Lincoln Electric IM10080 User Manual

IM10080-A

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August 2013

RED-D-ARC

LN25™ PRO EXTREME DUAL POWER

For use with machines having Code Numbers: 11750, 12164

OPERATOR’S MANUAL

Red-D-Arc Spec-Built Welding Equipment

This

RED-D-ARC

design specifications by Lincoln Electric.

Safety Depends on You

This welder is designed and built with safety in mind.

However, your overall safety can be increased by proper installation

... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.

And, most importantly, think before you act and be careful.

1-800-245-3660

North America’s Largest Fleet of Welding Equipment

welder is built to

RED-D-ARC Extreme Duty

i

SAFETY

i

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

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.

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

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

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.

____________________________________________________

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.

____________________________________________________

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.

___________________________________________________

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.

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.

___________________________________________________

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.

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.

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SAFETY

ii

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

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
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.

skin or wet clothing. Wear dry, hole-free

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

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some 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
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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.

ventilation and/or exhaust at the arc to keep

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.

vv

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 compe­tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip­ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

vivi

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec­tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob­lems of interference. Screening of the entire welding installation may be considered for special

applications

_________________________

1.

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”

viivii

Thank You

for selecting one of our QUALITY products. We want you to take
pride in operating this product ••• as much pride as we have in

CUSTOMER ASSISTANCE POLICY

The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to
meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for
advice or information about their use of our products. We respond to our customers based on the best informa­tion in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no
liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any responsibility for updating or correcting any such informa­tion or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the
control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the
results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing.

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 (if available)______________________________________________________

Serial Number (if available)__________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

viii

TABLE OF CONTENTS

Page

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ...............................................................................................................A-2

Location................................................................................................................................A-2

High Frequency Protection...................................................................................................A-2

Weld cable Sizes..................................................................................................................A-2

Analog Control Cable ...........................................................................................................A-3

Cable Connections and Control Cable Connector ...............................................................A-4

Shielding Gas Connection....................................................................................................A-4

Wire Drive Configuration ......................................................................................................A-5

Gun Receiver Bushing, Thumb Screw and Socket Head Cap Screw ..........................A-5, A-6

Procedure to Install Drive Rolls and Wire Guides ..............................................................A-7

Pressure Arm Adjustment ....................................................................................................A-8

Loading Spools of Wire ........................................................................................................A-8

Gun Connections..................................................................................................................A-8

Power Source to RED-D-ARC LN25™ PRO EXTREME DUAL POWER Cable Connection

Diagrams ..............................................................................................................A-9 thru A-11

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Graphic Symbols that appear on this Machine or in this Manual .........................................B-1

Definition of Welding Terms .................................................................................................B-2

General Description..............................................................................................................B-2

Recommended Processes, Process & Equipment Limitations, Recommended Power Sources

Wire Feed Speed CV and CC, Arc Volts..............................................................................B-3

Constant Current Wire Welding............................................................................................B-4

Case Front Controls .............................................................................................B-5, thru B-8

Internal Controls .........................................................................................................B-9, B-10

Rear Controls .....................................................................................................................B-11

Gas Purge Pushbutton, Flow Meter ...................................................................................B-12

________________________________________________________________________________

Accessories ....................................................................................................................Section C

Factory Installed Equipment.................................................................................................C-1

Drive Roll Kits used..............................................................................................................C-1

Accessories Used ..................................................................................................C-1 thru C-4

________________________________________________________________________________

Maintenance....................................................................................................................Section D

Safety Precautions ...............................................................................................................D-1

Routine Maintenance ...........................................................................................................D-1

Periodic Maintenance...........................................................................................................D-1

Calibration Specification.......................................................................................................D-1

________________________________________________________________________________

Troubleshooting .............................................................................................................Section E

How to Use Troubleshooting Guide .....................................................................................E-1

Digital Display Models Error Codes......................................................................................E-2

Troubleshooting Guide .................................................................................................E-3, E-4

________________________________________________________________________________

........B-2

viii

Wiring Diagram & Dimension Prints .............................................................................Section F

________________________________________________________________________________

Parts Pages ................................................................................................................P-670 Series

_______________________________________________________________________

________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS –

RED-D-ARC LN25™ PRO EXTREME DUAL POWER
(K2614-7)

INPUT VOLTAGE and CURRENT

INPUT VOLTAGE ± 10%

Across the Arc configuration 15-110 VDC
Control Cable configuration 24-42 VAC

RATED OUTPUT @ 104°F (40°C)

DUTY CYCLE

60% rating

GEARING - WIRE FEED SPEED RANGE-WIRE SIZE

GMAW

GEARING

WIRE SIZES

.023 – 1/16"

(0.6 – 1.6mm)

Standard Speed

WFS RANGE

50 – 700 ipm

(1.3 – 17.7m/min)

INPUT AMPERES

450

WFS RANGE

50 – 700 ipm

(1.3 – 17.7m/min)

INPUT AMPERES

4A

FCAW

WIRE SIZES

.030 - 5/64

(0.8 - 2.0mm)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

14.8 Inches 8.7 Inches 23.2 Inches 40 lbs
(376 mm) ( 221 mm) (589 mm) (18 kg)

Handle folded down

TEMPERATURE RANGE

OPERATION: -40°F to 104°F (-40°C to 40°C)
STORAGE: -40°F to 122°F (-40°C to 50°C)

Thermal tests have been performed at ambient temperature. The duty cycle (duty factor) at 40°C has been
determined by simulation.

Duty cycle is based upon the amount of welding performed in a 10 minute period.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the
disconnect switch or fuse box
before attempting to connect or
disconnect input power lines, out­put cables or control cables.

• Only qualified personnel should
perform this installation.

• Do not touch metal portions of the work clip
when the welding power source is on.

• Do not attach the work clip to the wire feeder.

• Connect the work clip directly to the work, as
close as possible to the welding arc.

• Turn power off at the welding power source
before disconnecting the work clip from the
work.

• Only use on power sources with open circuit
voltages less than 110 VDC.

------------------------------------------------------------------------

LOCATION

For best wire feeding performance, place the RED­D-ARC LN25™ PRO EXTREME DUAL POWER on
a stable and dry surface. Keep the wire feeder in
a vertical position. Do not operate the wire feeder
on an angled surface of more than 15 degrees.

Do not submerge the RED-D-ARC LN25™ PRO
EXTREME DUAL POWER.

The RED-D-ARC LN25™ PRO EXTREME DUAL
POWER is rated IP23 and is suitable for outdoor
use.

The handle of the RED-D-ARC LN25™ PRO
EXTREME DUAL POWER is intended for moving
the wire feeder about the work place only.

When suspending a wire feeder, insulate the
hanging device from the wire feeder enclosure.

HIGH FREQUENCY PROTECTION

CAUTION

Locate the RED-D-ARC LN25™ PRO EXTREME
DUAL POWER away from radio controlled machin­ery. The normal operation of the RED-D-ARC
LN25™ PRO EXTREME DUAL POWER may
adversely affect the operation of RF controlled
equipment, which may result in bodily injury or
damage to the equipment.

------------------------------------------------------------------------

WELD CABLE SIZE

Table A.1 located below are copper cable sizes rec­ommended for different currents and duty cycles.
Lengths stipulated are the distance from the welder to
work and back to the welder again. Cable sizes are
increased for greater lengths primarily for the purpose
of minimizing cable drop.

TABLE A.1

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

AMPERES

200
200
225
225
250
250
250
250
300
325
350
400
400
500

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables

larger than recommended, or cables rated higher than 167°F(75°C).

PERCENT

DUTY

CYCLE

60

100

20

40 & 30

30
40
60

100

60

100

60
60

100

60

0 to 50Ft.
(0 to15m)

2
2

4 or 5

3
3
2
1
1

1
2/0
1/0
2/0
3/0
2/0

50 to 100Ft.

(15 to 30m)

2
2
3
3
3
2
1
1

1
2/0
1/0
2/0
3/0
2/0

100 to 150 Ft.

(30 to 46m)

2
2
2
2
2
1
1
1

1
2/0
2/0
2/0
3/0
3/0

150 to 200 Ft.

(46 to 61m)

1
1
1
1
1
1
1

1
1/0
2/0
2/0
3/0
3/0
3/0

200 to 250 Ft.

(61 to 76m)

1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

A-3

INSTALLATION

ANALOG CONTROL CABLE K1797-XX

T

he control cable connecting the wire feeder to the
power source is specially made for the welding envi­ronment.

The wire feeder power requires overcurrent protec­tion. Connect the wire feeder only to power sources
where the overcurrent protection is no more than 15
amps.

Do not use more than 100 ft. (30.5 m) of control cable
between the wire feeder and power source.

A-3

Power Source

A

K

L

M

E

H

J

I

N

G

F

POWER SOURCE

Pin

unused

A

Chassis GND

B

Welding Output Control

C

(trigger from feeder)
Welding Output Control

D

(trigger from feeder)
Remote Voltage Control

E

("+" supply, from power source)
Remote Voltage Control

F

(control signal from feeder or remote.)
Remote Voltage Control

G

("-" supply, from power source)
Work connection to feeder

H

42 VAC to feeder

I

Reserved

J

Function

Wire Feeder

M

J

K

I

H

N

G

F

A

C

B

L

D

B

C

D

E

WIRE FEEDER

Lead #

--

GND

2

4

77

76

75

21
41

Pin

A

Reserved

B

Reserved

C

Welding Output Control
(trigger to power source)

D

Welding Output Control
(trigger to power source)

E

Remote Voltage Control
("+" supply, from power source)

F

Remote Voltage Control
(control signal from feeder or remote.)

G

Remote Voltage Control
("-" supply, from power source)

H

Work connection from power source

I

42 VAC to feeder

J

Reserved

Function

Lead #

--

2

4

77

76

75

21
41

42 VAC to feeder

K

Reserved

L

unused

M

Electrode voltage from feeder

N

42

67

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

K

42 VAC to feeder

L

Reserved

M

unused

N

Electrode voltage to power source

42

67

A-4

INSTALLATION

A-4

TRIGGER CONNECTIONS

There is one circular connector for the gun trigger on the
front of the RED-D-ARC LN25™ PRO EXTREME DUAL
POWER.
Note – if the gun trigger is already depressed when the
feeder is powered up, the feeder will not activate.
Release and then press the gun trigger to begin welding.

The 83% wire feed speed reduces the wire feed speed to
83% of the original set value when activated. For exam­ple, if the original wfs = 200 in/min, the feeder will regu­late to 0.83 x 200 = 166 in/min.

The 83% trigger requires a gun with a dual procedure
switch.

This feature is often useful when welding pipe, and a
“cooler” procedure is required on the bottom portion.

Picture

C

E

D

B

A

Function

5-pin trigger
connector for
push-guns
only.

Pin

A
B
C
D
E

Wiring

5 volt supply

Not used

Trigger

83% WFS switch

5 volt supply

CONTROL CABLE CONNECTOR

The control cable connector is present only on the
Dual Power Feeders.

Picture

WIRE FEEDER

J

K

I

N

H

G

M

F

Pin

A
B

Output Control to Power Source (2-4)

A

B

L

C

D

E

C

Output Control to Power Source (2-4)

D
E

Remote Voltage Control 77
Remote Voltage Control (wiper) 76

F

Remote Voltage Control 75

G
H

I

J
K
L

M

Electrode Sense Lead 67

N

Wiring

Not used
Not used

Work Sense Lead 21

42VAC

Not used

42VAC
Not used
Not used

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts.

• Welding Voltage is present on pins H,
I, K and N when Dual Power feeders
are operating as Accross the Arc
feeder.

SHIELDING GAS CONNECTION

WARNING

CYLINDER may explode if

damaged.

• Keep cylinder upright and
chained to support.

• Keep cylinder away from areas where it may be
damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live
electrical circuits.

• BUILD UP OF SHIELDING GAS MAY
HARM HEALTH OR KILL.

• Shut off shielding gas supply when not
in use.

• See American National Standard Z-49.1, "Safety
in Welding and Cutting” Published by the
American Welding Society.

------------------------------------------------------------------------

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 valves

and regulator for damaged threads, dirt, dust, oil or
grease. Remove dust and dirt with a clean cloth. DO

NOT ATTACH THE REGULATOR IF OIL, GREASE
OR DAMAGE IS PRESENT! Inform your gas supplier

of this condition. Oil or grease in the presence of high
pressure oxygen is explosive.

3. Stand to one side away from the outlet and open the

cylinder valve for an instant. This blows away any dust
or dirt which may have accumulated in the valve out­let.

4. Attach the flow regulator to the cylinder valve and

tighten the union nut(s) securely with a wrench. Note:
if connecting to 100% CO2cylinder, insert regulator
adapter between regulator and cylinder valve. If
adapter is equipped with a plastic washer, be sure it is
seated for connection to the CO2cylinder.

5. Attach one end of the inlet hose to the outlet fitting of

the flow regulator. Attach the other end to the welding
system shielding gas inlet. Tighten the union nuts with
a wrench.

6. Before opening the cylinder valve, turn the regulator

adjusting knob counterclockwise until the adjusting
spring pressure is released.

7. Standing to one side, open the cylinder valve slowly a

fraction of a turn. When the cylinder pressure gage
stops moving, open the valve fully.

8. The flow regulator is adjustable. Adjust it to the flow

rate recommended for the procedure and process
being used before making a weld.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

A-5

INSTALLATION

WIRE DRIVE CONFIGURATIONS

WARNING

A-5

6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the pre­cision fit, light tapping may be required to remove
the gun bushing.

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the
welding power source before instal­lation or changing drive rolls and/or
guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec­onds after the gun trigger is released.

• Do not operate with covers, panels or guards
removed or open.

• Only qualified personnel should perform mainte­nance work.

------------------------------------------------------------------------

GUN BUSHING, THUMB SCREW AND
SOCKET HEAD CAP SCREW

(See Figure A.2 for Code 11750)

Tools required:

• 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.

7. Disconnect the shielding gas hose from the gun
bushing, if required.

8. Connect the shielding gas hose to the new gun
bushing, if required.

9. Rotate the gun bushing until the thumb screw hole
aligns with the thumb screw hole in the feed plate.
Slide the gun receiver bushing into the wire drive
and verify the thumb screw holes are aligned.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun bushing and
tighten the thumb screw.

FIGURE A.2

THUMB SCREW

GUN RECEIVER BUSHING

OUTER WIRE GUI

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.

Important: Do not attempt to completely
remove the socket head cap screw.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

CONNECTOR BLOCK

SOCKET HEAD
CAP SCREW

LOOSEN TIGHTEN

A-6

INSTALLATION

A-6

GUN BUSHING, THUMB SCREW AND SET
SCREW

(See Figure A.2a for Code 12164)

The gun bushing is not interchangeable with other
bushings. It is designed to be mechanically mounted
in the feed plate and then bolted directly to the feed­erʼs internal electrical welding buss bar. It accepts
Magnum Pro guns (Tweco #2 to #4). This bushing
should be removed only for service replacement. It is
secured to the feed plate with an S11604-10 set
screw torqued between 35 to 45 in.-lbs.

Tools required:

• 1/4" hex key wrench, (2) 3/4” Box Wrenches,
3/4” STD. Socket, Adjustable Torque Wrench
(Snap Type)

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the welding buss bar from the gun bush­ing assembly.

10. Rotate the gun bushing until the thumb screw hole
aligns with the thumb screw hole in the feed plate.
Slide the gun bushing into the wire drive and verify
the thumb screw holes are aligned.

11. Tighten set screw 35 to 45 in-lbs. (3.95 to

5.08Nm).

12. Connect welding buss bar to gun bushing assem­bly and tighten bolts to 33 to 44 Ft. Lbs. (44.8 to

59.7Nm).

13. Insert the welding gun into the gun bushing and
tighten the thumb screw.

FIGURE A.2a

THUMB SCREW

GUN BUSHING
ASSEMBLY

OUTER WIRE GUIDE

WELDING BUSS
BAR

4. Remove the thumb screw from the wire drive.

5. Remove the welding gun from the wire drive.

6. Loosen set screw.

7. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the pre­cision fit, light tapping may be required to remove
the gun bushing.

8. Disconnect the shielding gas hose from the gun
bushing.

9. Connect the shielding gas hose to the new gun
bushing.

SET SCREW

LOOSEN TIGHTEN

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

A-7

INSTALLATION

A-7

PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES

WARNING

• Turn the input power OFF at the
welding power source before instal­lation or changing drive rolls and/or
guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec­onds after the gun trigger is released.

• Do not operate with covers, panels or guards
removed or open.

• Only qualified personnel should perform mainte­nance 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 them
from the feed plate.

4. Rotate the triangular lock and remove the drive
rolls.

PRESSURE ARM ADJUSTMENT

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the weld­ing power source before installation or
changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec­onds after the gun trigger is released.

• Do not operate with covers, panels or guards
removed or open.

• Only qualified personnel should perform mainte­nance work.

------------------------------------------------------------------------

The pressure arm controls the amount of force the
drive rolls exert on the wire. Proper adjustment of the
pressure arm gives the best welding performance.
Many welding problems can be attributed to setting
the pressure arm too high and causing wire deforma­tion. Set the pressure arm to minimum amount that
provides reliable feeding.

Set the pressure arm as follows:
(See Figure A.3)

Aluminum wires
Cored wires between 1 and 3
Steel, Stainless wires between 3 and 5

FIGURE A.3

between 1 and 2

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.

7. Install a drive roll on each hub assembly secure
with the triangular lock.

8. Install the outer wire guide by aligning it with the
pins and tightening the knurled thumbscrews.

9. Close the idle arm and engage the idle roll pressure
arm. Adjust the pressure appropriately.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

AL
FCAW
GMAW

6

LOADING SPOOLS OF WIRE

• Keep hands, hair, clothing and tools away from
rotating equipment.

WARNING

• 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 a
K468 spindle adapter for loading 2-1/2" (64mm) wide
spools.

A-8

INSTALLATION

A-8

1. Squeeze the release bar on the retaining collar and
remove it from the spindle.

2. Place the spindle adapter on the spindle, aligning
the spindle brake pin with the hole in the adapter.

3. Place the spool on the spindle and align the
adapter brake tab with one of the holes in the back
side of the spool. An indicator mark on the end of
the spindle shows the orientation of the brake tab.
Be certain the wire feeds off of the spool in the
proper direction.

4. Re-install the retaining collar. Make sure that the
release bar snaps out and that the retaining collar
fully engages the groove on the spindle.

GUN CONNECTION

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the weld­ing power source before installation or
changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec­onds after the gun trigger is released.

• Do not operate with covers, panels or guards
removed or open.

• Only qualified personnel should perform mainte­nance work.

------------------------------------------------------------------------

The RED-D-ARC LN25™ PRO EXTREME DUAL
POWER comes with a K1500-2 gun adapter installed.
(See Figure A.4 for Code 11750)

The RED-D-ARC LN25™ PRO EXTREME DUAL
POWER comes with an S29807-2 gun adapter
installed. (See Figure A.4a for Code 12164)

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.

FIGURE A.4a

THUMB SCREW

GUN

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.
Connect the trigger cable from the gun to the trigger

5.
connector on the front of the feeder.

Note: Not all gun bushings require the use of the

thumb screw.

FIGURE A.4

THUMB
SCREW

GUN

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

A-9

INSTALLATION

POWER SOURCE TO RED-D-ARC LN25™ PRO
DUAL POWERR CABLE CONNECTION DIAGRAMS

ACROSS THE ARC SET-UPS

CC Power Sources with Output Terminals Always
Hot (See Figure A.5)

CC Power Source

Classics
Big Red’s
Eagle 10,000 Plus
Pipeliner 200D Without Wire Feed module
SAE’s Without CV Adapter

SAE 400 with CV adapter
Engine Driven welder with
Wire Feed Module

Electrode

Work

RED-D-ARC LN25™
PRO EXTREME
DUAL POWER

A-9

Work clip

If the power source has a Remote/Local switch, place
the switch in the Local position.

Place the CV/CC switch in the feeder in the "CC" posi­tion.

CV Power Sources with Stud Connectors and

Remote/Local Switch (See Figure A.6)

CV-655
DC-400
DC-600
DC-655
V450-Pro

SAE 400 with CV adapter
Engine Driven welder with
Wire Feed Module
Ranger 250 GXT

Place the power source Remote/Local switch in the
Local position.

Place CV/CC switch in the feeder in the "CV" position.

Jumper

Electrode

Work

K#

K2614-7

KP1695-XX
KP1696-XX
KP1697-XX

See Magnum Pro Literature

K1803-XX

RED-D-ARC LN25™
PRO EXTREME
DUAL POWER

K#

K2614-7

KP1695-XX
KP1696-XX
KP1697-XX

See Magnum Pro Literature

K1803-XX

K484

Description

RED-D-ARC LN25™ PRO
EXTREME DUAL POWER

Drive Roll Kit

Welding Gun

CC power Source

Welding Cables

Work clip

Description

RED-D-ARC LN25™ PRO

EXTREME DUAL POWER

Drive Roll Kit

Welding Gun

CV power Source

Welding Cables
Jumper Plug kit

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

A-10

INSTALLATION

CV Power Sources with Stud Connectors and no
Remote/Local Switch(See Figure A.7)

A-10

RANGER 250, 250 LPG
RANGER 305G, 305D
RANGER 10,000
RANGER 3 PHASE
RANGER225, 225 GXT
COMMANDER 300

Electrode

VANTAGE 300, 400, 500
AIR VANTAGE 500

Work

Place CV/CC switch in the feeder in the "CV" position.

FIGURE A.7

RED-D-ARC LN25™
PRO EXTREME
DUAL POWER

K#

K2614-7

KP1695-XX
KP1696-XX
KP1697-XX

See Magnum Pro Literature

K1803-XX

Work clip

Description

RED-D-ARC LN25™ PRO

EXTREME DUAL POWER

Drive Roll Kit

Welding Gun

CC power Source

Welding Cables

CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.8)

V350-Pr
CV 305

o

El ect rod e

Work

Place the power source Remote/Local switch in the
Local position.

Place CV/CC switch in the feeder in the "CV" position.

FIGURE A.8

RED-D-ARC LN25™
PRO EXTREME
DUAL POWER

K#

K2614-7

KP1695-XX
KP1696-XX
KP1697-XX

See Magnum Pro Literature

K1841

K852-95

Work clip

Description

RED-D-ARC LN25™ PRO

EXTREME DUAL POWER

Drive Roll Kit

Welding Gun

CV power Source

Welding Cables

Twist-Mate Cable Plug

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

A-11

INSTALLATION

CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.9)

Jum p e

r

A-11

FIGURE A.9

CV-250

CV-300

El ect rod e

Work

Place CV/CC switch in the feeder in the "CV" position.

CONTROL CABLE SET-UPS

CV Power Source with 24-42 VAC
(See Figure A.10)

CV Power Source

CV-305

CV-400

CV-655

DC-400

DC-655

V-350

V-450

VANTAGE 300, 400, 500
RANGER 250, 305

ENGINE DRIVE WITH
WIRE FEED MODULE

SAE’s WITH K385-2

FIGURE A.10

Control C able

Electrode

RED-D-ARC LN25™
PRO EXTREME
DUAL POWER

K#

K2614-7

KP1695-XX
KP1696-XX
KP1697-XX

See Magnum Pro Literature

K1841-XX

K852-95

K484

RED-D-ARC LN25™
PRO EXTREME
DUAL POWER

Work clip

Description

RED-D-ARC LN25™ PRO

EXTREME DUAL POWER

Drive Roll Kit

Welding Gun

CV power Source

Welding Cables

Twist-Mate Cable Plug

Jumper Plug kit

WARNING

• When the wire feeder is connected to the power source with the control cable, the
contactor in the wire feeder is always closed and the wire drive and the gun may be at
welding potential.

If present, place the power source
Remote/Local Switch in the Remote
position.

Place CV/CC switch in the feeder in
the "CV" position.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

Work

ELECTRIC SHOCK CAN KILL.

K#

K2614-7

KP1695-XX
KP1696-XX
KP1697-XX

K1797-xx

K2335-1

See Magnum Pro Literature

KP1803-XX

K852-95

Description

RED-D-ARC LN25™ PRO
EXTREME DUAL POWER,

Drive Roll Kit

Control Cable

Adapter for Competitive Power Sources

Welding Gun

CV power source

Welding Cables

Twist-Mate Cable Plug

B-1

OPERATION

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.

B-1

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

WARNING

• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED fea­ture, when feeding with gun trig­ger, the electrode and drive
mechanism are always electri­cally energized and could
remain energized several sec­onds after the welding ceases..

• Do not touch electrically live part or electrode
with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

• Do not operate with covers, panels or guards
removed or open.

----------------------------------------------------------------------

• FUMES AND GASSES can be
dangerous.

• 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.

----------------------------------------------------------------------

SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE
UAL.

----------------------------------------------------------------------

FRONT OF THIS OPERATING MAN-

U

U

U

I

INPUT POWER

ON

OFF

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

0

1

2

1

OPEN CIRCUIT
VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

I

2

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

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