LN-25 PORTABLE CV/CC SEMIAUTOMATIC WIRE FEEDER
IM620-B
November, 2006
For use with machines having Code Number |
10556 |
11144 |
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10557 |
11145 |
RETURN TO MAIN MENU |
10558 |
11282 |
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11283 |
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Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and 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.
OPERATING MANUAL
Copyright © 2006 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 WEB SITE: www.lincolnelectric.com
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SAFETY
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WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional 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 ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes
outdoors.
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1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
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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 or repairing equipment.
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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is
running.
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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes 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 physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them 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 work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
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SAFETY |
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ELECTRIC SHOCK can 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-freegloves 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 area of 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 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.
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.
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.
ARC RAYS can burn.
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.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
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.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
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 specific 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.
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 products.
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.
AUG 06
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SAFETY
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WELDING SPARKS can
cause fire or explosion.
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.
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.
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.
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.
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).
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.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
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.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
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.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
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PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1.Protegez-vous contre la secousse électrique:
a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b.Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans l e s positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans 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.
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.
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 rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b.Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc.
c.Protéger l’autre personnel travaillant à proximité au soudage
à l’aide d’écrans appropriés et non-inflammables.
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, pantalons sans revers, et chaussures montantes.
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.
6.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8.S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
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.
2.Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3.Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4.Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
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for selecting a QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then “Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENTS
SAFETY .............................................................................................................................................................. |
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INSTALLATION .................................................................................................................................... |
SECTION A |
Technical Specifications ................................................................................................................................. |
A-1 |
Safety Precautions .......................................................................................................................................... |
A-2 |
Power Source Connections............................................................................................................................ |
A-2 |
Gun Cable Connection to Feeder ................................................................................................................. |
A-3 |
Weld Cable Connection .................................................................................................................................. |
A-4 |
Electrode Cable Connection ...................................................................................................................... |
A-4 |
Work Cable Connection ............................................................................................................................. |
A-4 |
Wire Feed Drive Roll and Guide Tube Kits ................................................................................................. |
A-4 |
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OPERATION.......................................................................................................................................... |
SECTION B |
Safety Precautions .......................................................................................................................................... |
B-1 |
General Description......................................................................................................................................... |
B-1 |
Recommended Processes and Equipment .................................................................................................. |
B-1 |
Welding Capability ........................................................................................................................................... |
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Controls and Settings...................................................................................................................................... |
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Sequence of Operation ................................................................................................................................... |
B-4 |
Loading Electrode ....................................................................................................................................... |
B-4 |
Loading Wire Drive ..................................................................................................................................... |
B-5 |
Idle Roll Pressure Setting .......................................................................................................................... |
B-5 |
Presetting Wire Feed Speed ..................................................................................................................... |
B-6 |
Making a Weld............................................................................................................................................. |
B-7 |
Procedure at End of Coil ................................................................................................................................ |
B-8 |
Automatic Protection Shutdown..................................................................................................................... |
B-8 |
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ACCESSORIES .................................................................................................................................... |
SECTION C |
LN-25 Option Chart ......................................................................................................................................... |
C-1 |
Options and Accessories................................................................................................................................ |
C-2 |
K430-2 Gas Solenoid Kit ........................................................................................................................... |
C-2 |
K434-1 Gas Flow Timer Kit ....................................................................................................................... |
C-2 |
K460-1 Pulse Power Adapter Kit .............................................................................................................. |
C-3 |
K461 Pulse Power Control Cable Assembly........................................................................................... |
C-3 |
K443-2, K443-3 LN-25 Contactor Kits .................................................................................................... |
C-3 |
Remote Output Control Options and Control Cable Assemblies.............................................................. |
C-3 |
K431-1 Remote Output Control Kit .......................................................................................................... |
C-3 |
K433 Power Source Remote Box............................................................................................................. |
C-4 |
K432 Remote Control Cable Assembly ................................................................................................... |
C-4 |
K439 Remote Extension Cable Assembly............................................................................................... |
C-4 |
K624-1 42V Remote Output Control Module .......................................................................................... |
C-4 |
K625, K626, K626 Remote Control Cable Assembly ............................................................................ |
C-4 |
K444, K444-1 or K444-2 Remote Voltage Control Kit........................................................................... |
C-5 |
K557-1 Rear Handle Kit ............................................................................................................................. |
C-5 |
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MAINTENANCE .................................................................................................................................... |
SECTION D |
Safety Precautions .......................................................................................................................................... |
D-1 |
Routine Maintenance ...................................................................................................................................... |
D-1 |
Circuit Protection and Automatic Shutdown ................................................................................................ |
D-1 |
Adjusting Speed Sensor Module ................................................................................................................... |
D-1 |
Calibration of the LN-25 Wire Speed Dial ................................................................................................... |
D-2 |
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TROUBLESHOOTING GUIDE............................................................................................................ |
SECTION E |
How to Use the Troubleshooting Guide ....................................................................................................... |
E-1 |
Troubleshooting Guide.................................................................................................................................... |
E-2 |
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WIRING DIAGRAM............................................................................................................................... |
SECTION F |
PHYSICAL DIMENSIONS.................................................................................................................... |
SECTION F |
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PARTS MANUAL .............................................................................................................................. |
P333 SERIES |
A-1 |
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INSTALLATION |
A-1 |
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TECHNICAL SPECIFICATIONS – LN-25 |
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VOLTAGE |
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Constant Voltage (CV) |
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15-40 VDC (110VDC Maximum OCV) |
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Constant Current (CC) |
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RATED |
CURRENT |
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Rated current without contactor |
500 Amps 60% Duty Cycle |
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Rated current with contactor |
300 Amps 60% Duty Cycle |
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WIRE FEED SPEED |
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50 – 700 Inches Per Minute (IPM) |
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WIRE DIAMETERS |
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.023” to 1⁄16” |
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SOLID STEEL WIRE |
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.045” to 5⁄64” |
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CORED WIRE |
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.035” to 1⁄16” |
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ALUMINUM WIRE |
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PHYSICAL DIMENSIONS |
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HEIGHT |
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WIDTH |
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DEPTH |
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WEIGHT |
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(Handle Down) |
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w/o Options |
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14 Inches |
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7.4 Inches |
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21 Inches |
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28 lbs |
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(354 mm) |
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(187 mm) |
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(531 mm) |
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(13 kg) |
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TEMPERATURE |
RANGE |
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OPERATION: |
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- 40o C to +40o C (- 40o F to +104o F) |
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STORAGE: |
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- 40o C to +85o C (- 40o F to +185o F) |
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ENVIRONMENTAL RATING |
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IP23 |
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LN-25
A-2 |
INSTALLATION |
A-2 |
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SAFETY PRECAUTIONS
WARNING
Unless an optional output control or contactor is used with the LN-25, the electrode circuit (including welding wire, wire drive and welding gun) is electrically hot when the welding power source is on. The gun trigger controls wire feed only.
Disconnect or shut off welding power source before making connections or installations to the LN-25.
Welding gun should be stored in the insulated gun holder, located near the rear on the top of the LN-25 case, to avoid accidental arcing.
The LN-25 should be positioned upright on a horizontal surface.
WARNING
ELECTRIC SHOCK can kill.
•Do not touch metal portions of the LN-25 lead clip when welding power source is on.
WARNING
ELECTRIC SHOCK can kill.
•Do not operate with covers removed.
•Turn off power source before installing or servicing.
•Do not touch electrically hot parts.
•Turn the input power to the welding power source off at the fuse box before working in the terminal strip.
•Only qualified personnel should install, use or service this equipment.
DC-250
a.Connect a jumper from 2 to 4 on the power source terminal strip so the output will be energized when the DC-250 is turned on.
POWER SOURCE CONNECTION
The LN-25 can be used with most DC welding power source. A constant voltage power source is recommended; however, the LN-25 can also be used with a constant current power source as long as the open circuit voltage is less than 110V DC.
CAUTION
Do not use LN-25 models below Code 9200 with any TIG or Square Wave welding power sources. Do not use LN-25 models equipped with internal contactors with nonLincoln TIG or Square Wave welding power sources. Damage to the LN-25 circuit can occur as a result of the high output inductance typically associated with these power sources. TIG high frequency power should never be applied to the LN-25.
If not using an LN-25 Remote Output Control option (See Remote Output Control Options and Cable Assemblies Section), the power source output must be electrically “hot” at all times when the power source is turned on.
See the power source instruction manual for proper power source connections and setting required.
b.Connect electrode cable to the “Innershield/ GMAW” output terminal of polarity required by electrode. Connect work lead to other “Innershield/GMAW” output terminal.
c.Place “Set to CV Electrode Cable Polarity” switch at appropriate position.
d.Place power source toggle switch in “Output Control at DC-250” position, unless a Remote Control is connected to 75, 76 and 77 on the DC250 terminal strip.
e.Place mode switch in “Innershield GMAW (CV)” position. Set CV arc control to “2” (or “NORMAL” on some machines). Initially set the output control on “7”.
DC-400 AND CV-400
a.Connect a jumper from 2 to 4 on the power source terminal strip so the output will be energized when the power source is turned on.
NOTE: DC-400 machines above Code 9200 have an output toggle switch to perform this function.
b.Connect the electrode cable to the output terminal of polarity required by electrode.
LN-25 |
Connect work lead to other output terminal. |
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A-3 |
INSTALLATION |
A-3 |
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c.Place “Set to Same Polarity As Electrode Cable Connection” switch at appropriate position.
d.Place power source toggle switch in “Output Control at DC(CV) -400” position, unless a remote control is connected to 75, 76 and 77 on the power source terminal strip.
e.If power source has a mode switch, set switch to Constant Voltage Innershield. Initially set the output control on “6”.
DC-600
a.Connect a jumper from 2 to 4 on the power source terminal strip so the output will be energized when the DC-600 is turned on. (For DC-600 below Code 8200, also jumper N to S.)
b.Connect the electrode cable to the output terminal of polarity required by electrode. Connect work lead to other output terminal.
c.Place “Set to Same Polarity As Electrode Cable Connection” switch at appropriate position.
d.Place power source toggle switch in “Output Control at DC-600” position, unless a remote control is connected to 75, 76 and 77 on the DC600 terminal strip.
e.Set mode switch to Constant Voltage Innershield. Initially set output control on “4”.
R3S-325
a. Connect a jumper from 4 to 32 on the power source terminal strip so that the output will be energized when the R3S-325 is turned on.
b. Connect the electrode cable to the output terminal of polarity required by electrode. Connect work lead to other output terminal.
c. Set power source per its instruction manual.
NOTE: Use of the optional Line Voltage Compensator available for the R3S-325 is recommended if input line voltage variation exceeds ±3%.
SAM-400, —650
a. Connect a jumper from 2 to C4 on the power source terminal strip so the output will be energized when the SAM power source is on.
b. Connect work lead to WORK stud. Connect electrode to AUTO EQUIPMENT stud. Connect SAM-650 “Tap” lead to the Innershield stud LN-25 desired.
c.Set ELECTRODE POLARITY switch to constant voltage polarity required by electrode.
d.Set toggle switch to “Constant Voltage” and set the Constant Voltage Control on welder and the portable field control on #5 for initial start.
SA-200, —250 OR SAE-300, —400 (WITH CV ADAPTER)
a. For electrode negative welding, connect the electrode lead from the LN-25 to the output terminal on the CV Adapter, and the work lead to the power source output terminal labeled “POSITIVE”. For electrode positive welding, interchange the above lead connections so the LN-25 electrode lead is then connected to the positive power source terminal.
b.Place both switches on the CV Adapter to the CV INNERSHIELD position and make appropriate power source settings per the CV Adapter instructions provided for the power source being used.
c.The output voltage is set with the voltage control on the CV Adapter.
NOTE: Refer to the Instruction Manual provided with the machine for details on connection and operation of the LN-25 with the power source.
INVERTEC, CV300 AND OTHER NEWER LINCOLN POWER SOURCES
Refer to the instruction manual provided with the power source for details on connection and operation of the LN-25 with these newer machines.
GUN CABLE CONNECTION TO FEEDER
Lay the cable out straight. Insert the connector on the welding conductor cable into the brass conductor block on the front of the wire drive unit. Make sure it is all the way in and tighten the hand wheel clamp. Keep this connection clean and bright. Connect the control cable polarized amphenol plug into the mating 5-cavity receptacle on the front panel of the wire feeder case.
FOR GMA GUN AND CABLES:
Requires installation of K430-1 Gas Solenoid Kit (factory installed on K446 and K449 models).
See K430-1 Gas Solenoid Kit Section (in Accessories Section) for gas solenoid operation and gas supply connection.
A-4 |
INSTALLATION |
A-4 |
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Install the barbed fitting and union nut to the 5⁄8-18 female inert gas fitting on the front panel of the LN-25 case. Connect the 3⁄16” I.D. gas hose from the gun cable to the barbed fitting.
When the gun is to be removed, this fitting can be easily detached by loosening the union nut.
WELD CABLE CONNECTION
The size of the electrode cable and work cable must be sufficient for the maximum weld current and total cable length to be used. Refer to table A.1.
TABLE A.1
Weld Current |
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Total Cable Length |
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60% Duty Cycle |
50’-100’ |
100’-150’ 150’-200’ |
200’-250’ |
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200Amps |
2 AWG |
2 AWG |
1 AWG |
1/0 |
300Amps |
1 AWG |
1 AWG |
1/0 |
2/0 |
400Amps |
2/0 |
2/0 |
3/0 |
3/0 |
500Amps |
2/0 |
3/0 |
3/0 |
4/0 |
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ELECTRODE CABLE CONNECTION
Route the electrode cable through the oval hole in the lower portion of the LN-25 rear panel. Connect the electrode cable to the LN-25 input stud using the 1⁄2” nut provided.
Secure the cable with the strain relief clamp provided. All units are supplied with an optional pigtail for customers that prefer to make a taped and bolted connection externally.
WORK CABLE CONNECTION
Connect a work lead of sufficient size between the proper output stud on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. Poor work lead connections can result in poor welding performance.
WIRE FEED DRIVE ROLL AND GUIDE TUBE KITS
WARNING
Turn off power source before installing or changing drive roll and/or guide tubes.
NOTE: The maximum wire sizes the LN-25 will satisfactorily feed are 5⁄64” cored and 1⁄16” solid electrodes.
The electrode sizes that can be fed with each roll and guide tube are stencilled(1) on each part. Check the kit for proper components. See the instructions, included with the drive roll kit, to install these parts on new machines or replace them on used machines. Refer to table A.2.
TABLE A.2
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Kit |
Instructions |
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Steel Wire Sizes: |
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.068-5⁄64 Cored |
KP653-3⁄32 |
L9932 |
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1⁄16 (.062) Cored or Solid |
-1⁄16 |
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Steel |
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(Can also be used for .052) |
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.045 and .052 Solid Steel |
-.052 |
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.045 and .052 Cored |
-.052C |
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.035 |
Solid Steel |
-.035S |
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.035 |
Cored |
-.035C |
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.030 |
Solid Steel |
-.030S |
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.025 Solid Steel |
-.025S |
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Aluminum Wire Sizes: |
KP654-1⁄16A |
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1⁄16 |
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L9932 |
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3⁄64 |
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-3⁄64A |
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.035 |
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-.035A |
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(1)Drive rolls for only cored electrode sizes are stencilled with a
“C” suffix to the wire sizes.
Drive rolls for only solid electrode sizes are stencilled with an “S” suffix to the wire sizes.
Drive rolls for aluminum wire sizes are stencilled with an “A” suffix to the wire sizes.
LN-25
B-1 |
OPERATION |
B-1 |
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SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE
WARNING
ELECTRIC SHOCK can kill.
•Do not touch electrically live part or electrode with skin or wet clothing.
•Insulate yourself from work and ground.
•Always wear dry insulating gloves.
FUMES AND GASSES can be dangerous.
• Keep your head out of fumes.
•Use ventilation or exhaust to remove fumes from breathing zone.
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear and body protection.
GENERAL DESCRIPTION
The LN-25 is a lightweight portable semiautomatic wire feeder designed for “across-the-arc” operation without a control cable on most any DC welding power source. Simply connect the LN-25 to the electrode cable, clip it to Work and it is ready to weld, using up to 30 lb. coils or spools.
The wire drive, controls and wire reel are fully enclosed in a rugged molded plastic case providing a compact and versatile welding package ideally suited to “on-the-go” field welding applications in virtually any environment.
RECOMMENDED PROCESSES AND EQUIPMENT
When combined with the quality drive roll kits and accessories available for use with the LN-25, a versatile portable welding system can be provided to meet the specific needs of Innershield, submerged arc or gas metal arc welding applications within the wire feed capabilities of the LN-25.
The LN-25 provides constant wire feed speed for use with constant voltage (CV) power sources, and arcsensing wire feed speed for use with constant current (CC) (formerly variable voltage) power sources. Wire speed is presettable on a dual-range calibrated dial.
The power sources recommended for use with the LN-25 include the DC-250, -400, -600, CV-400 and R3S type transformer machines, and the SAM-400, -650 engine welders, as well as the SA-200, -250 or SAE-300, -400 with CV Adapter and Pulse Power 500 with K460-1 LN-25 Kit.
WELDING CAPABILITY
The LN-25 will handle up to 500 Amp 60% duty cycle welding currents. However, when equipped with a K443-2 Contactor, the LN-25 will handle up to 300 Amp 60% duty cycle.
LN-25
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