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IM10031-A
TM
LN-25 PRO
November, 2010
For use with machines having Code Number: 11620, 11621, 11716, 11717
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
IP23
IEC 60974-5
OPERATOR’SꢀMANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
process used and properly operating
regulators designed for the gas and
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is compe-
tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
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SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-
lems of interference. Screening of the entire welding installation may be considered for special
1.
applications
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEbꢀSITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TAbLE OF CONTENTS
Page
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Location................................................................................................................................A-2
High Frequency Protection...................................................................................................A-2
Weld cable Sizes..................................................................................................................A-2
Analog Control Cable ...........................................................................................................A-3
Cable Connections and Control Cable Connector ...............................................................A-4
Shielding Gas Connection....................................................................................................A-4
Wire Drive Configuration ......................................................................................................A-5
Changing The Gun Receiver Bushing................................................................................A-5
Procedure to Install Drive Rolls and Wire Guides ..............................................................A-5
Pressure Arm Adjustment ....................................................................................................A-6
Loading Spools of Wire ........................................................................................................A-6
Gun Connections..................................................................................................................A-6
Power Source to LN-25™ Pro Dual Power Cable Connection Diagrams ..............A-7 thru A-9
________________________________________________________________________________
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-10
Flow Meter..........................................................................................................................B-10
Power-Up Sequence ..........................................................................................................B-10
________________________________________________________________________________
Accessories ....................................................................................................................Section C
Factory Installed Equipment.................................................................................................C-1
Drive Roll Kits used..............................................................................................................C-1
Accessories Used ..................................................................................................C-2 thru C-5
Installation of Water Cooling Kit...........................................................................................C-6
________________________________________________________________________________
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
Troubleshooting Guide .................................................................................................E-2, E-3
________________________________________________________________________________
Wiring Diagram & Dimension Prints .............................................................................Section F
________________________________________________________________________________
Parts Pages ................................................................................................................P-630 Series
_______________________________________________________________________________
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A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – LN-25™ PRO (K2613-1, K2613-2)
A-1
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
450
325
100% rating
GEARING - WIRE FEED SPEED RANGE-WIRE SIzE
GMAW
FCAW
GEARING
WIRE SIzES
WFS RANGE
WFS RANGE
WIRE SIzES
Extra torque
K2613-2
.023 – 1/16"
(0.6 – 1.6mm)
30 – 400 ipm
(0.8 – 10.1m/min)
30 – 400 ipm
(0.8 – 10.1m/min)
.030 - 3/32”
(10.3 – 2.4mm)
Standard Speed
K2613-1
.023 – 1/16"
(0.6 – 1.6mm)
50 – 700 ipm
(1.3 – 17.7m/min)
50 – 700 ipm
(1.3 – 17.7m/min)
.030 - 5/64
(0.8 - 2.0mm)
PHYSICAL DIMENSIONS
WIDTH
HEIGHT
DEPTH
WEIGHT
14.8 Inches
(376 mm)
Handle folded down
8.7 Inches
( 221 mm)
22.2 Inches
(589 mm)
36 lbs
(16 kg)
TEMPERATURE RANGE
OPERATION:
STORAGE:
-40°F to 104°F (-40°C to 40°C)
-40°F to 185°F (-40°C to 85°C)
LN-25™ PRO
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A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
The handle of the LN-25™ PRO is intended for
moving the wire feeder about the work place only.
WARNING
When suspending a wire feeder, insulate the
hanging device from the wire feeder enclosure.
ELECTRICꢀSHOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box
HIGH FREQUENCY PROTECTION
before attempting to connect or
disconnect input power lines, out-
put cables or control cables.
• Only qualified personnel should
perform this installation.
CAUTION
Locate the LN-25™ PRO away from radio controlled
machinery. The normal operation of the LN-25™
PRO may adversely affect the operation of RF con-
trolled equipment, which may result in bodily injury
or damage to the equipment.
• Do not touch metal portions of the work clip
when the welding power source is on.
• Do not attach the work clip to the wire feeder.
• Connect the work clip directly to the work, as
close as possible to the welding arc.
• Turn power off at the welding power source
before disconnecting the work clip from the
work.
----------------------------------------------------------------------------
• Only use on power sources with open circuit
voltages less than 110 VDC.
WELD CAbLE SIzE
------------------------------------------------------------------------
LOCATION
Table A.1 located below are copper cable sizes rec-
ommended for different currents and duty cycles.
Lengths stipulated are the distance from the welder to
work and back to the welder again. Cable sizes are
increased for greater lengths primarily for the purpose
of minimizing cable drop.
For best wire feeding performance, place the LN-
25™ PRO on a stable and dry surface. Keep the
wire feeder in a vertical position. Do not operate the
wire feeder on an angled surface of more than 15
degrees.
Do not submerge the LN-25™ PRO.
The LN-25™ PRO is rated IP23 and is suitable for
outdoor use.
TAbLE A.1
RECOMMENDED CAbLE SIzES (RUbbER COVERED COPPER - RATED 167°F or 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES PERCENT
DUTY
CYCLE
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
2
2
3
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
2
2
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
200
200
225
225
250
250
250
250
300
325
350
400
400
500
60
100
20
40 & 30
30
40
60
100
60
100
60
60
100
60
2
2
1
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).
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A-3
A-3
INSTALLATION
ANALOG CONTROL CAbLE K1797-xx
The control cable connecting the wire feeder to the
power source is specially made for the welding envi-
ronment.
The wire feeder power requires overcurrent protec-
tion. Connect the wire feeder only to power sources
where the overcurrent protection is no more than 15
amps.
Do not use more than 100 ft. (30.5 m) of control cable
between the wire feeder and power source.
Wire Feeder
Power Source
J
A
L
A
L
J
N
F
K
I
I
B
D
K
B
D
H
C
H
N
F
C
G
G
M
M
E
E
WIRE FEEDER
POWER SOURCE
Function
Pin
Lead #
Pin
Function
Lead #
unused
Chassis GND
Welding Output Control
(trigger from feeder)
A
B
C
--
GND
2
A Reserved
B Reserved
C Welding Output Control
(trigger to power source)
--
2
Welding Output Control
(trigger from feeder)
D
E
F
4
D Welding Output Control
(trigger to power source)
4
Remote Voltage Control
("+" supply, from power source)
Remote Voltage Control
(control signal from feeder or remote.)
Remote Voltage Control
("-" supply, from power source)
Work connection to feeder
42 VAC to feeder
77
76
75
E Remote Voltage Control
("+" supply, from power source)
F Remote Voltage Control
(control signal from feeder or remote.)
G Remote Voltage Control
("-" supply, from power source)
H Work connection from power source
77
76
75
G
H
I
21
41
21
41
I
42 VAC to feeder
Reserved
J
J Reserved
42 VAC to feeder
Reserved
K
L
42
67
K 42 VAC to feeder
L Reserved
42
67
unused
Electrode voltage from feeder
M
N
M unused
N Electrode voltage to power source
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A-4
A-4
INSTALLATION
SHIELDING GAS CONNECTION
CAbLE CONNECTIONS
WARNING
There is one circular connector for the gun trigger on
the front of the LN-25™ PRO.
CYLINDER may explode if
damaged.
• Keep cylinder upright and
chained to support.
Function
Wiring
Pin
• Keep cylinder away from areas where it may be
damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live
electrical circuits.
5-pin trigger
connector for
push-guns
only.
Trigger
Not used
Common
Not used
Not used
A
B
C
D
E
• bUILD UP OF SHIELDING GAS MAY
HARM HEALTH OR KILL.
• Shut off shielding gas supply when not
in use.
• See American National Standard z-49.1, "Safety
in Welding and Cutting” Published by the
American Welding Society.
C
B
------------------------------------------------------------------------
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-5
A-5
INSTALLATION
WIRE DRIVE CONFIGURATION
(See Figure A.2)
8. Connect the shielding gas hose to the new gun
bushing, if required.
9. Rotate the gun bushing until the thumb screw hole
aligns with the thumb screw hole in the feed plate.
Slide the gun receiver bushing into the wire drive
and verify the thumb screw holes are aligned.
10. Tighten the socket head cap screw.
CHANGING THE GUN RECEIVER
bUSHING
WARNING
11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
Tools required:
• 1/4" hex key wrench.
WARNING
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
Note: Some gun bushings do not require the use of
the thumb screw.
• Only qualified personnel should perform mainte-
nance work.
1. Turn power off at the welding power source.
2. Remove the welding wire from the wire drive.
3. Remove the thumb screw from the wire drive.
4. Remove the welding gun from the wire drive.
5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.
Important: Do not attempt to completely
remove the socket head cap screw.
6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the pre-
cision fit, light tapping may be required to remove
the gun bushing.
------------------------------------------------------------------------
1. Turn power off at the welding power source.
2. Release the idle roll pressure arm.
3. Remove the outer wire guide by turning the knurled
thumbscrews counter-clockwise to unscrew them
from the feed plate.
4. Rotate the triangular lock and remove the drive
rolls.
7. Disconnect the shielding gas hose from the gun
bushing, if required.
FIGURE A.2
THUMB SCREW
GUN RECEIVER BUSHING
5. Remove the inner wire guide.
OUTER WIRE GUIDE
6. Insert the new inner wire guide, groove side out,
over the two locating pins in the feed plate.
7. Install a drive roll on each hub assembly secure
with the triangular lock.
8. Install the outer wire guide by aligning it with the
pins and tightening the knurled thumbscrews.
9. Close the idle arm and engage the idle roll pressure
arm. Adjust the pressure appropriately.
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN
TIGHTEN
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A-6
A-6
INSTALLATION
1. Squeeze the release bar on the retaining collar and
remove it from the spindle.
PRESSURE ARM ADJUSTMENT
WARNING
2. Place the spindle adapter on the spindle, aligning
the spindle brake pin with the hole in the adapter.
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the weld-
ing power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
3. Place the spool on the spindle and align the
adapter brake tab with one of the holes in the back
side of the spool. An indicator mark on the end of
the spindle shows the orientation of the brake tab.
Be certain the wire feeds off of the spool in the
proper direction.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
The pressure arm controls the amount of force the
drive rolls exert on the wire. Proper adjustment of the
pressure arm gives the best welding performance.
4. Re-install the retaining collar. Make sure that the
release bar snaps out and that the retaining collar
fully engages the groove on the spindle.
GUN CONNECTION
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the weld-
ing power source before installation or
changing drive rolls and/or guides.
Set the pressure arm as follows:
(See Figure A.3)
Aluminum wires
Cored wires
Steel, Stainless wires between 4 and 6
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.
FIGURE A.3
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
The LN-25™ PRO comes with a K1500-2 gun adapter
installed. (See Figure A.4)
ALUMINUM WIRES
Al
Fe, CrNi
CORED WIRES
Fe, CrNi
STEEL, STAINLESS WIRES
6
To install a gun,
1. Turn power OFF.
2. Remove the thumb screw.
3. Push the gun the completely into the gun bushing.
4. Secure the gun in place with the thumb screw.
5. Connect the trigger cable from the gun to the trigger
connector on the front of the feeder.
LOADING SPOOLS OF WIRE
WARNING
• Keep hands, hair, clothing and tools
away from rotating equipment.
• Do not wear gloves when threading wire
or changing wire spool.
Note: Not all gun bushings require the use of the
thumb screw.
• Only qualified personnel should install,
use or service this equipment.
------------------------------------------------------------------------
Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.
FIGURE A.4
THUMB
SCREW
GUN
A K468 spindle adapter is required for loading 2"
(51mm) wide spools on 2" (51mm) spindles. Use a
K468 spindle adapter for loading 2-1/2" (64mm) wide
spools.
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A-7
A-7
INSTALLATION
POWER SOURCE TO LN-25™ PRO
CAbLE CONNECTION DIAGRAMS
ACROSS THE ARC SET-UPS
CC Power Sources with Output Terminals Always
Hot (See Figure A.5)
CC Power Source
Classics
FIGURE A.5
Big Red’s
Eagle 10,000 Plus
Pipeliner 200D Without Wire Feed module
SAE’s Without CV Adapter
LN-25™ PRO
SAE 400 with CV adapter
Engine Driven welder with
Wire Feed Module
Electrode
Work
Work clip
K#
Description
LN-25™ PRO
LN-25™ PRO Extra Torque
If the power source has a Remote/Local switch, place
the switch in the Local position.
K2613-1
K2613-2
KP1695-XX
Place the CV/CC switch in the feeder in the "CC" posi-
tion.
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
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
CV-655
DC-400
DC-600
LN-25™ PRO
DC-655
Electrode
Work
V450-Pro
SAE 400 with CV adapter
Engine Driven welder with
Wire Feed Module
Work clip
Ranger 250 GXT
K#
Description
K2613-1
K2613-2
KP1695-XX
LN-25™ PRO
LN-25™ PRO Extra Torque
Place the power source Remote/Local switch in the
Local position.
KP1696-XX
KP1697-XX
See magnum Literature
Drive Roll Kit
Place CV/CC switch in the feeder in the "CV" position.
Welding Gun
CV power Source
Welding Cables
K1803-1
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A-8
A-8
INSTALLATION
CV Power Sources with Stud Connectors and no
Remote/Local Switch. (See Figure A.7)
Place CV/CC switch in the feeder in the "CV" position.
FIGURE A.7
CV-400
DC-655
Ranger 250, 250 LPG
Ranger 305G, 305D
Ranger 10,000
Jumper
LN-25™ Pro
Electrode
Work
Ranger 3 Phase
Ranger 225GXT
Ranger 225
Commander 300
Vantage 300, 400, 500
Air Vantage 500
Work clip
K#
Description
K2613-1
K2613-2
KP484
LN-25™ PRO
LN-25™ PRO Extra Torque
Jumper Plug Kit
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
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
LN-25™ PRO
V350-Pro
CV 305
Electrode
Work clip
Work
K#
Description
Place CV/CC switch in the feeder in the "CV" position.
K2613-1
K2613-2
KP1695-XX
LN-25™ PRO
LN-25™ PRO Extra Torque
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CC power Source
Welding Cables
K1841
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A-9
A-9
INSTALLATION
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.9)
FIGURE A.9
Jumper
CV-250
CV-300
CV-305
LN-25™ PRO
Electrode
Work
Work clip
K#
Description
Place CV/CC switch in the feeder in the "CV" position.
K2613-1
K2613-2
KP1695-XX
LN-25™ PRO
LN-25™ PRO Extra Torque
Drive Roll Kit
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
THIS MACHINE OR IN THIS MANUAL
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
bEFORE OPERATING MACHINE.
INPUT POWER
ON
WARNING
• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED fea-
ture, when feeding with gun trig-
ger, the electrode and drive
mechanism are always electri-
cally energized and could
remain energized several sec-
onds after the welding ceases..
• Do not touch electrically live part or electrode
with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards
removed or open.
---------------------------------------------------------------------
• FUMES AND GASSES can be
dangerous.
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
INPUT POWER
---------------------------------------------------------------------
• WELDING SPARKS can cause
fire or explosion.
DIRECT CURRENT
• Keep flammable material away.
OPEN CIRCUIT
VOLTAGE
U
0
----------------------------------------------------------------------
ARCꢀRAYS can burn.
• Wear eye, ear and body protec-
tion.
U
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
1
2
---------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MAN-
UAL.
U
----------------------------------------------------------------------
I
1
I
OUTPUT CURRENT
2
PROTECTIVE
GROUND
WARNING OR
CAUTION
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b-2
b-2
OPERATION
General Functional Description
DEFINITION OF WELDING TERMS
The LN-25™ PRO as designed is a simple, robust
feeder. Standard features include a calibrated wire
feed speed dial, 2 step/trigger interlock switch, CV-CC
switch, Gas Purge and Cold Feed.
WFS
• Wire Feed Speed
CC
• Constant Current
RECOMMENDED PROCESSES
• GMAW
• FCAW
CV
• Constant Voltage
PROCESS LIMITATIONS
GMAW
• Gas Metal Arc welding
• GMAW-P procedures must be qualified by the cus-
tomer.
SMAW
• Shielded Metal Arc welding
• Across-the-Arc models are not recommended for
stitch or spot welding.
FCAW
• Flux Core Arc Welding
EQUIPMENT LIMITATIONS
• The duty cycle of the wire feeder is 325A, 100% and
450A, 60%. Duty cycle is based upon the amount of
welding performed in a 10 minute period.
GENERAL DESCRIPTION
• The maximum spool size is 45 lb, 12" diameter.
• Maximum FCAW gun length is 15 ft.
• Maximum GMAW gun length is 25 ft.
General Physical Description
The LN-25™ PRO is specially engineered to be the
most rugged portable wire feeder available.
• Push-pull guns do not work with the wire feeder.
Several models of the LN-25™ PRO are offered to
best meet individual welder needs. The Extra Torque
model features additional torque gearing for reliable
feeding of large diameter FCAW wires. All of the mod-
els include a gas solenoid and flow meter for the flexi-
bility to run most wire processes.
RECOMMENDED POWER SOURCES
• CV-250
• CV-300
• CV-305
• CV-400
• CV-655
• DC-400
• DC-600
• DC-655
• Invertec V-350 PRO
• Invertec V-450 PRO
• Multi-Weld 350
• Ranger 10,000
• Ranger 3 Phase
• Ranger 225
• Ranger 225 GXT
• Ranger 250
• Ranger 250 GXT
• Ranger 305
• SAE-400
The 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.
• Pipeliner 200G
• Classic 300
• Vantage 300
• Vantage 400
• Vantage 500
• Air Vantage 500
Big Red’s
The heart of the LN-25™ PRO is the 2 roll MAX-
TRAC™ drive. The patented features on the wire
drive offer tool-less changing of the drive rolls and
wire guides for quick spool changes. A tachometer
controlled motor powers the patent pending drive rolls
for smooth, steady feeding without slippage.
Eagle 10,000 Plus
Classic’s
The LN-25™ PRO has only two p.c. boards that are
designed to be simple, reliable and easy to service.
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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
2. WIRE FEED SPEED KNOb
Wire Feed Speed, CC Operation
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 LN-
25™ Pro to "CC".
Wire Feed Speed, CV Operation
2. Refer to the Figure B.1a graph for the setting for
the wire feed speed knob setting. Select the hori-
zontal line representing the Desired Wire Feed
Speed. (See Figure B.1a arrow for 375 in/min.)
3. Select the diagonal line representing the Arc
Volts. (See Figure B.1a for 29 volts.)
4. Determine the vertical line representing the CC
representing the CC Wire Feed Speed setting
where the above two lines cross. (See Figure
B.1a arrow line for 450.) Set the LN-25™ Pro
wire feed speed knob to this value.
When Across the Arc models are operated with CV
power sources, the wire feed speed will remain a con-
stant value, independent of arc voltage changes, as
along as the arc voltage does not drop below the val-
ues per the following table.
CV OPERATION
Maximum WFS Maximum WFS
Standard Spin (Extra Torque
Minimum Arc Volts
CC WFS dial setting = desired WFS x 35
Arc Volts
Example:
375 in/min. (Horizontal Line) x 35
Gearing
280
340
Gearing)
210
235
15 V
17 V
21 V
24 V
27 V
=
29 Arc Volts (Diagonal Line)
440
520
400
400
= 452.5 (Vertical Line) Use 450 setting
(See Figure B.1a)
600
400
FIGURE b.1a
1
5
1
5
02
5
50
4
5
5
5
6
6
7
4
2
6
3
35
33
31
29
27
25
23
21
19
17
15
700
650
600
550
500
450
ARC
VOLTS
A constant voltage (CV) power
source is recommended for flux-
cored arc welding. (FCAW) and
gas metal arc welding (GMAW) to
obtain code quality results.
However, this wire feeder may also
be used with a constant current
(CC) power source to obtain pass-
able results for noncritical quality
applications.
400
375
350
300
250
200
150
100
50
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
-
POLARITÉ
POLARDAD
POLARITY
+
lights when the wire
feeder is connected
for positive polarity.
Use the polarity
LED to verify the
+ POLARITY
POLARDAD
- POLARITÉ
wire feeder is connected for the proper polarity.
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b-6
b-6
OPERATION
INTERNAL CONTROLS
FIGURE b.2
5
4
6
3
2
1
8
7
12
10
11
9
ITEM
DESCRIPTION
1
2
3
4
5
2 Step Trigger Interlock Switch
CV / CC Switch
Pressure Adjustment Arm
Optional Timer Kit (See Accessories Section)
Spool Retainer
6
Spindle Brake
7
8
Gun Bushing
Thumb Screw for securing the welding Gun
9
Socket Head Cap Screw for securing the Gun Bushing
10
11
12
Drive Hubs
Inlet Wire Guide
Cold Feed Pushbutton
LN-25™ PRO
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b-7
b-7
OPERATION
(See Figure B.2)
INTERNAL CONTROLS DESCRIPTION
(See Figure B.2)
The CV/CC switch sets the wire feed speed control
method for the wire feeder.
CV
CC
2 Step - Trigger Interlock Switch
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.
CC
The 2 Step - Trigger Interlock
switch changes the function of the
gun trigger. 2 Step trigger opera-
tion turns welding on and off in
direct response to the trigger.
Trigger Interlock operation allows
welding to continue when the trig-
ger is released for comfort on long
welds.
In the CC position, the wire feed
CV
speed varies during welding. The
arc length is maintained by chang-
ing the wire feed speed.
COLD FEED PUSHbUTTON
(See Figure B.2)
Place the toggle switch in the DOWN position for 2
Step operation or in the UP position for Trigger
Interlock operation.
When cold feeding, the wire drive will feed electrode
but neither the power source nor the gas solenoid will
be energized. Adjust the
2 Step Trigger
2 Step trigger operation is the most common. When
the gun trigger is pulled, the welding power source
energizes the electrode output and the wire feeder
feeds wire for welding. The power source and wire
feeder continue welding until the trigger is released.
speed of cold feeding by rotat-
ing the WFS knob. Cold feed-
ing, or "cold inching" the elec-
trode is useful for threading the
electrode through the gun.
Trigger Interlock
Trigger Interlock operation provides for operator com-
fort when making long welds. When the gun trigger is
first pulled, the welding power source energizes the
output and the wire feeder feeds wire for welding.
The gun trigger is then released while the weld is
made. To stop welding, the gun trigger is pulled
again, and when it is released the welding power
source output turns off and the wire feeder stops feed-
ing wire.
CAUTION
If the arc goes out while welding with
trigger interlock operation, the elec-
trode output from the welding power
source remains energized and the
wire feeder will continue to feed wire
until the gun trigger is again pulled
and then released.
------------------------------------------------------------------------
CV/CC SWITCH
LN-25™ PRO
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b-8
b-8
OPERATION
CONSTANT CURRENT WIRE WELDING
(See Figure B.3)
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.
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
Wire
Feeder
+
-
CTWD
WFS
Constant Current
Power Source
Current
LN-25™ PRO
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b-9
b-9
OPERATION
REAR CONTROLS:
4
S
l
t
o
nal
n
g
r
e
r
c
o
o
l
e
d
g
un
ITEM
6
D
E
S
C
R
I
T
I
N
5
4
2
1
1
2
3
4
5
6
ITEM
DESCRIPTION
1
2
3
4
Gas Purge Pushbutton
Flow Meter Ball
Flow Meter Valve
Shielding Gas Inlet
5
6
Electrode Lead
Optional Water cooled gun
connections
LN-25™ PRO
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b-10
b-10
OPERATION
GAS PURGE PUSHbUTTON
POWER-UP SEQUENCE
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.
On feeders with analog voltmeters, the thermal LED
will briefly light during power-up.
If the gun trigger is activated during power up, the
feeder will not operate until the gun trigger is released.
FLOW METER
The flowmeter shows the flow rate of shielding gas
and has a valve to adjust the flow. The flow meter is
scaled for CO , Ar, and Ar/CO blends. The middle of
2
2
the ball indicates the flow rate of shielding gas.
Adjust the flow rate while depressing the GAS
PURGE switch by turning the valve at the bottom of
the meter. Most weld procedures require 25-40 scfh
(11.8 - 18.9 lpm) for sufficient shielding gas coverage.
Gun angle, nozzle diameter, joint configuration and
wind conditions may effect the amount of shielding
gas required.
When using a wire feeder with
a flow meter, adjust the regu-
lator at the shield gas bottle or
supply to a flow rate that is
higher than the flow rate indi-
cated on the feeder flow
meter. Note that most regula-
tors are calibrated based upon
having low restrictions on the
outlet. The valve on the feeder
flow meter creates a high
90
80
70
60
50
restriction and may cause
errors in the readings at the
40
Ball
30
20
supply regulator. Set the gas
flow rate using the feeder flow
10
meter reading and not the
supply regulator reading.
Valve
SCFH
10
20
Liter/Min.
4.7
9.4
30
40
50
60
70
80
14.2
18.9
23.6
28.3
33.1
37.8
LN-25™ PRO
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C-1
C-1
ACCESSORIES
FACTORY INSTALLED EQUIPMENT
• K1500-2 Gun Receiver Bushing.
DRIVE ROLL KITS
KP KIT
WIRE TYPE
Steel Wires:
ELECTRODE SIzE
.023-.030 (0.6-0.8mm)
.035 (0.9mm)
KP1696-030S
KP1696-035S
KP1696-045S
KP1696-052S
Includes: 2 V groove
drive rolls and inner
.045 (1.2mm)
.052 (1.4mm)
1/16 (1.6mm)
.035,.045 (0.9, 1.2mm)
.040 (1.0mm)
KP1696-1/16S wire guide.
KP1696-1
KP1696-2
.030-.035" (0.8-0.9mm) KP1697-035C
.040-.045" (1.0-1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
.068-.072" (1.7-1.8mm)
5/64" (2.0mm)
3/32” (2.4mm)
KP1697-045C
KP1697-052C
KP1697-1/16C
KP1697-068
KP1697-5/64
KP1697-3/32
KP1695-035A
KP1695-040A
KP1695-3/64A
KP1695-1/16A
Cored Wires:
Includes: 2 Knurled
drive rolls and inner
wire guide.
.035" (0.9 mm)
.040" (1.0mm)
3/64" (1.2mm)
Includes: 2 polished
U groove drive rolls,
outer wire guide and
inner wire guide.
Aluminum Wires:
1/16" (1.6mm)
LN-25™ PRO
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C-2
C-2
ACCESSORIES
K1796-xx
AWG 1/0 Co-Axial Power Cable
AWG #1 Coaxial Power Cable
Work and Feeder Cables Package
Includes: 1/0 Coaxial weld
cable of length "xx". Ends of
the weld cable have lug con-
nections. Use for Pulse weld-
ing.
K2593-xx
K1803-1
Includes: AWG #1 Coaxial
weld cable of length "xx".
Ends of the weld cable have
lug connections. Use for
Pulse or STT™ welding.
Includes: Twist-Mate to Lug
2/0 cable 14' (1.2m) long with
Ground Clamp, and Twist-
Mate to Lug 2/0 Cable 9'
(2.7m) long.
K1840-xx
K1842-xx
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).
Weld Power Cable, Lug to Lug
Includes: 14 pin to 14 pin wire
feeder to power source control
cable.
Control Cable
K1797-xx
Includes: 14 pin circular con-
nector with jumper for leads 2-
4. For use in power sources
for turning the weld terminals
"ON" at all times.
Jumper Plug Kit
K484
K1798
(requires
remote control
kit
Adapter Cable for Control Cable to Includes: 14 circular connector
Terminal Strip Power Sources
with leads to connect to a ter-
minal strip.
LN-25™ PRO
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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
guns and compatible with Tweco®
#2-#4)
and hex key wrench.
Gun Receiver Bushing (for guns Includes: Gun receiver bush-
with K613-7 Lincoln gun connec- ing with hose nipple, set screw
K1500-3
tors; Magnum 550 guns and com-
patible with Tweco® #5)
and hex key wrench.
LN-25™ PRO
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C-4
C-4
ACCESSORIES
Gun Receiver Bushing (for gun Includes: Gun receiver bush-
with K466-3 Lincoln gun connec- ing with hose nipple, set screw
K1500-4
K1500-5
K489-7
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: 2 hoses with female
quick connectors at each end, 2
male connectors for 3/16" ID
hose, 2 male connectors for _" ID
hose, and mounting hardware.
Water Connection Kit (for
European and Control cable mod-
els only)
K590-6
K586-1
Includes: Deluxe Gas Regulator
for Mixed Gases, Adapter for
CO2 and 10' (3.0m) Hose.
Deluxe Adjustable Gas Regulator
LN-25™ PRO
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C-5
C-5
ACCESSORIES
4. Use a 5/16" nut driver to remove the screws holding
the water cooling cover on the case front of the
inner module and on the rear of the case.
INSTALLATION OF THE K590-6 WATER
COOLING KIT
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the dis-
connect switch before working on
this equipment.
• Do not touch electrically hot parts.
• Only qualified personnel should
install, use or service this equipment.
------------------------------------------------------------------------
The K590-6 components are rated up to 70 psi (5 bar)
and 158°F (70°C). Use a coolant fluid that is compati-
ble with the water cooler and the gun.
5. Install the fitting and hose assembly to the case
front. Route the hoses along the bottom of the
inner module and out through the cutout of the
cover. Slide the module back into the case.
Tools required:
• 3/8" wrench
• 5/16" nut driver
• medium flat bladed screw driver
• cutting tool
1. Turn power off at the welding power source.
2. Remove the screws securing the case to the inner
module using a 3/8" wrench.
6. Secure the module to the case with the screws.
(Shown in Step 2)
7. Install the fitting assembly to the rear of the case
3. Remove the module from the case by lifting the
front of the module approximately .25" (6 mm) and
then sliding forward.
ALUMINUM CASE
PLASTIC CASE
8. Slide the hose clamps on to the hoses. Trim the
hoses to length so that they lay flat on the case bot-
tom. Slide hose clamps on the hose. Slide the
hoses on to the fittings on the case rear and secure
with the hose clamps.
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D-1
D-1
MAINTENANCE
5. Energize the output circuit of the power source.
Adjust the power source output to 20±1 VDC as
measured on the reference meter.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
6. Verify that LN-25™ PRO voltmeter reads between
19 and 21 volts.
• 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.
If the voltmeter reading is out of range, check for
loose connections or replace the voltmeter. There is
no calibration adjustment for the LN-25™ PRO volt-
meter.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several
seconds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform main-
tenance work.
----------------------------------------------------------------------
ROUTINE MAINTENANCE
Flow Meter Validation
Tools required:
• Flow meter reference standard.
• Constant voltage DC welding power source (DC-
400, V-350, CV-400 or equivalent).
To verify the flow meter accuracy:
1. Turn power OFF.
• Check weld cables, control cables and gas hoses
for cuts.
• Clean and tighten all weld terminals.
2. Connect the LN-25™ PRO to the constant voltage
DC welding power source. The work lead of the
LN-25™ PRO must be connected to the work ter-
minal of the power source.
PERIODIC MAINTENANCE
• Clean drive rolls and inner wire guide and replace if
worn.
• Blow out or vacuum the inside of the feeder.
3. Connect a supply of CO2 to the wire feeder. Do
not exceed the maximum inlet pressure of the wire
feeder.
CALIbRATION SPECIFICATION
4. Disconnect the shielding gas hose that connects to
the gun bushing.
Voltmeter Validation, Across the Arc Analog Meter
Models
5. Connect the shielding gas hose to flow meter refer-
ence standard.
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).
6. Orient the LN-25™ PRO in a vertical position.
7. Turn power ON.
8. Adjust the flow meter on the LN-25™ PRO to 40
scfh while pressing the GAS PURGE button.
To verify the analog voltmeter accuracy:
1. Turn power OFF.
9. Measure the gas flow with the calibrated flow
meter while pressing the GAS PURGE button.
2. Connect the LN-25™ PRO to the constant voltage
DC welding power source. The work lead of the
LN-25™ PRO must be connected to the work ter-
minal of the power source.
10. The measured flow rate should be between 35
and 45 scfh.
3. Connect the reference voltmeter between the
brass block of the LN-25™ PRO and the work
lead.
4. Turn power ON.
LN-25™ PRO
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D-2
D-2
MAINTENANCE
The LN-25™ PRO flow meter cannot be calibrated. If
the flow meter reads incorrectly, check for leaks or
kinks in the gas hose. Replace the flow meter if neces-
sary.
To change the wire feed speed calibration:
(See Figure D.2)
Wire Feed Speed Validation
Tools required:
• 5/16" nut driver
• RPM meter
(See Figure D.1)
Calibration of the LN-25™ PRO may be required when
the p.c. board, wire feed speed potentiometer or motor is
replaced or serviced. Calibration matches the scale on
the name plate to the actual wire feed speed.
• Shorting plug. The shorting plug shorts pins 4 & 8 of
connector J3 on the Control P.C. Board. J3 is a 8 pin
molex connector.
1. Turn power OFF.
Tools required:
• RPM meter
2. Remove the 4 screws holding the rear cover inside
the feeder and remove the cover.
• Constant voltage DC welding power source (DC-400,
V-350, CV-400 or equivalent)
• 7/16" open end wrench
3. Open the idle arm.
To verify if calibration is necessary:
1. Turn power OFF.
4. Set the wire feed speed per the table.
Model gearing Wire Feed Speed
Standard Speed 400 in/min
2. Set the wire feed speed per the table.
Model gearing Wire Feed Speed Acceptable Range
Extra Torque
150 in/min
5. Connect the LN-25™ PRO to the constant voltage DC
welding power source. The work lead of the LN-25™
PRO must be connected to the work terminal of the
power source.
Standard Speed 400 in/min
Extra Torque 150 in/min
69 - 77 rpm
25 - 31 rpm
3. Remove the plastic cover from the lower portion of the
wire drive with a 7/16" wrench.
6. Turn power ON.
4. Connect the LN-25™ PRO to the constant voltage DC
welding power source. The work lead of the LN-25™
PRO must be connected to the work terminal of the
power source.
7. Insert the shorting plug into connector J3 on the
Control P.C. Board. The shorting plug shorts pins 4 &
8.
8. Remove the shorting plug.
5. Turn power ON.
9. Turn power OFF.
6. Measure the motor rpm when the COLD FEED button
is pressed.
10. Replace the cover and secure with the screws.
7. Verify the rpm is within the acceptable range.
FIGURE D.2
COVER
FIGURE D.1
MOTORꢀ
SHAFT
COVER
P.C. bOARD
LN-25™ PRO
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E-1
E-1
TROUbLESHOOTING
HOW TO USE TROUbLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the welding power source before installation or changing
drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and drive mechanism are "hot" to work
and ground and could remain energized several seconds after the gun trigger is
released.
• Welding power source must be connected to system ground per the National Electrical
Code or any applicable local codes.
• Only qualified personnel should perform maintenance work.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
LN-25™ PRO
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E-2
E-2
TROUbLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Output Problems
The feeder does power up - no dis- 1. The work sense lead is discon-
1. Connect the work sense lead to
the work in a location free of dirt,
rust and paint.
2. Turn ON the power source.
3. Reset the circuit breakers.
play, no cold feed.
nected or is a poor electrical con-
nection. (Across the arc models)
2. The power source is OFF.
3. The circuit breaker for the wire
feeder on power source have
tripped. (control cable models)
4. The control cable may be loose or
damaged. (control cable models)
4. Tighten, repair or replace the con-
trol cable.
The wire feeder power up but there 1. The contactor coil connections are
is no output when the trigger is loose.
pulled. The shielding gas is flowing 2. The contactor has failed.
and the drive rolls turn.
1. Verify the contactor coil connec-
tions.
2. Replace the contactor.
No shielding gas.
1. The gas supply is OFF or empty.
2. The gas hose is cut or crushed.
1. Verify the gas supply is ON and
flowing.
2. Route the gas hose so it avoids
sharp corners and make sure
nothing is on top of it. Repair or
replace damaged hoses.
3. The flow meter valve is closed.
4. Dirt or debris is in the solenoid.
3. Open the flow meter valve.
4. Apply filtered shop at 80psi to the
solenoid to remove dirt.
5. There is a loose solenoid connec-
tion.
5. Remove the cover and check that
all connections are in good condi-
tion.
6. The solenoid has failed.
Inconsistent wire feeding or wire not 1. The gun cable is kinked and/or
feeding but drive rolls turning.
1. Keep the gun cable as straight as
possible. Avoid sharp corners or
bends in the cable.
twisted.
2. The wire is jammed in the gun and
cable.
2. Remove the gun from the wire
feeder and pull the jammed wire
out of the gun and cable.
3. The gun liner is dirty or worn.
4. The electrode is rusty or dirty.
3. Blow dirt out of the liner with low
pressure (40psi or less). Replace
the liner if worn.
4. Use only clean electrode. Use
quality electrode, like L-50 or L-56
from Lincoln Electric.
5. The contact tip is partially melted
or has spatter.
5. Replace the contact tip.
6. Improper gun liner, tip, drive rolls
and/or inner wire guide.
6. Verify the proper parts are
installed.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
LN-25™ PRO
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E-3
E-3
TROUbLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Output Problems
7. Incorrect tension arm pressure on 7. Adjust the tension arm per the
the drive rolls.
Instruction Manual. Most elec-
trodes feed well at a tension arm
setting of "3".
8. The spindle brake is too tight.
9. Worn drive roll.
8. Verify the spool of wire moves
with minimal effort.
9. Replace the drive rolls if worn or
filled with dirt.
Wire feed speed consistently oper-
ates at the wrong value. The speed
changes when the wire feed speed
knob is adjusted.
1. The jumper lead for normal 1. Properly connect the normal
speed/extra torque is connected
improperly.
2. The wrong gear is installed in the the wire drive.
speed/extra torque jumper.
2. Install the proper pinion gear in
wire drive.
3. Replace the motor/gearbox
3. The brushes on the motor are assembly.
worn.
The wire feed speed stuck at 200-
300 in/min and there is no change
when the wire feed speed knob is
adjusted.
1. The tachometer is connected 1. Verify all of the tachometer leads
improperly.
2. The tachometer has failed.
are properly connected.
2. Replace the motor and tachome-
ter assembly.
Variable or "hunting" arc.
1. Wrong size, worn and/or melted 1. Replace the contact tip.
contact tip.
2. Worn work cable or poor work 2. Verify all work and electrode con-
connection.
nections are tight and that the
cables are in good condition.
Clean/replace as necessary.
3. Adjust polarity to the recommend-
ed procedure.
3. Wrong polarity.
4. The gas nozzle is extended 4. Adjust the gas nozzle and shorten
beyond the contact tip or the wire the stickout to 3/8 to 1/2 inches.
stickout is too long.
5. Poor gas shielding on processes 5. Check gas flow and mixture.
requiring gas.
Remove or block sources of
drafts.
Poor arc starts with sticking or
"blast-offs", weld porosity, narrow
and ropy looking bead.
1. Improper procedures or tech- 1. See "Gas Metal Arc Welding
niques. Guide" (GS-100).
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
LN-25™ PRO
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ENHANCED DIAGRAM
F-1
F-1
DIAGRAMS
LN-25™ PRO
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F-2
F-2
DIMENSION PRINT
LN-25™ PRO
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l Do not touch electrically live parts or
electrode with skin or wet clothing.
l Insulate yourself from work and
ground.
l Keep flammable materials away.
l Wear eye, ear and body protection.
WARNING
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible
l Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
l Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
l Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
l Gardez à l’écart de tout matériel
inflammable.
l Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
l Isolez-vous du travail et de la terre.
German
l Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
l Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
l 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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l Keep your head out of fumes.
l Use ventilation or exhaust to
remove fumes from breathing zone.
l Turn power off before servicing.
l Do not operate with panel open or
guards off.
WARNING
Spanish
l Los humos fuera de la zona de res-
piración.
l Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
l Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
l No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux
tien.
l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
l Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
l Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
l Vermeiden Sie das Einatmen von
Schweibrauch!
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer
serviço.
l Mantenha-se afastado das partes
moventes.
l Não opere com os paineis abertos
ou guardas removidas.
l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
l 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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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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