THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.
This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followedto avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.
READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.
USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from your face.
If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).
PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.
PROTECT others from splatter, flash, and glarewith protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work areaAT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018
SECTION A:WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,
or other reproductive harm.• Always start and operate the engine in a
well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. Foradditional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWEREDEQUIPMENT.
1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engineexhaust fumes outdoors.
1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating orrepairing equipment.
1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.
1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.
ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS
2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018
ELECTRIC SHOCK CAN KILL.
3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skin or wet clothing.Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your full areaof physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
FUMES AND GASESCAN BE DANGEROUS.
5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
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
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018
WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings to adjacent areas. Avoid welding near hydraulic lines.Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, specialprecautions 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.
6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper 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 SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IFDAMAGED.
7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.
7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjectedto physical damage.
• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tightexcept 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 forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.
FOR ELECTRICALLYPOWERED EQUIPMENT.
8.a. Turn off input power using the disconnectswitch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018
vSAFETYv
Electromagnetic Compatibility (EMC)
ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 15 Dec2004 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 harmonizedstandard: 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.
IntroductionAll electrical equipment generates small amounts of electromagnetic emission. Electrical emission may betransmitted through power lines or radiated through space, similar to a radio transmitter. When emissionsare received by other equipment, electrical interference may result. Electrical emissions may affect manykinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlledmachines, telephone systems, computers, etc. Be aware that interference may result and extra precautionsmay be required when a welding power source is used in a domestic establishment.
Installation and UseThe user is responsible for installing and using the welding equipment according to the manufacturer’sinstructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of thewelding equipment to resolve the situation with the technical assistance of the manufacturer. In some casesthis remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases itcould involve construction of an electromagnetic screen enclosing the power source and the work completewith associated input filters. In all cases electromagnetic disturbances must be reduced to the point wherethey 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 parallelwelding current return paths which may damage the earth circuits of other equipment.
Assessment of AreaBefore 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 thewelding 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 beingused 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.
viSAFETYvi
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains SupplyWelding 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 mainssupply. 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. Theshielding should be connected to the welding power source so that good electrical contact is maintainedbetween the conduit and the welding power source enclosure.
Maintenance of the Welding EquipmentThe 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 changesand adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking andstabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding CablesThe welding cables should be kept as short as possible and should be positioned close together, running ator close to floor level.
Equipotential BondingBonding 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 couldreceive a shock by touching these metallic components and the electrode at the same time. The operatorshould be insulated from all such bonded metallic components.
Earthing of the WorkpieceWhere the workpiece is not bonded to earth for electrical safety, not connected to earth because of its sizeand position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduceemissions in some, but not all instances. Care should be taken to prevent the earthing of the workpieceincreasing 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 countrieswhere direct connection is not permitted, the bonding should be achieved by suitable capacitance, selectedaccording to national regulations.
Screening and ShieldingSelective 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
applications1.
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-uct standard for arc welding equipment.”
viiiviii TAbLE OF CONTENTSPage
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1Safety Precautions ...............................................................................................................A-2Location................................................................................................................................A-2High Frequency Protection...................................................................................................A-2Weld cable Sizes, Electrode Lead........................................................................................A-2Shielding Gas Connection....................................................................................................A-3Wire Drive Configuration ......................................................................................................A-4Gun Receiver Bushing, Thumb Screw, Socket Head Cap Screw ......................................A-4
Procedure to Install Drive Rolls and Wire Guides ................................................................A-5Loading Spools of Wire ........................................................................................................A-5Pressure Arm Adjustment ....................................................................................................B-6Gun Connections..................................................................................................................A-6Power Source to LN-25™ Pro Dual Power Cable Connection Diagrams ..............A-7 thru A-9
________________________________________________________________________________Operation.........................................................................................................................Section b
Safety Precautions ...............................................................................................................B-1Graphic Symbols that appear on this Machine or in this Manual .........................................B-1Definition of Welding Terms .................................................................................................B-2General Description..............................................................................................................B-2Recommended Processes, Equipment Limitations, Recommended Power Sources ..........B-2Case Front Controls ...............................................................................................B-3 thru B-6Constant Current Wire Welding ....................................................................................B-4, B-5Case Front Controls Description ..........................................................................................B-6Internal Controls ...................................................................................................................B-7Internal Controls Decription..................................................................................................B-8Rear Controls .......................................................................................................................B-9
________________________________________________________________________________Accessories ....................................................................................................................Section C
Factory Installed Equipment.................................................................................................C-1Drive Roll Kits used..............................................................................................................C-1Accessories Used ..................................................................................................C-2 thru C-4
________________________________________________________________________________Maintenance....................................................................................................................Section D
________________________________________________________________________________Troubleshooting .............................................................................................................Section E
How to Use Troubleshooting Guide .....................................................................................E-1Troubleshooting Guide .................................................................................................E-2, E-4
Wiring Diagram & Dimension Prints .............................................................................Section F________________________________________________________________________________
Parts Pages ................................................................................................................P-667 Series_______________________________________________________________________________
A-1INSTALLATION A-1
LN-25™ PRO
TEMPERATuRE RANGE
OPERATION: -40°F to 104°F (-40°C to 40°C)
STORAGE: -40°F to 122°F (-40°C to 50°C)
INPuT VOLTAGE and CuRRENT
TEChNICAL SPECIFICATIONS – LN-25™ PRO (K2613-5, K2613-7)
Thermal tests have been performed at ambient temperature. The duty cycle (duty factor) at 40°C has been deter-mined by simulation.
Duty cycle is based upon the amount of welding performed in a 10 minute period.
IP23
WELD CAbLE SIzE
Table A.1 located below are copper cable sizes rec-ommended for different currents and duty cycles.Lengths stipulated are the distance from the welder towork and back to the welder again. Cable sizes areincreased for greater lengths primarily for the purposeof minimizing cable drop.
ELECTRODE LEADThe electrode lead is a 4/0 cable.
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cableslarger than recommended, or cables rated higher than 167°F(75°C).
RECOMMENDED CAbLE SIzES (RubbER COVERED COPPER - RATED 167°F or 75°C)**CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES
200200225225250250250250300325350400400500
PERCENTDUTY
CYCLE
6010020
40 & 3030406010060100606010060
0 to 50Ft.(0 to15m)
22
4 or 5332111
2/01/02/03/02/0
50 to 100Ft.(15 to 30m)
223332111
2/01/02/03/02/0
100 to 150 Ft.(30 to 46m)
222221111
2/02/02/03/03/0
150 to 200 Ft.(46 to 61m)
11111111
1/02/02/03/03/03/0
200 to 250 Ft.(61 to 76m)
1/01/01/01/01/01/01/01/02/03/03/04/04/04/0
TAbLE A.1
A-2INSTALLATION
LN-25™ PRO
A-2
SAFETY PRECAuTIONS
ELECTRIC ShOCK CAN KILL.• Turn the input power OFF at thedisconnect switch or fuse boxbefore attempting to connect ordisconnect input power lines, out-put cables or control cables.
• Only qualified personnel shouldperform this installation.
• Do not touch metal portions of the LN-25™ PROwork 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 thework.
• Only use on power sources with open circuitvoltages less than 110 VDC.
For best wire feeding performance, place the LN-25™ Pro on a stable and dry surface. Keep the wirefeeder in a vertical position. Do not operate the wirefeeder on an angled surface of more than 15degrees.
Do not submerge the LN-25™ Pro.
The LN-25™ Pro is rated IP23 and is suitable foroutdoor use.
The handle of the LN-25™ Pro is intended formoving the wire feeder about the work place only.
When suspending a wire feeder, insulate thehanging device from the wire feeder enclosure.
hIGh FREQuENCY PROTECTION
Locate the LN-25™ PRO away from radio controlledmachinery. The normal operation of the LN-25™PRO may adversely affect the operation of RF con-trolled equipment, which may result in bodily injuryor damage to the equipment.----------------------------------------------------------------------------
WARNING
CAuTION
A-3INSTALLATION
LN-25™ PRO
A-3
ShIELDING GAS CONNECTION
CYLINDER may explode ifdamaged.
• Keep cylinder upright andchained to support.
• Keep cylinder away from areas where it may bedamaged.
• Never lift welder with cylinder attached.• Never allow welding electrode to touch cylinder.• Keep cylinder away from welding or other live
electrical circuits.• buILD uP OF ShIELDING GAS MAY
hARM hEALTh OR KILL.• Shut off shielding gas supply when not
in use.• See American National Standard z-49.1, "Safety
in Welding and Cutting” Published by theAmerican Welding Society.
------------------------------------------------------------------------Maximum inlet pressure is 100 psi. (6.9 bar.)
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
2. Remove the cylinder cap. Inspect the cylinder valvesand regulator for damaged threads, dirt, dust, oil orgrease. Remove dust and dirt with a clean cloth. DONOT ATTACh ThE REGuLATOR IF OIL, GREASEOR DAMAGE IS PRESENT! Inform your gas supplierof this condition. Oil or grease in the presence of highpressure oxygen is explosive.
3. Stand to one side away from the outlet and open thecylinder valve for an instant. This blows away any dustor dirt which may have accumulated in the valve out-let.
4. Attach the flow regulator to the cylinder valve andtighten the union nut(s) securely with a wrench. Note:if connecting to 100% CO2 cylinder, insert regulatoradapter between regulator and cylinder valve. Ifadapter is equipped with a plastic washer, be sure it isseated for connection to the CO2 cylinder.
5. Attach one end of the inlet hose to the outlet fitting ofthe flow regulator. Attach the other end to the weldingsystem shielding gas inlet. Tighten the union nuts witha wrench.
WARNING
6. Before opening the cylinder valve, turn the regulatoradjusting knob counterclockwise until the adjustingspring pressure is released.
7. Standing to one side, open the cylinder valve slowly afraction of a turn. When the cylinder pressure gagestops moving, open the valve fully.
8. The flow regulator is adjustable. Adjust it to the flowrate recommended for the procedure and processbeing used before making a weld.
GUN RECEIVER BUSHING
LOOSEN TIGHTEN
THUMB SCREW
OUTER WIRE GUIDE
SOCKET HEAD
CAP SCREW
CONNECTOR BLOCK
FIGuRE A.2
WIRE DRIVE CONFIGuRATION(See Figure A.2)
GuN buShING, ThuMb SCREW ANDSOCKET hEAD CAP SCREW
ELECTRIC ShOCK can kill.• Turn the input power OFF at the
welding power source before instal-lation or changing drive rolls and/orguides.
• Do not touch electrically live parts.• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work andground and could remain energized several sec-onds after the gun trigger is released.
• Do not operate with covers, panels or guardsremoved or open.
• Only qualified personnel should perform mainte-nance work.
• 1/4" hex key wrench.Note: Some gun bushings do not require the use of
the thumb screw.
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 theconnector bar against the gun bushing.Important: Do not attempt to completelyremove the socket head cap screw.
6. Remove the outer wire guide, and push the gunbushing out of the wire drive. Because of the pre-cision fit, light tapping may be required to removethe gun bushing.
7. Disconnect the shielding gas hose from the gunbushing, if required.
8. Connect the shielding gas hose to the new gunbushing, if required.
WARNING
A-4INSTALLATION
LN-25™ PRO
A-4
9. Rotate the gun bushing until the thumb screw holealigns with the thumb screw hole in the feed plate.Slide the gun receiver bushing into the wire driveand verify the thumb screw holes are aligned.
10. Tighten the socket head cap screw 10 to 14 ft-lbs(13.5 to 19.0 Nm).
11. Insert the welding gun into the gun bushing andtighten the thumb screw.
LOADING SPOOLS OF WIRE• Keep hands, hair, clothing and tools
away from rotating equipment.• Do not wear gloves when threading wire
or changing wire spool.• Only qualified personnel should install, use or
service this equipment.------------------------------------------------------------------------Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.
A K468 spindle adapter is required for loading 2"(51mm) wide spools on 2" (51mm) spindles. Use aK468 spindle adapter for loading 2-1/2" (64mm) widespools.
WARNING
A-5INSTALLATION
LN-25™ PRO
A-5
PROCEDuRE TO INSTALL DRIVE ROLLSAND WIRE GuIDES
• Turn the input power OFF at thewelding power source before instal-lation or changing drive rolls and/orguides.
• Do not touch electrically live parts.• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work andground and could remain energized several sec-onds after the gun trigger is released.
• Do not operate with covers, panels or guardsremoved or open.
• Only qualified personnel should perform mainte-nance work.
------------------------------------------------------------------------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 themfrom the feed plate.
4. Rotate the triangular lock and remove the driverolls.
5. Remove the inner wire guide.6. Insert the new inner wire guide, groove side out,
over the two locating pins in the feed plate.
WARNING
7. Install a drive roll on each hub assembly securewith the triangular lock.
8. Install the outer wire guide by aligning it with thepins and tightening the knurled thumbscrews.
9. Close the idle arm and engage the idle roll pressurearm. Adjust the pressure appropriately.
1. Squeeze the release bar on the retaining collar andremove it from the spindle.
2. Place the spindle adapter on the spindle, aligningthe spindle brake pin with the hole in the adapter.
3. Place the spool on the spindle and align theadapter brake tab with one of the holes in the backside of the spool. An indicator mark on the end ofthe spindle shows the orientation of the brake tab.Be certain the wire feeds off of the spool in theproper direction.
4. Re-install the retaining collar. Make sure that therelease bar snaps out and that the retaining collarfully engages the groove on the spindle.
THUMBSCREW
GUN
A-6INSTALLATION
LN-25™ PRO
A-6
GuN CONNECTION
ELECTRIC ShOCK can kill.• Turn the input power OFF at the weld-
ing power source before installation orchanging 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 andground and could remain energized several sec-onds after the gun trigger is released.
• Do not operate with covers, panels or guardsremoved or open.
• Only qualified personnel should perform mainte-nance work.
The LN-25™ PRO comes with a K1500-2 gun adapterinstalled. (See Figure A.4)
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.
Note: Not all gun bushings require the use of thethumb screw.
FIGuRE A.4
WARNING
PRESSuRE ARM and ADJuSTMENT
ELECTRIC ShOCK can kill.• Turn the input power OFF at the
welding power source before instal-lation or changing drive rolls and/orguides.
• Do not touch electrically live parts.• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work andground and could remain energized several sec-onds after the gun trigger is released.
• Do not operate with covers, panels or guardsremoved or open.
• Only qualified personnel should perform mainte-nance work.
------------------------------------------------------------------------The pressure arm controls the amount of force thedrive rolls exert on the wire. Proper adjustment of thepressure arm gives the best welding performance.Many welding problems can be attributed to settingthe pressure arm too high and causing wire deforma-tion. Set the pressure arm to minimum amount thatprovides reliable feeding.
Set the pressure arm as follows:(See Figure A.3)
Aluminum wires between 1 and 2Cored wires between 1 and 3Steel, Stainless wires between 3 and 5
FIGuRE A.3
WARNING
6
AlFCAWGMAW
ALUMINUM WIRESCORED WIRESSTEEL, STAINLESS WIRES
A-7INSTALLATION
LN-25™ PRO
A-7
ACROSS ThE ARC SET-uPS
CC Power Sources with Output Terminals Alwayshot (See Figure A.5)
If the power source has a Remote/Local switch, placethe switch in the Local position.
Place the CV/CC switch in the feeder in the "CC" posi-tion.
CV Power Sources with Stud Connectors andRemote/Local Switch (See Figure A.6)
Place the power source Remote/Local switch in theLocal position.
Place CV/CC switch in the feeder in the "CV" position.
Work clipWork
Electrode LN-25™ PRO
CC Power Source
ClassicsBig Red’sEagle 10,000 Plus Pipeliner 200D Without Wire Feed moduleSAE’s Without CV Adapter
SAE 400 with CV adapterEngine Driven welder withWire Feed Module
A-9CV Power Source with Twist-Mate Connectors andno Remote/Local Switch. (See Figure A.9)
Place CV/CC switch in the feeder in the "CV" position.
Work clip
Work
Electrode
Jumper
LN-25™ PRO(Across the Arc)
CV-250CV-300
FIGuRE A.9
K#
K2613-5K2613-7
KP1695-XXKP1696-XXKP1697-XX
See Magnum Literature
K1841-XXK852-95
K484
Description
LN-25™ PRO LN-25™ PRO Extra Torque
Drive Roll Kit
Welding GunCV power SourceWelding Cables
Twist-Mate Cable plugJumper Plug kit
b-1OPERATION
LN-25™ PRO
b-1
• ELECTRIC ShOCK CAN KILL.unless using COLD FEED fea-ture, when feeding with gun trig-ger, the electrode and drivemechanism are always electri-cally energized and couldremain energized several sec-onds after the welding ceases..
• Do not touch electrically live part or electrodewith 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 bedangerous.
• Keep your head out of fumes.• use ventilation or exhaust to
remove fumes from breathingzone.
---------------------------------------------------------------------• WELDING SPARKS can cause
fire or explosion.• Keep flammable material away.
---------------------------------------------------------------------ARC RAYS can burn.• Wear eye, ear and body protec-
tion.---------------------------------------------------------------------SEE ADDITIONAL WARNING INFORMATIONuNDER ARC WELDING SAFETY PRECAuTIONSAND IN ThE FRONT OF ThIS OPERATING MAN-uAL.---------------------------------------------------------------------
WARNING
SAFETY PRECAuTIONSREAD AND uNDERSTAND ENTIRE SECTIONbEFORE OPERATING MAChINE.
INPuT POWER
ON
OFF
WIRE FEEDER
POSITIVE OuTPuT
NEGATIVE OuTPuT
INPuT POWER
DIRECT CuRRENT
OPEN CIRCuIT VOLTAGE
INPuT VOLTAGE
OuTPuT VOLTAGE
INPuT CuRRENT
OuTPuT CuRRENT
PROTECTIVEGROuND
WARNING ORCAuTION
u0
u1
u2
I1
I2
GRAPhIC SYMbOLS ThAT APPEAR ONThIS MAChINE OR IN ThIS MANuAL
b-2OPERATIONb-2
LN-25™ PRO
DEFINITION OF WELDING TERMS
WFS• Wire Feed Speed
CC• Constant Current
CV• Constant Voltage
GMAW• Gas Metal Arc welding
SMAW• Shielded Metal Arc welding
FCAW• Flux Core Arc Welding
GENERAL DESCRIPTION
General Physical DescriptionThe LN-25™ PRO is specially engineered to be themost rugged portable wire feeder available.
Several models of the LN-25™ PRO are offered tobest meet individual welder needs. The Extra Torquemodel features additional torque gearing for reliablefeeding of large diameter FCAW wires. The Standardand Dual Power models feature wire drive gearing forgreat performance for both FCAW and GMAW wiresof common sizes. All of the models include a gassolenoid for the flexibility to run most wire processes.
The plastic case is molded from a high impact, flameretardant plastic for durability and low weight.
The heart of the LN-25™ PRO is the 2 roll MAX-TRAC™ drive. The patented features on the wiredrive offer tool-less changing of the drive rolls andwire guides for quick spool changes. A tachometercontrolled motor powers the patented drive rolls forsmooth, steady feeding without slippage.
With a 450 amp, 60% duty cycle rating, these feedersare ready for heavy duty welding.
General Functional DescriptionAll LN-25™ PRO’s have adjustable WFS range forimproving the knob sensitivity. The low range is greatfor critical welds with Innershield wires, and the upperrange is suitable for general purpose welding.Selection of the WFS range is by a rocker switch orthrough the set-up menu on meters with digital dis-plays.
RECOMMENDED PROCESSES• GMAW• FCAW
PROCESS LIMITATIONS
• GMAW-P procedures must be qualified by the cus-tomer.
• Across-the-Arc models are not recommended forstitch or spot welding.
EQuIPMENT LIMITATIONS• The duty cycle of the wire feeder is 450A, 60%.
Duty cycle is based upon the amount of weldingperformed in a 10 minute period.
• The maximum spool size is 45 lb. (24 Kg), 12”(305mm) diameter.
• Maximum FCAW gun length is 15 ft.• Maximum GMAW gun length is 25 ft.• K2330-1 Timer Kits do not work with the feeder. Use
K2330-2 kits. • Push-pull guns do not work with the LN-25™ PRO.• Not compatible with K489-7 Euro connector (except
1. ANALOG VOLTMETERReads 0 – 40 VDC and is polarity insensitive.Shows OCV when not welding and arc voltagewhen welding.
(See Customer Assistance Policy in the front of thisInstruction Manual)
CASE FRONT CONTROLS (See Figure b.1)
ITEM DESCRIPTION
1 Analog Voltmeter2 Wire Feed Speed Knob3 Wire Feed Speed Range Switch4 5-pin gun trigger connector5 Work sense lead6 Thermal LED, Motor Overload7 Polarity LED
LN-25™ PRO
1
6
5
27
3
4
FIGuRE b.1
Maximum WFS(StandardTorque)
400450570650700
Maximum WFS(Extra Torque )
220250300350400
Minimum Arc Volts
15 V17 V21 V24 V27 V
b-4OPERATIONb-4
Wire Feed Speed, CC Operation
When Across the Arc models are operated with CCpower sources, the wire feed speed changes as thearc voltage changes. When the arc voltage increases,the wire feed speed will increase; and when the arcvoltage decreases, the wire feed speed will decrease.
To preset the wire feed speed on CC power sources:
1. Set the Wire Feed Mode switch inside the LN-25™ Pro to "CC".
2. Refer to the Figure B.1a graph for the setting forthe wire feed speed knob setting. Select the hori-zontal line representing the Desired Wire FeedSpeed. (See Figure B.1a arrow for 375 in/min.)
3. Select the diagonal line representing the ArcVolts. (See Figure B.1a for 29 volts.)
4. Determine the vertical line representing the CCrepresenting the CC Wire Feed Speed settingwhere the above two lines cross. (See FigureB.1a arrow line for 450.) Set the LN-25™ Prowire feed speed knob to this value.
CC WFS dial setting = desired WFS x 35Arc Volts
Example:375 in/min. (Horizontal Line) x 3529 Arc Volts (Diagonal Line)
A constant voltage (CV) powersource is recommended for flux-cored arc welding. (FCAW) andgas metal arc welding (GMAW) toobtain code quality results.However, this wire feeder may alsobe used with a constant current(CC) power source to obtain pass-able results for noncritical qualityapplications.
=
use 450 setting
The serviceability of a product or structure utilizing theLN-25™ PRO wire feeder is and must be the soleresponsibility of the builder/user. Many variablesbeyond the control of The Lincoln Electric Companyaffect the results obtained in using the LN-25™ PROwire feeder. These variables include, but are not lim-ited to, welding procedure, plate chemistry and tem-perature, weldment design, fabrication methods andservice requirements. The available range of the LN-25™ PRO wire feeder may not be suitable for allapplications, and the builder/user is and must be sole-ly responsible for welding settings.
b-5OPERATIONb-5
LN-25™ PRO
CONSTANT CuRRENT WIRE WELDING (See Figure B.3)
Most semiautomatic welding processes perform betterusing constant voltage power sources.
Welding codes usually do not address the powersource selection or specifically, whether the weldingprocess is to be operated in the constant voltage orconstant current mode. Instead, codes typically speci-fy limitations on the current, voltage, heat input andpreheat temperature based on the material to bewelded. The intention is to assure that proper weldmaterial properties will develop.
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 existingstick (SMAW) power source and the power sourcecan be placed at a distant location without any provi-sion for adjusting the output settings.
For constant current operation, the power source isset to deliver the specified current. The power sourceregulates this current regardless of changes in thewelding circuit, including cable length, electrode diam-eter, wire feed speed, contact tip to work distance,etc.
Changes in the wire feed speed (WFS) or contact tipto work distance (CTWD) affect the arc voltage whenconstant current power sources are used. Loweringthe wire feed speed raises the voltage, raising thewire feed speed lowers the voltage. Lengthening thecontact tip to work distance raises the voltage, short-ening the contact tip to work distance lowers the volt-age.
If the contact tip to work distance is properly main-tained, a satisfactory operating voltage range may beachieved, 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 byincreasing the wire feed speed to regulate the voltage.Even if the voltage and current remain unchanged, theincreased wire feed speed may result in a depositionrate well beyond the specified range of the electrode.Under these conditions, the specified weld metal prop-erties may not be achieved.
Constant voltage power sources deliver large currentsurges to stabilize the arc when the electrode is short-ed or the arc length is very short. However, a constantcurrent power source does not provide such aresponse to stabilize the arc. It may be difficult toachieve required weld metal properties, or to achievethe required quality of welds needed to pass nonde-structive tests, when such welds are made under con-stant current operation.
For these reasons, Lincoln Electric does NOT recom-mend constant current semiautomatic welding forapplications which need to meet specified weld metalchemical or mechanical property requirements or weldquality requirements.
FIGuRE b-3
For best results, keep the gun cable and conduit asstraight as possible. Perform regular maintenanceand cleaning on the gun liner, conduit and gun.Always use quality electrode, such as L-50 or L-56from Lincoln Electric.
7. POLARITY LED
The Polarity LEDlights when the wirefeeder is connectedfor positive polarity.Use the polarityLED to verify thewire feeder is connected for the proper polarity.
b-6OPERATIONb-6
LN-25™ PRO
2. WIRE FEED SPEED KNObUse the Wire Feed Speed Knob to adjust the rate ofwire feed speed.
WFS range for standard torque:High = 50 to 700 ipm Low = 50 to 200 ipm
WFS range for extra torque:High = 50 to 400 ipmLow = 50 to 200 ipm
Because the wire feeder is powered by the arc volt-age, the full range of wire feed speed may not beavailable at low voltages.
3. WIRE FEED SPEED RANGE SWITChUse to select either the low range or high range forthe wire feed speed knob. Note – selecting the lowrange does not increase the torque of the wiredrive.
4. 5-PIN GuN TRIGGER CONNECTORThere is one circular connector for the gun triggeron the front of the LN-25™ PRO. Note – if the guntrigger is already depressed when the feeder ispowered up, the feeder will not activate. Releaseand then press the gun trigger to begin welding.
5. WORK SENSE LEADAlways turn power off at the welding power sourcebefore moving the work sense lead.
The work sense lead attaches to the item beingwelded.
6. ThERMAL LED, MOTOR OVERLOAD
The thermal light illuminates when thewire drive motor draws too much current.If the thermal light illuminates, the wiredrive will automatically shutdown for up to30 seconds to allow the motor to cool. Tostart welding again, release the gun trigger, inspectthe gun cable, liner (and conduit). Clean and makerepairs as necessary. Start welding again when theproblem has been safely resolved.
+ POLARITY POLARDAD- POLARITÉ
AE
C B
D
Pin
ABCDE
Wiring
5 volt supplyNot usedTrigger
Not usedNot used
Function
5-pin triggerconnector for push-gunsonly.
b-7OPERATIONb-7
INTERNAL CONTROLS
LN-25™ PRO
1 2 Step Trigger Interlock Switch2 CV / CC Switch3 Pressure Adjustment Arm4 Optional Timer Kit 5 Spool Retainer 6 Spindle Brake7 Gun Bushing, Thumb Screw and Socket Head Cap Screw
ITEM DESCRIPTION
1
98
7
632
8 Drive Hubs9 Cold Feed Pushbutton
4 5
FIGuRE b.2
b-8OPERATIONb-8
INTERNAL CONTROLS DESCRIPTION(See Figure B.2)
1. 2 STEP - TRIGGERINTERLOCK SWITCh
The 2 Step - Trigger Interlockswitch changes the function of thegun trigger. 2 Step trigger opera-tion turns welding on and off indirect response to the trigger.Trigger Interlock operation allowswelding to continue when the trig-ger is released for comfort on longwelds.
Place the toggle switch in the DOWN position for 2Step operation or in the UP position for TriggerInterlock operation.
2 Step Trigger
2 Step trigger operation is the most common. Whenthe gun trigger is pulled, the welding power sourceenergizes the electrode output and the wire feederfeeds wire for welding. The power source and wirefeeder continue welding until the trigger is released.
Trigger Interlock
Trigger Interlock operation provides for operator com-fort when making long welds. When the gun trigger isfirst pulled, the welding power source energizes theoutput and the wire feeder feeds wire for welding.The gun trigger is then released while the weld ismade. To stop welding, the gun trigger is pulledagain, and when it is released the welding powersource output turns off and the wire feeder stops feed-ing wire.
If the arc goes out while welding withtrigger interlock operation, the elec-trode output from the welding powersource remains energized and thewire feeder will continue to feed wireuntil the gun trigger is again pulledand then released.
The CV/CC switch sets the wirefeed speed control method for thewire feeder.
In the CV position, the wire feedspeed remains constant duringwelding. A steady arc voltage isregulated by the power source byadjusting the arc current.
In the CC position, the wire feedspeed varies during welding. Thearc length is maintained by chang-ing the wire feed speed.
3. PRESSuRE ARM and ADJuSTMENT(SEE INSTALLATION SECTION)
4. OPTIONAL TIMER KIT
The optional Timer Kit provides control of preflow
time, burnback, and postflow time.
5. SPOOL RETAINERTo release the spool retainer, squeeze the metal barinwards. When securing the spool, verify the spoolretainer is fully seated in place in one of the threegrooves of the spindle.
6. SPOOL bRAKEAdjust the spool brake to provide enough friction tostop wire overrun. Excessive brake force may causemotor thermal overloads or welding problems.
7. GuN buShING, ThuMb SCREW ANDSOCKET hEAD CAP SCREW(SEE INSTALLATION SECTION)
8. DRIVE ROLLS AND WIRE GuIDES(SEE INSTALLATION SECTION)
9. COLD FEED PuShbuTTONWhen cold feeding, the wiredrive will feed electrode but nei-ther the power source nor thegas solenoid will be energized.Adjust the speed of cold feed-ing by rotating the WFS knob.Cold feeding, or "cold inching"the electrode is useful forthreading the electrode through
the gun.
LN-25™ PRO
CV
CC
CAuTION
b-9OPERATIONb-9
REAR CONTROLS:(See Figure B.4)
FIGuRE b.4
LN-25™ PRO
1 Gas Purge Pushbutton2 Shielding Gas Inlet3 Electrode Lead
ITEM DESCRIPTION
1
3
2
1. GAS PuRGE PuShbuTTON
The gas solenoid valve will energize but neither thepower source output nor the drive motor will be turnedon. The Gas Purge switch is useful for setting theproper flow rate of shielding gas. Flow meters shouldalways be adjusted while the shielding gas is flowing.
Includes: 2 Spindle Adapters,one for 2" wide spools and the
other for 3" wide spools.
Includes: 2 hoses with femalequick connectors at each end, 2
male connectors for 3/16" IDhose, 2 male connectors for _" ID
hose, and mounting hardware.
Includes: Deluxe Gas Regulatorfor Mixed Gases, Adapter forCO2 and 10' (3.0m) Hose.
Includes: A wire feed speedmeter with digital display.
K1500-2
K1500-3
Gun Receiver Bushing (for gunswith K466-2, K466-10 Lincoln gunconnectors; Magnum 200/300/400guns and compatible with Tweco®
#2-#4)
Gun Receiver Bushing (for gunswith K613-7 Lincoln gun connec-tors; Magnum 550 guns and com-
patible with Tweco® #5)
Includes: Gun receiver bush-ing with hose nipple, set screw
and hex key wrench.
Includes: Gun receiver bush-ing with hose nipple, set screw
and hex key wrench.
ELECTRIC ShOCK can kill.• Turn the input power OFF at the
welding power source beforeinstallation or changing driverolls and/or guides.
• Do not touch electrically liveparts.
• When inching with the gun trigger, electrodeand drive mechanism are "hot" to work andground and could remain energized several sec-onds after the gun trigger is released.
• Do not operate with covers, panels or guardsremoved or open.
• Only qualified personnel should perform mainte-nance work.
• Check weld cables, control cables and gas hosesfor cuts.
• Clean and tighten all weld terminals.
PERIODIC MAINTENANCE
• Clean drive rolls and inner wire guide and replace ifworn.
• Blow out or vacuum the inside of the feeder.• Inspect the motor brushes every 6 months. Replace
if shorter than 0.5” (12.7mm).
CALIbRATION SPECIFICATION
VOLTMETER VALIDATION(See Figure D.1)
To verify the analog voltmeter accuracy:
1. Turn power OFF.2. Connect the LN-25™ PRO to the constant voltage DC
power supply capable of supply at least 4 amps.Connect the electrode to the “+” positive terminal andthe work clip to the “-“ negative terminal.
3. Connect a reference voltmeter between the brassblock of the LN-25™ PRO and the work lead.
4. Turn power ON.5. Energize the power supply. Adjust the power source
output to 20.0 VDC as measured on the referencemeter.
6. Verify that LN-25™ PRO voltmeter reads 20 volts.Adjust the voltmeter as necessary by turning the screwon the voltmeter.
FIGuRE D.1
CalibrationScrew
D-2MAINTENANCED-2
WIRE FEED SPEED VALIDATION
Calibration of the LN-25™ PRO may be required whenthe P.C. board, wire feed speed potentiometer or motoris replaced or serviced. Calibration matches the scale onthe name plate to the actual wire feed speed.
To calibrate the LN-25™ PRO:
1. Turn power OFF at the welding source.
2. Remove the spool of wire and the cover from thefeeder. Remove the gun from the feeder plate, leav-ing the gun trigger attached to the feeder. Removethe plastic cover on the feed plate to reveal themotor gear.
3. Place the WFS range switch in the “high” setting. Setthe WFS knob to
• 50 ipm for K2613-5• 25 ipm for K2613-7
4. Trigger the LN-25™ PRO and measure the rpm ofthe motor gear. Adjust the WFS knob as requireduntil the rpm measures 8.9 to 9.2 rpm.
5. Insert the shorting plug into the control board for 1second and then remove the shorting plug. Theshorting plug shorts pins 4 and 7 of J3.
6. Set the WFS knob to• 800 ipm for K2613-5• 400 ipm for K2613-7
7. Trigger the LN-25™ PRO and measure the rpm ofthe motor gear. Adjust the WFS knob as requireduntil the rpm measure 128.0 to 130.0 rpm.
8. Insert the shorting plug into the control board for 1second and then remove the shorting plug. Theshorting plug shorts pins 4 and 7 of J3.
9. Turn power OFF and reassemble.
LN-25™ PRO
FIGuRE D.2
E-1TROubLEShOOTINGE-1
LN-25™ PRO
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAuTION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
hOW TO uSE TROubLEShOOTING GuIDE
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
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 isreleased.
• Welding power source must be connected to system ground per the National ElectricalCode or any applicable local codes.
• Only qualified personnel should perform maintenance work.
WARNING
E-2TROubLEShOOTINGE-2
LN-25™ PRO
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAuTION
PRObLEMS(SYMPTOMS)
POSSIbLE CAuSE
RECOMMENDEDCOuRSE OF ACTION
Err 81
Err 82
The feeder does power up - no dis-play, no cold feed.
(Across the Arc models)The wire feeder power up but thereis no output when the trigger ispulled. The shielding gas is flowingand the drive rolls turn.
No shielding gas.
Motor overload, long term.
Motor overload, short term.
1. The work sense lead is discon-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 havetripped. (control cable models)
4. The control cable may be loose ordamaged. (control cable models)
1. The contactor coil connections areloose.
2. The contactor has failed.
1. The gas supply is OFF or empty.
2. The gas hose is cut or crushed.
3. The flow meter valve is closed.4. Dirt or debris is in the solenoid.
5. There is a loose solenoid connec-tion.
6. The solenoid has failed.
1. Check that the electrode slideseasily through the gun and cable.
2. Remove tight bends from the gunand cable.
3. Check that the spindle brake isnot too tight.
4. Verify a high quality electrode isbeing used.
5. Wait for the error to reset and themotor to cool (approximately 1minute).
1. Check that motor can turn freelywhen idle arm is open.
2. Verify that the gears are free ofdebris and dirt.
1. Connect the work sense lead tothe work in a location free of dirt,rust and paint.
2. Turn ON the power source.3. Reset the circuit breakers.
4. Tighten, repair or replace the con-trol cable.
1. Verify the contactor coil connec-tions.
2. Replace the contactor.
1. Verify the gas supply is ON andflowing.
2. Route the gas hose so it avoidssharp corners and make surenothing is on top of it. Repair orreplace damaged hoses.
3. Open the flow meter valve.4. Apply filtered shop at 80psi to the
solenoid to remove dirt.5. Remove the cover and check that
all connections are in good condi-tion.
6. Replace solenoid.
Digital Display Models Error Codes
Output Problems
E-3TROubLEShOOTINGE-3
LN-25™ PRO
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAuTION
PRObLEMS(SYMPTOMS)
POSSIbLE CAuSE
RECOMMENDEDCOuRSE OF ACTION
Inconsistent wire feeding or wire notfeeding but drive rolls turning.
Wire feed speed consistently oper-ates at the wrong value. The speedchanges when the wire feed speedknob is adjusted.
The wire feed speed stuck at 200-300 in/min and there is no changewhen the wire feed speed knob isadjusted.
1. The gun cable is kinked and/ortwisted.
2. The wire is jammed in the gun andcable.
1. The jumper lead for normalspeed/extra torque is connectedimproperly.
2. The wrong gear is installed in thewire drive.
3. The brushes on the motor areworn.
1. The tachometer is connectedimproperly.
2. The tachometer has failed.
1. Keep the gun cable as straight as
possible. Avoid sharp corners or
bends in the cable.2. Remove the gun from the wire
feeder and pull the jammed wireout of the gun and cable.
3. Blow dirt out of the liner with lowpressure (40psi or less). Replacethe liner if worn.
4. Use only clean electrode. Usequality electrode, like L-50 or L-56from Lincoln Electric.
5. Replace the contact tip.6. Verify the proper parts are
installed.7. Adjust the tension arm per the
Instruction Manual. Most elec-trodes feed well at a tension armsetting of "3".
8. Verify the spool of wire moveswith minimal effort.
9. Replace the drive rolls if worn orfilled with dirt.
1. Properly connect the normalspeed/extra torque jumper.
2. Install the proper pinion gear inthe wire drive.
3. Inspect and replace the motorbrushes.
1. Verify all of the tachometer leadsare properly connected.
2. Replace the motor and tachome-ter assembly.
E-4TROubLEShOOTINGE-4
LN-25™ PRO
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
4. The gas nozzle is extendedbeyond the contact tip or the wirestickout is too long.
5. Poor gas shielding on processesrequiring gas.
1. Improper procedures or tech-niques.
1. Replace the contact tip.
2. Verify all work and electrode con-nections are tight and that thecables are in good condit ion.Clean/replace as necessary.
3. Adjust polarity to the recommend-ed procedure.
4. Adjust the gas nozzle and shortenthe stickout to 3/8 to 1/2 inches.
5. Check gas flow and mixture.Remove or block sources ofdrafts.
1. See "Gas Metal Arc WeldingGuide" (GS-100).
Output Problems
F-1DIAGRAMSF-1
LN-25™ PRO
NOTE
: T
his
dia
gra
m is for
refe
rence o
nly
. It m
ay n
ot
be a
ccura
te f
or
all
machin
es c
overe
d b
y t
his
manual.
The s
pe
cific
dia
gra
m f
or
a p
art
icu
lar
co
de
is p
aste
d in
sid
e t
he
machin
e o
n o
ne o
f th
e e
nclo
sure
panels
. If th
e d
iagra
m is ille
gib
le,
write
to t
he S
erv
ice D
epart
ment
for
a r
epla
cem
en
t.
Giv
e t
he
eq
uip
me
nt
co
de
nu
mb
er.
F-2DIMENSION PRINTF-2
LN-25™ PRO
17.1
9
8.65
16” C
IRCL
E
12” x
18”
ELL
IPSE
23.1
7
14.8
1
NOTES
LN-25™ PRO
WARNING
AVISO DEPRECAuCION
ATTENTION
WARNuNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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.
l Do not touch electrically live parts orelectrode with skin or wet clothing.
l Insulate yourself from work andground.
l No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
l Aislese del trabajo y de la tierra.
l Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
l Isolez-vous du travail et de la terre.
l Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
l Isolieren Sie sich von denElektroden und dem Erdboden!
l Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
l Isole-se da peça e terra.
l Keep flammable materials away.
l Mantenga el material combustiblefuera del área de trabajo.
l Gardez à l’écart de tout matérielinflammable.
l Entfernen Sie brennbarres Material!
l Mantenha inflamáveis bem guarda-dos.
l Wear eye, ear and body protection.
l Protéjase los ojos, los oídos y elcuerpo.
l Protégez vos yeux, vos oreilles etvotre corps.
l Tragen Sie Augen-, Ohren- und Kör-perschutz!
l Use proteção para a vista, ouvido ecorpo.
WARNING
AVISO DEPRECAuCION
ATTENTION
WARNuNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
l Keep your head out of fumes.l Use ventilation or exhaust to
remove fumes from breathing zone.
l Los humos fuera de la zona de res-piración.
l Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
l Gardez la tête à l’écart des fumées.l Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
l Vermeiden Sie das Einatmen vonSchweibrauch!
l Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
l Mantenha seu rosto da fumaça.l Use ventilação e exhaustão para
remover fumo da zona respiratória.
l Turn power off before servicing.
l Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
l Débranchez le courant avant l’entre-tien.
l Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
l Não opere com as tampas removidas.l Desligue a corrente antes de fazer
serviço.l Não toque as partes elétricas nuas.
l Do not operate with panel open orguards off.
l No operar con panel abierto oguardas quitadas.
l N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
l Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
l Mantenha-se afastado das partesmoventes.
l Não opere com os paineis abertosou guardas removidas.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers andto exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of ourproducts. We respond to our customers based on the best informationin our possession at that time. Lincoln Electric is not in a position towarrant or guarantee such advice, and assumes no liability, withrespect to such information or advice. We expressly disclaim anywarranty of any kind, including any warranty of fitness for anycustomer’s particular purpose, with respect to such information oradvice. As a matter of practical consideration, we also cannot assumeany responsibility for updating or correcting any such information oradvice once it has been given, nor does the provision of informationor advice create, expand or alter any warranty with respect to the saleof our products.
Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.
Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
