOW  
TIMERS  
(OPTIONAL)  
The polarity switch is located on the front panel of  
the LN-25 case.  
ELECTRODE  
POLARITY  
SWITCH  
Set the switch to the same polarity as the electrode  
lead connection to the power source. If the switch is  
not set for the correct polarity, the wire feeder will not  
operate.  
WORK CLIP  
LEAD  
GAS  
FITTING  
(OPTIONAL)  
GUN  
CONNECTION  
BLOCK  
WIRE FEED MODE SWITCH  
GUN  
TRIGGER  
AMPHENOL  
CONNECTOR  
The CV-VV (CC) Wire Feed Mode switch is located  
inside the LN-25 case. The toggle switch extends  
from beneath the control box just above the wire  
drive.  
The forward “CV” position provides constant wire  
feed speed mode for use with constant voltage (CV)  
welding power sources.  
OPTIONAL  
GAS INPUT  
FITTING  
The backward “VV (CC)” position provides arc-sensing  
wire feed speed mode for use with constant current  
(formerly variable voltage) welding power sources.  
GAS PURGE  
BUTTON  
WIRE SPEED DIAL AND RANGE SWITCH  
The Wire Speed control dial on the front panel of the  
LN-25 has two calibrated dial ranges selected by the  
HI-LO Dial Range switch.  
ELECTRODE  
CABLE  
When switched to the LO range position, the constant  
wire feed speed (CV Wire Feed Mode) is set on the  
inside (white) dial range calibrated for 50 to 350  
in/min.  
FIGURE B.1 CONTROL LOCATIONS  
VOLTMETER  
When switched to the HI range position, the constant  
wire feed speed (CV Wire Feed Mode) is set on the  
outside (black) dial range calibrated for 50 to  
700 in/min.  
(Factory installed on model Codes above 9218)  
The 40V DC analog voltmeter is mounted to the front  
control panel of the LN-25 and is connected to read  
the arc voltage between the LN-25 electrode cable  
connection and the work clip lead.  
The volts marks around the HI range calibrated dial  
indicate the minimum arc volts required to obtain the  
indicated HI range wire feed speeds. For example; if  
LN-25  
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OPERATION  
B-3  
wire speed is set to 400 in/min., a welding procedure  
arc voltage of at least 17V would be required to  
obtain the 400 in/min. wire feed speed.  
AWG  
Maximum Length  
#14  
#12  
#10  
#6  
25 Ft  
50 Ft  
100 Ft  
200 Ft  
WORK CLIP LEAD  
WARNING  
ELECTRIC SHOCK can kill.  
REMOTE ARC VOLTAGE CONTROL (OPTIONAL)  
• Do not touch metal portions  
of the LN-25 lead clip when  
welding power source is on.  
This rheostat control allows you to control the power  
source output arc voltage level. Refer to K444, K444-  
1 and K444-2 Remote Voltage Kits in the  
Accessories section.  
GAS FITTING (OPTIONAL)  
WARNING  
Provides gas output connection to the welding gun  
for the GMAW process. Refer to K430-1 Gas  
Solenoid Kit in the Accessories Section.  
IMPORTANT SAFETY NOTE: To avoid possible  
electrical shock, do not touch the metal portions of  
the LN-25 work lead clip if the power source output  
is on. The clip will be electrically “HOT” to work if the  
input electrode cable to the LN-25 is electrically  
“HOT” even if the gun trigger is off and even if an  
internal contactor is used. Care should be taken to  
only handle the LN-25 work clip by its non-metal  
insulated portions and/or the welding power source  
should be turned off before handling the work clip.  
GAS POST PRE-FLOW TIMERS (OPTIONAL)  
Allows for variable adjustment of gas pre-flow &  
post-flow at the start and end of the weld. Refer to  
K434-1 Gas Flow Timer Kit in Accessories Section.  
The 15 ft work clip lead attached to the front panel  
of the LN-25 case must be connected directly to the  
work using the spring clip on the end of the lead.  
If not connected, the LN-25 will not operate even if  
a K431-1 or K624-1 (42V) Remote Output Control  
option (refer to Accessories Section) is used.  
However, the electrode will still be electrically “HOT”  
when the clip lead is disconnected, if K431-1 or  
K624-1 (42V) Remote Output Control Option, or  
Internal Contactor (K443-1), is not used.  
When used with a K460-1 Pulse Power Adapter Kit,  
the LN-25 does not need a clip lead.  
NOTE: The clip lead also serves as a work sensing  
lead for the LN-25 Voltmeter (if installed). If the clip  
lead is extended by the user beyond the standard 15  
ft. length, the voltmeter reading will be lower than the  
actual arc volts due to the LN-25 motor control cur-  
rent flowing through the resistance of the extended  
lead. To minimize this voltmeter error, the following  
minimum lead size is recommended for the  
maximum extended lengths shown:  
LN-25  
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OPERATION  
B-4  
g. To remove Readi-Reel from Adapter, depress re-  
taining spring tab with thumb while pulling the  
Readi-Reel cage from the molded adapter with  
both hands. It is not necessary to remove  
adapter from spindle.  
SEQUENCE OF OPERATION  
LOADING ELECTRODE  
WARNING  
ELECTRIC SHOCK can kill.  
h. Load wire into wire drive per Loading Wire Drive  
Section.  
• Unless an optional output  
control or internal contactor  
is used with the LN-25, the  
electrode circuit is electri-  
cally “Hot” when the power  
source is on.  
MOUNTING 10 TO 30 LB SPOOLS  
For 12” Diameter Spools:  
a. Remove the locking collar and the Readi-Reel  
adapter shipped on the 2” diameter spindle  
(adapter is not required).  
• Turn off the power source  
while mounting electrode  
coils.  
b. Place the spool on the spindle so the brake  
holding pin enters one of the holes in the back  
side of the spool. Be sure the wire comes off the  
spool in a clockwise direction when dereeled  
from the bottom of the coil.  
®
MOUNTING 22 TO 30 LB READI-REEL COILS  
The LN-25 is factory equipped with a K363-P Readi-  
®
c. Replace and tighten the locking collar.  
Reel Adapter which is required to load Lincoln 22 to  
30 lb Readi-Reel coils.  
d. See Loading Wire Drive section for loading  
instructions.  
a. Make certain that the threaded locking collar is  
tight and securely locks the adapter on the  
spindle (see figure B.2).  
For 8” Diameter Spools (Requires optional K468  
Spindle Adapter for 8” Spools):  
b. Rotate the spindle and adapter so the retaining  
spring is at the 12 o’clock position.  
a. Remove the locking collar and the Readi-Reel  
adapter shipped on the 2” diameter spindle  
(adapter is not required).  
c. Position the Readi-Reel so that it will rotate in a  
clockwise direction when feeding (wire is to be  
dereeled from bottom of the coil).  
b. Slide S18221 Spindle Adapter onto the 2”  
spindle so the brake holding pin enters the  
adapter pin hole.  
d. Set one of the Readi-Reel inside cage wires on  
the slot in the retaining spring tab.  
c. Place the spool on the spindle so the adapter tab  
enters one of the holes in the back side of the  
spool. Be sure the wire comes off the spool in a  
clockwise direction when dereeled from the  
bottom of the coil.  
e. Lower the Readi-Reel to depress the retaining  
spring and align the other inside cage wires with  
the grooves in the molded adapter.  
f. Slide cage all the way onto the adapter until the  
retaining spring “pops up” fully.  
d. Replace and tighten the Locking Collar.  
e. Load wire into wire drive per Loading Wire Drive  
Section.  
WARNING  
Check to be sure the retaining spring has fully  
returned to the locking position and has securely  
locked the Readi-Reel cage in place. Retaining  
spring must rest on the cage, not the welding  
electrode.  
MOUNTING 13 OR 14 LB INNERSHIELD COILS  
(Requires Optional K435 Spindle Adapter for 14 lb  
Coils.)  
a. Remove the locking collar and the Readi-Reel  
adapter shipped on the 2” diameter spindle  
(adapter is not required).  
b. Mount K435 Spindle Adapter and Innershield coil  
per the Instructions (S18256) included with the  
K435.  
LN-25  
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OPERATION  
B-5  
FIGURE B.2 READI-REEL INSTALLATION  
MOLDED ADAPTER  
2" O.D. SPINDLE  
RETAINING SPRING  
BRAKE HOLDING PIN  
(MUST ENGAGE HOLE IN  
ADAPTER RIB)  
GROOVES  
READI-REEL  
INSIDE CAGE WIRES  
LOADING WIRE DRIVE  
THREAD LOCKING COLLAR  
a. Turn the reel or spool until the free end of the  
electrode is accessible.  
f. Inch the electrode through the gun.  
g. Adjust the brake tension with the thumbscrew on  
the spindle hub until the reel turns freely, but  
with little or no overrun when wire feeding is  
stopped. Do not overtighten.  
b. While tightly holding the electrode, cut off the  
bent end and straighten the first six inches. Cut  
off the first inch. (If the electrode is not properly  
straightened, it may not feed or may not go into  
the outgoing guide tube causing a “birdnest”.)  
CAUTION  
Keep gun in LN-25 gun holder when not feeding wire  
to prevent accidental arcing.  
c. Insert the free end through the incoming guide  
tube to the drive roll.  
d. Turn on the welding power source.  
WARNING  
IDLE ROLL PRESSURE SETTING  
Unless an optional output control or internal  
contactor is used with the LN-25, the electrode circuit  
is electrically “hot” when the power source is on.  
The idle roll pressure is set at the factory backed out  
two turns from full pressure. This is an approximate  
setting. For small wire sizes and aluminum wire, the  
optimum idle roll pressure varies with type of wire,  
surface condition, lubrication and hardness. The op-  
timum idle roll setting can be determined as follows:  
e. Press the gun trigger and push the electrode  
until it just enters the drive roll.  
1. Press end of gun against a solid object that is  
electrically isolated from the welder output.  
Press the gun trigger for several seconds.  
WARNING  
When inching with gun trigger, the electrode and  
drive mechanism are always “hot” to work and  
ground. Use the “cold” inch switch on models with  
internal contactor.  
2. If the wire “birdnests,” jams or breaks at the drive  
roll, the idle roll pressure is too great. Back the  
1
pressure setting out 2 turn, run new wire through  
gun, and repeat above steps.  
LN-25  
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OPERATION  
B-6  
3. If the only result is drive roll slippage, shut off  
the power source, then loosen the gun cable  
clamping screw in the gearbox conductor block  
and pull the gun cable forward about six inches.  
There should be a slight waviness in the  
exposed wire. If there is no waviness, the  
pressure is too low. Increase the pressure  
1
setting ⁄4 turn, lock the gun cable in place and  
repeat the above steps.  
PRESETTING WIRE FEED SPEED  
The LN-25 permits accurate presetting of the desired  
wire feed speed, before welding, in both CV and CC  
wire feed modes.  
SETTING CONSTANT WIRE FEED SPEED  
(CV MODE)  
a. Set Wire Feed Mode switch to CV position.  
b. Set Dial Range switch to LO position for wire  
feed speeds up to 350 in/min., or HI position for  
wire feed speeds over 350 in/min.  
FIGURE B.3 CC WIRE SPEED SETTING  
c. Set Wire Feed dial to the desired wire feed  
speed on the selected calibrated dial range.  
(Hl or LO Range)  
The wire speed will remain constant at the value set,  
independent of arc voltage changes, as long as the  
arc voltage does not drop below the value per the  
chart below for the max. wire feed speed shown:  
b. Referring to the graph located above the Mode  
switch (also shown in Figure B.3):  
1. Select the horizontal line representing the DE-  
SIRED IN/MIN. for the welding procedure.  
(See example arrow line for 375 in/min.)  
Maximum Speed  
Minimum Arc Volts  
350 IPM  
400 IPM  
500 IPM  
600 IPM  
700 IPM  
15V  
17V  
21V  
24V  
27V  
2. Select the diagonal line representing the ARC  
VOLTS to be used for the welding procedure.  
(See example arrow line for 29 volts.)  
3. Determine the vertical line representing the  
CC WIRE SPEED SETTING where the above  
two lines cross. (See example arrow line for  
450.)  
SETTING ARC SENSING WIRE FEED SPEED  
(VV [CC] MODE)  
When using a constant current (formerly variable  
voltage) power source, welding performance is im-  
proved using arc sensing wire feed speed (VV [CC]  
mode). In this wire feed mode the wire speed  
increases if arc voltage increases, and decreases if  
arc voltage decreases, but remains constant at any  
specific voltage level.  
c. Set the Wire Speed dial to the value determined  
in Step (3) above (450 for example used). Use  
HI Dial Range if value to be set is over 350.  
The wire will feed at the DESIRED IN/MIN speed  
when the welding power source is set to the arc  
voltage to be used for the weld procedure (375  
in/min. at 29V for example used).  
The LN-25 permits accurate VV (CC) mode  
presetting of the desired wire feed speed, for the  
desired arc voltage to be used, by setting the Wire  
Speed dial in the following manner before welding:  
A chart representation of the VV (CC) wire speed  
setting graph is shown in Figure B.4, giving the Wire  
Speed dial setting required for the DESIRED IN/MIN  
and ARC VOLTS used for the welding procedures:  
a. Set Wire Feed Mode switch to VV (CC) position.  
LN-25  
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OPERATION  
B-7  
MAKING A WELD  
Arc Volts Used  
SETUP  
Desired  
In/Min  
16 18 20 22 24 26 28 30 32 34  
a. Connect work cable to metal to be welded. Work  
cable must make good electrical contact to the  
work. The work must also be grounded as stated  
in “Arc Welding Safety Precautions.”  
50  
60  
70  
80  
90  
109 97 88 80 73 67 63 58 55 51  
131 117 105 95 88 81 75 70 66 62  
153 136 123 111 102 94 88 82 77 72  
175 156 140 127 117 108 100 93 88 82  
197 175 158 143 131 121 113 105 98 93  
b. Check that the LN-25 is properly connected to  
the power source for the polarity and process to  
be used, and appropriate power source settings  
are made for the procedure to be used. (Refer to  
power source operating and connection  
instructions.)  
100  
110  
120  
130  
140  
219 194 175 159 146 135 125 117 109 103  
241 214 193 175 160 148 138 128 120 113  
263 233 210 191 175 162 150 140 131 124  
284 253 228 207 190 175 163 152 142 134  
306 272 245 223 204 188 175 163 153 144  
150  
160  
170  
180  
190  
328 292 263 239 219 202 188 175 164 154  
350 311 280 255 233 215 200 187 175 165  
372 331 298 270 248 229 213 198 186 175  
394 350 315 286 263 242 225 210 197 185  
416 369 333 302 277 256 238 222 208 196  
NOTE: If the K431-1 Remote Output Control Kit or  
K624-1 42V Remote Control Module is installed but  
the LN-25 is to be used without the K432 Remote  
Control Cable Assembly, then the Remote Board  
harness plug must be removed from the 16-pin  
receptacle on the Control Board and the jumper plug  
(T13498-21) reinstalled.  
200  
210  
220  
230  
240  
438 389 350 318 292 269 250 233 219 206  
459 408 368 334 306 283 263 245 230 216  
481 428 385 350 321 296 275 257 241 226  
503 447 403 366 335 310 288 268 252 237  
525 467 420 382 350 323 300 280 263 247  
NOTE: If the K460-1 Pulse Power Adapter Kit is  
installed but the LN-25 is to be used without the K461  
Pulse Power Control Cable Assembly, then the  
instructions for returning the unit to across the arc  
operation included with the Installation Instructions  
(L9636) must be followed.  
250  
260  
270  
280  
290  
547 486 438 398 365 337 313 292 273 257  
569 506 455 414 379 350 325 303 284 268  
591 525 473 430 394 365 338 315 295 278  
613 544 490 445 408 377 350 327 306 288  
634 564 508 461 423 390 363 338 317 299  
300  
310  
320  
330  
340  
656 583 525 477 438 404 375 350 328 309  
678 603 543 493 452 417 388 362 339 319  
700 622 560 509 467 431 400 373 350 329  
642 578 525 481 444 413 385 361 340  
661 595 541 496 458 425 397 372 350  
c. Place the LN-25 conveniently near the work area  
in a location to minimize exposure to weld spatter  
and to avoid sharp bends in the gun cable.  
350  
360  
380  
400  
420  
681 613 557 510 471 438 408 383 360  
700 630 572 526 484 450 420 394 370  
666 604 554 512 472 444 416 392  
700 636 584 538 500 466 438 412  
668 612 566 526 490 460 432  
d. Connect the LN-25 Clip Lead to work and set Po-  
larity Switch to same polarity as electrode.  
e. Set WIRE FEED MODE switch to CV or CC, as  
appropriate for the power source, then set the  
proper DIAL RANGE and WIRE SPEED dial set-  
ting for the proper wire feed speed per the  
welding procedure:  
440  
460  
480  
500  
700 642 592 550 514 482 452  
670 620 576 536 504 472  
700 646 600 560 526 494  
674 626 584 546 514  
For CV: Set dial to the calibrated IN/MIN  
desired. (Refer to Setting Constant Wire Feed  
Speed Section.)  
520  
540  
560  
580  
600  
700 650 606 568 536  
676 630 590 556  
700 654 612 576  
676 634 598  
For CC: Set dial to value determined from the  
CC Wire Speed Graph for the DESIRED IN/  
MIN and ARC VOLTS to be used. (Refer to  
Setting Arc Sensing Wire Feed Speed  
Section.)  
700 656 618  
620  
640  
660  
680  
700  
678 638  
700 658  
680  
700  
NOTE: If procedure permits a range of acceptable  
arc voltage, use the middle of the range to  
determine proper WIRE SPEED setting.  
Desired IPM  
Arc Volts  
VV (CC) Speed Setting =  
X 35  
f. If using the optional Gas Flow Timer, set the de-  
sired PREFLOW TIME and POSTFLOW TIME.  
FIGURE B.4 VV(CC) WIRESPEED SETTING  
LN-25  
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OPERATION  
B-8  
g. Be sure the proper contact tip for the wire size  
being used is in the gun, and the gun is safe  
from work contact. (Use the LN-25 insulated  
gun holder.)  
c. Lower welding helmet, close gun trigger, and  
begin welding. Hold the gun so the contact tip to  
work distance gives the correct electrical stickout  
as required for the procedure being used.  
NOTE: If the arc voltage is not within the proper  
procedure range adjust the power source output  
control. (The CC mode WIRE SPEED setting should  
not be changed from the preset procedure value for  
the proper arc voltage.)  
h. Turn on the welding power source, as well as the  
shielding gas supply (if used).  
WARNING  
d. To stop welding, release the gun trigger and  
then pull the gun away from the work. Store the  
gun in the LN-25 insulated gun holder when  
not welding.  
Unless an optional output control or internal contactor  
is used, the electrode is electrically “hot” when the  
power source is on. The gun trigger controls wire  
feed only.  
PROCEDURE AT END OF COIL  
WARNING  
When the wire on the reel is used up, the following  
procedure is to be followed for removing the old wire  
from the gun cable and loading a new reel.  
CYLINDER may explode if  
damaged.  
• Keep cylinder upright and  
chained to support.  
a. Shut off power source if a Remote Output  
Control Option or internal contactor is not used.  
• Keep cylinder away from  
areas where it may be dam-  
aged.  
b. Cut the end of the electrode off at the gun end.  
Do not break it off by hand since this puts a slight  
bend in the wire and makes it difficult or  
impossible to pull it back through the nozzle.  
• Never lift welder with cylin-  
der attached  
c. Uncouple the gun conductor cable from  
the LN-25.  
• Never allow welding elec-  
trode to touch cylinder.  
d. Lay the cable out straight.  
• Keep cylinder away from  
welding or other live electri-  
cal circuits.  
e. Using pliers to grip the wire, pull it out of the  
cable from the connector end. Do not pull it from  
the gun end.  
f. Put the conductor cable back on wire drive unit  
after the electrode has been removed.  
WELDING  
g. Load a new coil of wire and feed it through the  
cable as described in Loading Electrode Section.  
WARNING  
ARC RAYS can burn.  
OPEN ARC WELDING WITH A  
CONSTANT CURRENT (formerly  
variable voltage) POWER  
SOURCE  
• Do not touch metal por-  
tions of the LN-25 lead  
Clip when welding power  
source is on.  
3
Although a constant voltage (CV) power source  
a. Cut the electrode within approximately 8” of the  
®
is recommended for Innershield and gas metal  
end of the contact tip for solid wire and within  
approximately ⁄4” of the extension guide for cored  
3
arc (GMAW) open arc welding, satisfactory general  
purpose welding may be obtained using the  
LN-25 with a constant current (CC) power source  
for noncritical commercial quality mild steel  
welding applications.  
wire.  
b. Position electrode over joint. End of electrode  
should be slightly off the work.  
LN-25  
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OPERATION  
B-9  
Arc shorting is more difficult to avoid when using  
a CC power source, and requires a more refined  
operator technique than when using a CV power  
source. Improved performance can be obtained  
on CC power source applications within the  
following guidelines:  
CAUTION  
Do not use LN-25 models below Code 9200 with  
any TIG or Square Wave welding power sources.  
Do not use LN-25 models equipped with internal  
contactors with non-Lincoln TIG or Square Wave  
welding power sources. Damage to the LN-25 circuit  
can occur as a result of the high output inductance  
typically associated with these power sources. TIG  
high frequency power should never be applied to  
the LN-25.  
1. Flatter slope power sources with higher arc  
force (short circuit current) will improve  
performance over steep slope machines. The  
steeper the slope, the more critical it is to hold  
proper electrode stickout to maintain arc  
stability. Welding techniques, such as weaving,  
will be more difficult to control. Use the highest  
output current tap or setting capable of providing  
the voltage adjustment required for the  
procedure.  
While welding with a continuously fed electrode,  
weld current variations are continuously taking place.  
There are many causes for these variations, but  
predominantly they occur due to changes in  
electrical stickout (operator hand movements, nozzle  
tip contact variations, etc.) and the dynamic metal  
transfer characteristics of the process or procedure  
being used (short arc, globular transfer, etc.).  
2. Use spray or non-shorting small ball type  
transfer processes at higher procedure voltage  
levels. Generally, open arc processes with  
procedure voltage levels over 22 volts perform  
satisfactorily. Arc stability at procedure voltage  
levels below 22 volts may be more difficult to  
control, with the general exception of fine (.023—  
.035) solid steel electrodes with Argon-rich  
shielding gas or NR-152 and NR-211 Innershield.  
When using a CV power source, these current  
variations have essentially no effect on the welding  
arc stability since CV power sources can provide a  
wide range of weld current levels with virtually no  
change in average arc voltage. These “flat slope” CV  
power sources, therefore, provide the arc power  
required to produce the best welding characteristics  
and ease of operation for most open arc, constant  
wire feed speed, welding processes.  
AUTOMATIC PROTECTION  
SHUTDOWN  
The LN-25 control provides automatic electronic  
protection circuits which shut down the LN-25 for  
excessively high power source open circuit voltage  
or excessive motor overload.  
CC (formerly VV) power sources, on the other hand,  
permit the arc voltage to decrease with increases in  
welding current. The output characteristics of these  
power sources can range from a “drooping slope,”  
which provide minor arc voltage changes with weld  
current variations, to “steep slope” which provide  
broad voltage changes with only minor current  
variations. The steeper the slope the more difficult it  
becomes to maintain arc voltage stability with a  
constant wire speed open arc process.  
OVERVOLTAGE SHUTDOWN  
If the power source open circuit voltage exceeds  
about 110-120 volts, the LN-25 will not operate until  
the power source voltage drops below about 102-  
110 volts.  
To aid in stabilizing the arc voltage when welding on  
CC power sources the LN-25 is provided with a VV  
(CC) wire feed mode. This arc voltage sensing feed  
mode decreases (or increases) the wire speed when  
the arc voltage decreases (or increases). However,  
if the electrode shorts to the work, the arc voltage  
will essentially drop to zero and the short circuit  
current supplied by the CC power source may not  
provide enough power to re-establish the arc  
(especially with steeper slope machines). Under this  
condition the LN-25 feeder will stop, as if the trigger  
was released, and not restart until the short has  
been opened.  
MOTOR OVERLOAD SHUTDOWN  
If excessive motor overload occurs (due to prolonged  
excessive feeding force, jammed drive rolls or  
shorted motor leads), the LN-25 will shut down within  
a few seconds after the overload occurs.  
The shutdown will reset automatically when the gun  
trigger is released, but will reoccur if the overload  
situation is not remedied.  
LN-25  
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ACCESSORIES  
C-1  
How to use Table C.1.  
Determine which Kit No. is to be used. Locate that Kit No. in the left hand vertical column.  
Scan horizontally to determine which LN-25 model is required and what additional kits may be required.  
TABLE C.1  
LN-25 OPTION CHART  
O = CANNOT BE USED WITH X = REQUIRED = REQUIRESSEEOTNEXET OF THESE + = INCLUDED WITH  
LN-25 MODELS  
LN-25 KITS  
Solenoid  
Kit  
K430-1  
K431-1  
X
+
+
Remote Output  
Control Module  
O
X
X
X
X
O
O
O
O
O
O
Remote  
K432  
K433  
X
X
Control Cable  
115VAC  
Power Source  
Remote Box  
Gas Flow  
Timer Kit  
K434-1  
K439  
50 Ft.  
Ext. Cable  
X
Contactor  
Kit  
K443-1  
K444  
+
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
Remote for Power  
Source w/Terminal Strip  
Remote for Power  
Source w/6 Pin Amphenol  
K444-1  
K444-2  
K-624-1  
K625  
Remote for Power  
Source w/14 Pin Amphenol  
42VAC Remote  
Output Control Module  
O
O
O
O
O
O
O
O
500 Amp Cable /w Stud-  
Type Output Terminals  
X
X
X
O
350 Amp Cable /w Stud-  
Type Output Terminals  
K626  
400 Amp Cable /w Twist-  
Mate Type Terminals  
K627  
Pulse Power  
Adapter Kit  
K460-1  
K461  
O
O
X
Pulse Power  
Control Cable  
X
IMPORTANT SAFETY NOTE: This wire feeder provides “COLD” electrode when gun trigger is released if  
equipped with K431-1, K432 or K433 remote output control system, or K443-1 internal contactor kit. This feature  
and the use of a DC Constant Voltage welder provide an added margin of safety when welding must be performed  
under electrically hazardous conditions such as:  
• Damp locations • While wearing wet clothing • On metal structures, or, • In cramped positions (sitting, kneeling  
or lying) if there is a high risk of unavoidable or accidental contact with the workpiece or ground.  
LN-25  
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ACCESSORIES  
C-2  
OPTIONAL ACCESSORIES  
WARNING  
WARNING  
CYLINDER may explode if  
damaged.  
ELECTRIC SHOCK can kill.  
• Do not operate with covers  
removed.  
• Keep cylinder upright and  
chained to support.  
• Turn off power source before  
installing or servicing.  
• Keep cylinder away from areas where it may  
be damaged.  
• Do not touch electrically hot  
parts.  
• Never lift welder with cylinder attached.  
• Turn the input power to the  
welding power source off at  
the fuse box before working  
in the terminal strip.  
• Never allow welding electrode to touch cylin-  
der.  
• Keep cylinder away trom welding or other live  
electrical circuits.  
• Only qualified personnel  
should install, use or ser-  
vice this equipment.  
• See American National Standard Z-49.1, “Safety in Welding  
and Cutting” published by the American Welding Society.  
K430-1 GAS SOLENOID KIT  
See GMA Gun Cable Gas Connection.  
(Factory Installed on K446 and K449 Models)  
Installation instructions (M17587) are included with  
the kit.  
The kit permits the LN-25 to be used for Gas  
Metal Arc Welding (GMAW) processes with a  
GMA gun cable.  
K434-1 GAS FLOW TIMER KIT  
(Requires either a K431-1 Remote Output Control Kit,  
K460-1 Pulse Power Adapter Kit, K624-1 42V  
Remote Output Control Kit, or internal contactor  
K443-1 installed in LN-25).  
The kit can be used with or without a Remote Output  
Control option installed in the LN-25 and provides  
flow of shielding gas:  
1. With wire feed, when the gun trigger is closed.  
The K434-1 Gas Flow Timer Kit is used with the  
LN-25 Gas Solenoid when the LN-25 is equipped  
with any of the Remote Output Control Options or  
internal contactor.  
2. Without wire feed, when the kit’s Purge button  
(located beneath the gas inlet fitting) is pressed.  
NOTE: Always shut off the valve at the gas cylinder  
before making any gas connections to the LN-25.  
This kit provides the following gas flow timer functions:  
User must provide a supply of shielding gas, a pres-  
sure regulator, a flow control valve and a hose from  
the flow valve to the gas inlet fitting of the LN-25.  
Install by connecting a supply hose from the gas flow  
1. Preflow Control - Provides flow of shielding  
gas to the work before the arc is established.  
The solenoid valve is energized immediately  
when the gun trigger is closed, but the time  
delay before the wire feeder and welding output  
are energized is adjustable between at least  
0 to 1 second.  
5
valve outlet to the 8-18 female inert gas fitting on the  
back panel of the LN-25 case.  
The LN-25 can be used with any shielding gas  
recommended in the electrode’s product literature at  
a maximum pressure of 60 psi (4.1 bar). This may  
include gases such as Argon, Helium, Nitrogen and  
blended gasses such as Ar-He, Ar-N , Ar-O , Ar-  
2. Postflow Control - Provides flow of shielding  
gas to the work after welding is stopped. Delay  
of the shut off of the solenoid valve after the gun  
trigger is released is adjustable between at least  
2
2
CO , CO , Ar-CO -O .  
0.5 to 5 seconds.  
2
2
2
2
MAR97  
LN-25  
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ACCESSORIES  
C-3  
Installation instructions (M17590) are included with  
this kit.  
CAUTION  
K460-1 PULSE POWER ADAPTER KIT  
This kit can only be used with LN-25’s above Code  
9200 or with LN-25’s equipped with a G1757-3 (or  
higher part number) Control PC board. To prevent  
possible damage to the LN-25 with internal  
contactor, do not connect to non-Lincoln TIG or  
Square Wave power sources. TIG high frequency  
power should never be applied to the LN-25.  
(For use with K461 Pulse Power Control Cable.)  
This kit enables the LN-25 to pulse weld with a Pulse  
Power 500 power source above Code 9300 (or lower  
Codes updated with S18506 Kit).  
The kit includes a Remote PC board with output  
voltage control, and control cable receptacle which  
mount and connect inside the LN-25 control box  
per the Installation Instructions (L9636) included with  
the kit.  
NOTE: The K443-1 cannot be used with K431-1 or  
K624-1 Remote Output Control Kit or K460-1 Pulse  
Power Adapter Kit. If remote voltage control is  
desired along with the internal contactor, obtain a  
K444, K444-1 or K444-2 Remote Voltage Control Kit.  
NOTE: If the K460-1 Pulse Power Adapter Kit is in-  
stalled but the LN-25 is to be used without the K461  
Pulse Power Control Cable Assembly, then the in-  
structions for returning the unit to across the arc op-  
eration included with the Installation Instructions  
(L9636) must be followed.  
REMOTE OUTPUT CONTROL OPTIONS  
AND CONTROL CABLE ASSEMBLIES  
Remote Output Control Options are available to pro-  
vide the LN-25 with the following additional features:  
K461 PULSE POWER CONTROL CABLE  
ASSEMBLY  
1. “Cold” electrode until the gun trigger is pressed,  
and a fixed burnback time delay to prevent elec-  
trode from sticking in the weld crater when the  
gun trigger is released.  
(Requires K460-1 Pulse Power Adapter Kit installed  
in LN-25.)  
2. Remote (10K ohm rheostat) control of power  
source output arc voltage level.  
The K461 control cable assemblies include an elec-  
trode cable, rated for up to 500 amps 60% duty  
cycle, and a 9-conductor control cable. The control  
cable pin connector connects to the LN-25 and the  
lugged leads connect to the Pulse Power. Available  
in 25, 50, 75 and 100 ft. lengths.  
K431-1 REMOTE OUTPUT CONTROL KIT  
(For use with K432 Remote Control Cable and K433  
Power Source Remote Box.)  
K443-1 LN-25 CONTACTOR KIT  
The Kit includes a Remote PC board and control  
cable receptacle which mount and connect inside the  
LN-25 control box per the Installation Instructions  
(M17584) included with the kit.  
(Factory installed in K449 Model.)  
The internal contactor provides “cold” electrode until  
the gun trigger is pressed, and a fixed burnback time  
delay to prevent electrode from sticking in the weld  
crater when the trigger is released. The contactor is  
rated for use up to 300 amps. A cold inch switch  
allows the wire to be loaded into the system without  
being electrically “hot”.  
NOTE: If the K431-1 Remote Output Control Kit is  
installed but the LN-25 is to be used without the  
K432 Remote Control Cable Assembly, then the Re-  
mote Board harness plug must be removed from the  
12-pin receptacle on the Control Board and the  
jumper plug (T13498-21) reinstalled.  
K433 POWER SOURCE REMOTE BOX  
Installation Instructions (L9676) are included with  
the kit.  
(Requires K431-1 Remote Output Control Kit installed  
in LN-25 using K432 Remote Control Cable.)  
The Remote Box is designed to mount and connect  
®
to Lincoln Idealarc semiautomatic power sources  
per the Installation Instructions (M15324) and power  
source connection diagrams included with the kit.  
LN-25  
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ACCESSORIES  
C-4  
The Remote Box provides the proper welding power  
source control interface and isolated 24V AC input  
supply for the LN-25 equipped with the K431-1  
Remote Output Control Kit.  
K624-1 42V REMOTE OUTPUT CONTROL  
MODULE  
(For use with K625, K626, K627 Remote  
Control Cable)  
Remote Box requires 115V AC, 50/60 Hz input and  
a welding power source using a contact closure  
output pilot circuit, as available on appropriate  
Lincoln welding power sources.  
The Module includes a 42V Remote PC board and  
control cable receptacle which mount and connect  
inside the LN-25 control box per the Installation  
Instructions (M17253) included with the kit.  
K432 REMOTE CONTROL CABLE ASSEMBLY  
NOTE: If the K624-1 42V Remote Output Control  
Module is installed but the LN-25 is to be used  
without the K625, K626 or K627 Remote Control  
Cable Assembly, then the Remote Board harness  
plug must be removed from the 16-pin receptacle on  
the Control Board and the jumper plug (T13498-21)  
reinstalled.  
(Requires K431-1 Remote Output Control Kit  
installed in LN-25 and K433 Remote Box mounted to  
power source with 115V AC auxiliary power.)  
The K432 control cable assemblies include an  
electrode cable, rated for up to 500 amps 60% duty  
cycle, and a 6-conductor control cable with pin  
connectors on both ends. Available in 25, 50, 75 and  
100 ft. lengths.  
K625, K626, K627 REMOTE CONTROL CABLE  
ASSEMBLY  
The cable assembly end with the socket pin  
connector connects to the LN-25 per the Instructions  
(M17584) included with the K431-1 kit.  
(Requires K624-1 Remote Output Control Module  
installed in LN-25.)  
The K625, K626, K627 control cable assem-  
blies include an electrode cable and a 8-conductor  
control cable:  
The cable assembly end with the male pin connector  
connects to the K433 and power source per the In-  
structions included with the K433 kit.  
K439 REMOTE EXTENSION CABLE ASSEMBLY  
CABLE  
TYPE  
60% DUTY  
RATING  
POWER SOURCE  
ELECTRODE  
The 50 ft. Extension cable assemblies are used to  
extend the K432 Remote Control Cable Assembly  
when longer cable lengths are required.  
CONNECTION  
K625  
K626  
K627  
500 Amps  
350 Amps  
400 Amps  
Stud Terminal  
Stud Terminal  
Twist-Mate™  
Multiple K439 Extensions may be used, however, to  
prevent excessive weld cable voltage drops, the 500  
amp max. rating of the K432 should be reduced by  
at least 50 amps for each K439 Extension used. For  
example, if three K439 Extensions are used (150 ft  
total extension), the maximum welding current used  
should be less than 350 amps.  
The cable assembly end with the socket pin  
connector connects to the LN-25 per the Instructions  
(M17253) included with the K624-1 Kit.  
The K439 Extension cable end with the male pin  
connector connects to the K433 Remote Box and  
power source per the Instructions included with the  
K433 kit.  
The cable assembly end with the male pin connector  
connects to the power source per the Instructions  
(M17253) included with the K624-1 kit.  
The K439 Extension cable end with the socket pin  
connector connects to the mating K432 cable end (or  
next K439 Extension cable end). The electrode  
cables are connected using the bolt and nut provided  
with the K439 Extension. Properly insulate the bolted  
connection with electrical tape.  
LN-25  
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ACCESSORIES  
C-5  
K444, K444-1 OR K444-2 REMOTE VOLTAGE  
CONTROL KIT  
(Not required if using K431-1 or K624-1 Remote  
Output Control Kit or K460-1 Pulse Power Adapter  
Kit.)  
The Remote Voltage Control Kit provides remote  
(10K ohm rheostat) control of power source output  
arc voltage level.  
K444 connects to power sources with control  
terminal strip connections for lead numbers 75, 76  
and 77.  
K444-1 connects to power sources with a 6-pin  
control receptacle.  
NOTE: To use a K444-1 with power sources with  
only a 14-pin control receptacle, a K864 Adapter is  
required to connect to K444-1 and if using a power  
source without an output control switch, a K484  
Jumper Plug will also be required to jumper the  
output pilot circuit (2-4).  
K444-2 connects to power sources with a 14-pin  
control receptacle and provides a 2-4 jumper to  
activate power source output.  
Installation Instructions are included with the kit.  
K577-1 REAR HANDLE KIT  
(For LN-25 model codes above 9383)  
The fold-down handle mounts to the rear of the LN-  
25 case per the Installation Instructions (M16567)  
shipped with the kit.  
This handle provides a means to also carry the LN-  
25 in the vertical position, especially convenient for  
passing the unit through a manhole.  
LN-25  
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ACCESSORIES  
C-6  
The following Figures C.1 and C.2 should serve as a guide to determine if a particular gun or switch  
can be connected to the LN-25.  
GUN CABLE CONNECTOR REQUIREMENTS  
TO PERMIT PROPER CONNECTION TO  
LINCOLN LN-25 WIRE FEEDER.  
LN-25 Cable Connector for .023 through .052 Wire  
(For all other dimensions, see above)  
FIGURE C.1  
SWITCH REQUIREMENTS  
Amp AC 24 Volts – Inductive  
Amp DC 24 Volts – Inductive  
NOTE: Connector part with .749/.747 diameter  
1
2
should be made from brass if it is to be part of the  
welding current carrying circuit.  
1
2
“A Dia. Hole”  
To be Concentric to .749/.747  
Wire Size  
Dia. Within .008 F.I.M.  
5
1
.068 thru 64  
.125 ( ⁄8 Drill)  
1
5
16  
(.062)  
.078 ( ⁄64 Drill)  
1
.045 & .052  
.062 ( ⁄16 Drill)  
.023 thru .035  
.055 (#54 Drill)  
Drive Roll & Guide Tube  
Kit No.  
Wire Sizes Used  
S12024-1 (L.E. Part No.)  
3
5
T-13355- ⁄32  
64, .072 & .068  
Amphenol AN3057-10 (or equiv.)  
S12020-6 (L.E. Part No.)  
1
(1)  
1
T-13355- ⁄16  
16, .062  
Amphenol MS-3106A-18-11P (or equiv.)  
T-13355-.052C  
T-13355-.052  
T-15010.-.035S  
.045, .052 Cored  
.045, .052 Solid  
.023 thru .035 Solid  
(1)  
Can also be used for .052” wire  
FIGURE C.2 SWITCH REQUIREMENTS  
LN-25  
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MAINTENANCE  
D-1  
CONTROL BOX  
SAFETY PRECAUTIONS  
WARNING  
Every six months open and inspect the control sec-  
tion. The accumulated dirt should be gently blown off  
all of the electrical components. Be sure the air that  
is being used is dry. Check that lead plugs are secure  
in their receptacles.  
ELECTRIC SHOCK can kill.  
• Do not operate with covers  
removed.  
WIRE DRIVE MOTOR AND GEAR BOX  
• Turn off power source before  
installing or servicing.  
Every year examine the gear box. Paint the gear  
teeth with molydisulfide filled grease. Lincoln  
specification E2322. Do not use a graphite grease.  
• Do not touch electrically hot  
parts.  
Check the motor brushes. Replace if they are worn  
• Turn the input power to the  
welding power source off at  
the fuse box before working  
in the terminal strip.  
1
down to 4’’ or less. When ordering feed motor  
brushes, give all information from the motor  
nameplate.  
GUN AND CABLE MAINTENANCE  
• Only qualified personnel  
should install, use or ser-  
vice this equipment.  
See IM manual provided with the gun and cable  
assembly.  
CIRCUIT PROTECTION AND  
AUTOMATIC SHUTDOWN  
ROUTINE MAINTENANCE  
DRIVE ROLLS AND GUIDE TUBES  
CONTROL PC BOARD FUSE  
After feeding every coil of wire, inspect the drive roll  
section. Clean it as necessary. Do not use a solvent  
for cleaning the idle roll because it may wash the  
lubricant out of the bearing. The drive roll, idle roll  
and guide tubes are stamped with the wire sizes they  
will feed. If a wire size other than that stamped on  
the rolls is to be used, the rolls and guide tubes must  
be changed.  
1
On G1757-6 (or higher part no.) P.C. Boards the 8  
amp fuse was replaced with electronic protection for  
trigger circuit faults to electrode circuit.  
1
On G1757-2 through -5 part no. PC boards, the 8  
amp fuse interrupts the 500A lead to the trigger  
switch. On G1757- 1 PC boards a 5 amp fuse was  
used to interrupt the 667 lead. The LN-25 will not  
operate if the fuse is blown.  
The drive rolls for .035 through .052 cored electrode  
1
5
and ⁄16 through ⁄64 electrode have a double set of  
teeth so they can be reversed for additional life.  
Drive rolls for .023 through .052 solid electrode and  
aluminum sizes have no teeth but use two grooves  
so they also can be reversed for additional life.  
AUTOMATIC PROTECTION SHUTDOWN  
(See Automatic Protection Shutdown Section.)  
ADJUSTING SPEED  
SENSOR MODULE  
See Wire Feed Drive Roll and Guide Tube Kits Sec-  
tion for roll changing instructions.  
WIRE REEL SPINDLE  
The LN-25 Speed Sensor Module is a three lead Hall  
Effect switch device encased in an externally  
threaded housing which is screwed into a mounting  
plate on the motor side of the wire drive gearbox.  
No routine maintenance required. Do not lubri-  
cate spindle.  
Proper positioning of this module is critical to proper  
operation of the LN-25 wire feed speed control. If the  
LN-25  
4/96  
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MAINTENANCE  
D-2  
device is not screwed in far enough, the LN-25 motor  
speed could be unstable or run at full speed with no  
control. If screwed in too far, it will rub a moving part  
inside the gearbox.  
WARNING  
Electrode will be electrically “hot”. Do not allow fed  
wire to contact any metal common with welding work.  
The module is properly mounted to the gearbox  
as shipped from the factory. If the device is ever  
removed or replaced, proper mounting technique is  
as follows:  
An alternate means to measure wire feed speed  
is as follows:  
1. Be sure all power to the LN-25 is shut off at the  
power source.  
a. Cut wire off at the end of the gun tip.  
b. Press trigger to feed wire for exactly 30 seconds.  
2. Check that the module mounting plate is screwed  
securely to the side of the gearbox.  
c. Cut fed wire off at the end of the gun tip and  
accurately measure its length.  
3. Gently screw the module into the mounting plate  
until it just touches and stops against the  
rotating part inside the gearbox.  
d. Multiply the measured length by 2 to obtain  
the wire speed (IN/MIN).  
1
e. Repeat above steps to assure repeatable  
accuracy.  
4. Back the module out 2 turn, then snug the  
module locknut without rotating the module  
position. Do not overtighten locknut.  
4. Carefully slip speed knob onto potentiometer  
shaft so it points precisely to the wire speed  
measured in step 3, then secure the knob set  
screw without disturbing the position. Recheck by  
repeating step 3.  
CALIBRATION OF LN-25 WIRE  
SPEED DIAL  
Calibration of the LN-25 Wire Speed dial is achieved  
by proper mounting of the dial knob to the speed  
potentiometer shaft. Whenever the knob is removed,  
the dial is recalibrated as follows:  
NOTE: Knob set screw does not seat on shaft flat.  
1. Be sure the Wire Speed potentiometer mounting  
nut is securely tightened, then rotate the  
potentiometer shaft so its flat faces about to the  
100 mark on the LO range calibrated dial.  
2. Set DIAL RANGE switch to LO and WIRE FEED  
MODE switch to CV position.  
3. Press gun trigger to feed wire and measure  
the wire feed speed (IN/MIN) using a Portable  
Digital Wire Feed Speed Meter (Lincoln K283).  
Take at least two readings to assure repeat-  
able accuracy.  
Feed Speed Meter (Lincoln K283). Take at least  
two readings to assure repeatable accuracy.  
LN-25  
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TROUBLESHOOTING  
E-1  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs  
performed on this equipment may result in danger to the technician and machine operator and will invalidate your  
factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions  
detailed throughout this manual.  
This Troubleshooting Guide is provided to help you  
locate and correct possible machine malfunctions or  
misadjustments. Simply follow the three-step  
procedure listed below.  
Step 2. PERFORM EXTERNAL TESTS.  
The second column labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)” lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the order  
listed. In general, these tests can be conducted  
without removing the case wrap-around cover.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM  
(SYMPTOMS)”. This column describes possible  
symptoms that the machine may exhibit. Find the  
listing that best describes the symptom that the  
machine is exhibiting.  
Step 3. CONSULT LOCAL AUTHORIZED  
FIELD SERVICE FACILITY.  
If you have exhausted all of the recommended tests  
in Step 2, Consult your Local Authorized Field Service  
Facility.  
Symptoms are grouped into the following categories:  
Output Problems, Feeding Problems and Welding  
Problems.  
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 LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before  
you proceed.  
LN-25  
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TROUBLESHOOTING  
E-2  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FEEDING PROBLEMS  
No wire feed when gun trigger is  
pulled  
1. Power source must be on  
and open circuit voltage  
(OCV) present at weld  
terminals.  
2. LN-25 work clip may not be  
connected.  
3. LN-25 polarity switch must  
match electrode polarity.  
4. Jumper plug on control or  
option board may be loose  
or missing.  
5. The power source O.C.V.  
must be above 15 VDC. But  
not more than 110 VDC.  
Contact your local  
Lincoln Authorized  
Field Service Facility  
6. The gun trigger may be  
faulty.- Replace gun.  
Wire feeds for a short time but  
stops feeding. When gun trigger  
is released and retriggered wire  
feeding starts but stops again.  
1. The drive motor may be  
overloaded. Check the wire  
feeding system. EX. Drive  
roll tension, reel brake and  
gun cable liner.  
Wire feeds OK, but stubs or  
stops while welding.  
1. If the power source is a  
constant current type  
supply the arc voltage may  
be “dipping” below 15 VDC  
causing the LN-25 to stop  
or hesitate.  
2. Connect a constant voltage  
type power supply to the  
LN-25.  
3. Make sure wire-feed mode  
switch (S3) is in the proper  
position.  
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  
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TROUBLESHOOTING  
E-3  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FEEDING PROBLEMS  
Rough wire feeding or wire not  
feeding but drive rolls turning.  
1. Gun cable kinked and/or  
twisted.  
2. Wire jammed in gun and cable.  
3. Incorrect size or installation  
of drive roll and guide tubes.  
4. Drive roll loose.  
Contact your local  
Lincoln Authorized  
Field Service Facility  
5. Gun cable dirty.  
6. Worn drive roll.  
7. Electrode rusty and/or dirty.  
8. Worn nozzle or cable liner.  
9. Partially flashed or melted  
contact tip.  
10. Incorrect idle roll pressure.  
11. Wire reel brake tension set  
too high.  
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  
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TROUBLESHOOTING  
E-4  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Solenoid does not close when  
trigger is pulled or purge button  
is pressed. Wire feeds properly.  
1. Make certain that plugs J2  
and J3 are connected to the  
control board securely.  
WELD PROBLEMS  
Variable or “hunting” arc.  
1. Worn and/or melted contact  
tip -Replace.  
Contact your local  
Lincoln Authorized  
Field Service Facility  
2. Worn work cable or poor  
work connection.  
3. Loose electrode connect-  
ions. -Check for loose or  
faulty connections.  
4. Wrong electrode polarity for  
process being used.  
Weld porosity, narrow and ropey  
bead, or electrode stubbing into  
plate when welding.  
1. Contaminated weld joint or  
improper procedures. -  
Clean joint and check  
procedure (wire speed and  
all voltage).  
Motor feeds but there is no wire  
feed speed control.  
1. Make sure all molex plugs  
and leads are securely  
connected to the control  
board.  
2. Check speed sensor - see  
maintenance section.  
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  
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WIRING DIAGRAM  
F-1  
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ꢇꢂꢈ  
ꢀꢁꢂꢌ  
ꢀꢁꢂ  
ꢇꢂꢇ  
ꢀꢂꢂ  
ꢀꢄꢅ  
ꢇꢂꢈ  
ꢀꢁꢂꢌ  
ꢀꢁꢂ  
ꢇꢂꢇ  
ꢀꢂꢂ  
ꢀꢄꢅ  
ꢇꢂꢈ  
ꢀꢁꢂꢌ  
ꢀꢁꢂ  
    
  !   
    
    
    
      
      
      
    
  $  
    
    
    
    
    
    
    
  $  
      
      
  $  
    
    
    
      
    
      
  !   
      
  $  
     
     
     
     
MAR97  
LN-25  
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DIMENSIONS  
F-2  
LN-25 PHYSICAL DIMENSIONS  
16.60  
14.00  
.25  
21.00  
7.40  
LN-25  
4/96  
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