Lincoln Electric IM10080 User Manual

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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

SAFETY

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.

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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.

___________________________________________________

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.

SAFETY

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

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.

SAFETY

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.

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

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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

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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

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

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

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

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

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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

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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

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

100

40 & 30

30 40 60

100

60 60

100

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

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

POWER SOURCE

unused

Chassis GND

Welding Output Control

(trigger from feeder) Welding Output Control

(trigger from feeder) Remote Voltage Control

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

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

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

42 VAC to feeder

Reserved

Function

Wire Feeder

WIRE FEEDER

Lead #

GND

21 41

Reserved

Welding Output Control (trigger to power source)

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

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

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

Work connection from power source

42 VAC to feeder

Reserved

Function

Lead #

21 41

42 VAC to feeder

Reserved

unused

Electrode voltage from feeder

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

42 VAC to feeder

Reserved

unused

Electrode voltage to power source

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

Function

5-pin trigger connector for push-guns only.

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

A B

Output Control to Power Source (2-4)

D E

Remote Voltage Control 77 Remote Voltage Control (wiper) 76

Remote Voltage Control 75

G H

J K L

Electrode Sense Lead 67

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.

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

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

K2614-7

KP1695-XX KP1696-XX KP1697-XX

See Magnum Pro Literature

K1803-XX

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

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

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

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

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

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

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.

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-

INPUT POWER

OFF

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

WARNING OR CAUTION

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-2

DEFINITION OF WELDING TERMS

WFS

• Wire Feed Speed

• Constant Current

• Constant Voltage

GMAW

• Gas Metal Arc welding

SMAW

• Shielded Metal Arc welding

FCAW

• Flux Core Arc Welding

OPERATION

General Functional Description

The RED-D-ARC LN25™ PRO EXTREME DUAL POWER have adjustable WFS range for improving the knob sensitivity. The low range is great for critical welds with Innershield wires, and the upper range is suitable for general purpose welding. Selection of the WFS range is through the set-up menu.

RECOMMENDED PROCESSES

• GMAW

• FCAW

PROCESS LIMITATIONS

B-2

GENERAL DESCRIPTION

General Physical Description

The RED-D-ARC LN25™ PRO EXTREME DUAL POWER is specially engineered to be the most rugged portable wire feeder available.

The RED-D-ARC LN25™ PRO EXTREME DUAL POWER has patented technology enabling the wire feeder to run either across the arc or with a control cable. The change over is automatic – simply disconnect the work sense clip and connect the control cable. The dual power feeder is a universal feeder great for both field and shop service.

(For Code 12164 only) a dedicated gun adapter is mechanically secured into the feed plate but directly bolted to the feederʼs internal electrical welding buss bar to reduce the likelihood of overheating occurring at the feed plate. The bushing accepts Magnum Pro guns (Tweco #2 to #4).

The plastic case is molded from a high impact, flame retardant plastic for durability and low weight.

The heart of the RED-D-ARC LN25™ PRO EXTREME DUAL POWER is the 2 roll MAXTRAC™ drive. The patented features on the wire drive offer tool-less changing of the drive rolls and wire guides for quick spool changes. A tachometer controlled motor powers the patent pending drive rolls for smooth, steady feeding without slippage.

With a 450 amp, 60% duty cycle rating, these feeders are ready for heavy duty welding.

• GMAW-P procedures must be qualified by the customer.

• Across-the-Arc models are not recommended for stitch or spot welding.

EQUIPMENT LIMITATIONS

• The duty cycle of the wire feeder is 450A, 60%. Duty cycle is based upon the amount of welding performed in a 10 minute period.

• The maximum spool size is 45 lb. (24 Kg), 12” (305mm) diameter.

• Maximum FCAW gun length is 15 ft.

• Maximum GMAW gun length is 25 ft.

• K2330-1 Timer Kits do not work with the feeder. Use K2330-2 kits.

• Push-pull guns do not work with the LN25™ PRO EXTREME DUAL POWER

• The digital displays do not show preset voltage

RED-D-ARC

RECOMMENDED POWER SOURCES

• Ranger 3 Phase

• CV-305

• CV-400

• CV-655

• DC-400

• DC-600

• DC-655

• Invertec V-350

• FlexTec 450

• Multi-Weld 350

• Ranger 10,000

• Ranger 225

• Ranger 225 GXT

• Ranger 250

• Ranger 305

• SAE-400

• Pipeliner 200G

• Classic 300

• Vantage 300

• Vantage 400

• Vantage 500

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-3

OPERATION

B-3

The serviceability of a product or structure utilizing the RED-D-ARC LN25™ PRO EXTREME DUAL POWER wire feeder is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the RED-D-ARC LN25™ PRO EXTREME DUAL POWER wirefeeder. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of the RED-D-ARC LN25™ PRO EXTREME POWER wirefeeder may not be suitable for all applications, and the builder/user is and must be solely responsible for welding settings.

CONSTANT CURRENT OPERATION

Setting Wire Feed Speed in CC mode

When Across the Arc models are operated with CC power sources, the wire feed speed changes as the arc voltage changes. When the arc voltage increases, the wire feed speed will increase; and when the arc voltage decreases, the wire feed speed will decrease.

To preset the wire feed speed on CC power sources:

1. Set the Wire Feed Mode switch inside the LN25™ Pro to "CC".

2. Refer to the Figure B.1a graph for the setting for the wire feed speed knob setting. Select the horizontal line representing the Desired Wire Feed Speed. (See Figure B.1a arrow for 375 in/min.)

3. Select the diagonal line representing the Arc Volts. (See Figure B.1a for 29 volts.)

4. Determine the vertical line representing the CC representing the CC Wire Feed Speed setting where the above two lines cross. (See Figure B.1a arrow line for 450.) Set the LN25™ Pro wire feed speed knob to this value.

CC WFS dial setting = desired WFS x 35

Arc Volts

Example:

375 in/min. (Horizontal Line) x 35

29 Arc Volts (Diagonal Line)

= 452.5 (Vertical Line)

Use 450 setting

(See Figure B.1)

FIGURE B.1

700

650

600

550

500

450

400 375 350

300

250

200

150

in/min.

100

50 100 150 200 250 300 350 400 450 500 550

600

650 700

ARC

VOLTS

A constant voltage (CV) power

source is recommended for flux-

cored arc welding. (FCAW) and

gas metal arc welding (GMAW) to

obtain code quality results. However, this wire feeder may also be used with a constant current (CC) power source to obtain passable results for noncritical quality applications.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-4

OPERATION

B-4

CONSTANT CURRENT WIRE WELDING

(See Figure B.2)

Most semiautomatic welding processes perform better using constant voltage power sources.

Welding codes usually do not address the power source selection or specifically, whether the welding process is to be operated in the constant voltage or constant current mode. Instead, codes typically specify limitations on the current, voltage, heat input and preheat temperature based on the material to be welded. The intention is to assure that proper weld material properties will develop.

Welding is sometimes performed using constant current power sources. The operation can be more convenient because it may allow the use of an existing stick (SMAW) power source and the power source can be placed at a distant location without any provision for adjusting the output settings.

For constant current operation, the power source is set to deliver the specified current. The power source regulates this current regardless of changes in the welding circuit, including cable length, electrode diameter, wire feed speed, contact tip to work distance, etc.

If the contact tip to work distance is properly maintained, a satisfactory operating voltage range may be achieved, and a sound weld may result. However, when a welder uses a longer contact tip to work distance, an arc-sensing wire feeder compensates by increasing the wire feed speed to regulate the voltage. Even if the voltage and current remain unchanged, the increased wire feed speed may result in a deposition rate well beyond the specified range of the electrode. Under these conditions, the specified weld metal properties may not be achieved.

Constant voltage power sources deliver large current surges to stabilize the arc when the electrode is shorted or the arc length is very short. However, a constant current power source does not provide such a response to stabilize the arc. It may be difficult to achieve required weld metal properties, or to achieve the required quality of welds needed to pass nondestructive tests, when such welds are made under constant current operation.

For these reasons, Lincoln Electric does NOT mend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality requirements.

recom-

Changes in the wire feed speed (WFS) or contact tip to work distance (CTWD) affect the arc voltage when constant current power sources are used. Lowering the wire feed speed raises the voltage, raising the wire feed speed lowers the voltage. Lengthening the contact tip to work distance raises the voltage, shortening the contact tip to work distance lowers the voltage.

FIGURE B-2

Current

Constant Current

Power Source

Cu rr ent

Wire

Feeder

CTWD

WFS

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-5

OPERATION

B-5

CASE FRONT CONTROLS

Figure B.3

POWER-UP SEQUENCE

All of the LEDʼs will briefly illuminate during power-up.

1. WIRE FEED SPEED/AMPERAGE DISPLAY

Idle

The left display shows the preset wire feed speed. The right display shows OCV. The wire feed speed LED is lit. If the wire feeder is connected for electrode negative welding, then the voltage display shows a minus sign.

Welding

The value in the left display will show actual wire feed speed or amperage as indicated by the LED below the display. The right display shows the arc voltage. If the wire feeder is connected for electrode negative welding, then the voltage display shows a minus sign.

WFS

AVERTISSEMENT

ITEM DESCRIPTION

1 Digital Display 2 Wire Feed Speed Knob 3 5 pin gun trigger connector 4 Work sense lead 5 Set-up Pushbutton 6 Remote Voltage Control Knob

AMPS

VOLTAGE

AVERTISSEMENT

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-6

OPERATION

B-6

2. WIRE FEED SPEED KNOB

Use the Wire Feed Speed Knob to adjust the rate of wire feed speed.

Because the wire feeder is powered by the arc voltage, the full range of wire feed speed may not be available at low voltages. While welding, the display will show actual wire feed speed. If the actual WFS is less than set WFS, then the arc voltage may be too low for procedure.

Arc Voltage Max WFS (std torque)

15V 280 ipm 17V 340 ipm 21V 440 ipm 24V 520 ipm 27V 600 ipm

3. TRIGGER CONNECTOR

(See Installation Section for Details)

4. WORK SENSE LEAD

Always turn power off at the welding power source before moving the work sense lead.

5. SET-UP MENU

Preparation for WFS Calibration:

• Place the CV/CC switch in CV.

• Set the display to the desired wire feed speed (example: 400 inches per minute)

• Measure the actual wire feed speed (example: 405 inches per minute)

• Place the WFS knob in the 12 oʼclock position.

Preparation for Amperage Calibration:

Connect the feeder to a power source and grid. Adjust the power source and grid to the desired amperage. (example: 220 Amps)

Record the amperage display on the wire feeder. (example: 210 amps)

The work sense lead attaches to the item being welded.

Pushbutton

To enter the set-up menu, use paper clip to press the small button located on the case front.

WIRE FEED SPEED UNITS

Rotate the WFS knob to the left to use “inches/minute” for the wire feed speed units.

Rotate the WFS knob to the right to use “meters/minute” for the wire feed speed units.

LN-25 PRO

WFS

LN-25 PRO

Press the set-up button to enter the WFS calibration menu.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

WFS

B-7

OPERATION

B-7

RUN-IN

“Run-in” refers to the wire feed speed during the time from when the trigger is pulled to when an arc is struck.

When Run-in is “ON”, the wire feed speed is reduced until an arc is struck. Factory setting is Run-In “OFF”.

Model Run-in Wire Feed Speed

Extra Torque Models 25 in/min Standard Speed Models 50 in/min

When Run-in is “OFF”, the wire feed speed is the same as the welding wire feed speed. Turn Run-In “OFF” for fast, crisp starts, especially when running with .035 or .045 (0.9 or 1.2mm) solid steel wires at high wire feed speeds.

To change the Run-in setting:

Rotate the WFS knob to the left to turn Run-In OFF.

LN-25 PRO

WFS CALIBRATION

Measurements for adjusting the WFS calibration must be made before entering the set-up menu. When first entering WFS Calibration, the calibration factor displayed is based upon the position of the knob and does not reflect the actual calibration factor stored in memory.

If no changes are being made to the calibration, then press the set-up button to enter Left Display Selection.

While in the set-up menu, adjust the calibration factor as follows:

Actual WFS 405 Set WFS 400

Press the set-up button when calibration factor is set.

Calibration Factor Example=1.01

WFS

Rotate the WFS knob to the right to turn Run-In ON..

LN-25 PRO

OOWFS

Then rotate the WFS knob to the 12 oʼclock position.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-8

OPERATION

B-8

LEFT DISPLAY SELECTION

The left display can show either amperage or actual WFS during welding. Note that actual WFS is not the same as preset WFS. For example, the preset WFS may be set to 400 ipm, but the arc voltage is only 15V. The actual WFS will be approximately 280 ipm because there is not enough arc voltage to run at 400 ipm.

To change the left display reading:

Rotate the WFS knob to the left to display amperage (current).

Rotate the WFS knob to the right to display actual WFS.

Then rotate the knob to the 12 oʼclock position.

LN-25 PRO

AMPERAGE CALIBRATION

Measurements for adjusting the Amperage calibration must be made before entering the set-up menu.

When first entering Amperage Calibration, the calibration factor displayed is the value in memory. If the knob is rotated, the calibration factor changes based upon the position of the knob.

If no changes are being made to the calibration, then press the set-up button to enter Display Hold.

While in the set-up menu, adjust the calibration factor as follows:

Power Source Amperage 200 Feeder Amperage 210

= Calibration Factor Example:

= 1.05

Press the set-up button again to enter the Amperage Calibration.

Rotate the knob to the 12 oʼclock position, then press the set-up button to enter Display Hold.

DISPLAY HOLD

WFS

Press the set-up button.

WFS KNOB RANGE

For wire feeders equipped with standard torque gearing, the WFS range can be changed to provide better knob sensitivity at low wire feed speeds. This is often useful when welding with Innershield™ wires.

To change the WFS knob range:

Rotate the WFS knob to the left for the low wire feed speed range of 40 – 405 ipm

Rotate the WFS knob to the right for the high wire feed speed range of 40 – 715 ipm.

Then rotate the knob to the 12 oʼclock position.

LN-25 PRO

After welding, the RED-D-ARC LN25™ PRO EXTREME DUAL POWER will hold the last values from welding on the display. The values will continue to be displayed until the hold period is finished, the trigger is pulled again, or the cold feed/gas purge switch is activated.

To change the Display Hold time:

Rotate the WFS knob to the left for 5 seconds Hold.

Rotate the WFS knob to the right for 300 seconds Hold.

Press the set-up button to exit the set-up menu.

WFS

Press the set-up button.

WFS

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-9

INTERNAL CONTROLS

OPERATION

B-9

FIGURE B.4

ITEM DESCRIPTION

1 2-Step Trigger Interlock Switch

2 CV / CC Switch 3 Pressure Adjustment Arm

4 Optional Timer Kit (See Accessories Section)

5 Spool Retainer

6 Spool Brake

7 Gun Bushing, Thumb Screw and Socket Head Cap Screw(For Code 11750)

7a Gun Bushing, Thumb Screw and Socket Set Screw(For Code 12164)

8 Drive Hubs

9 Cold Feed Pushbutton

(For Code 11750)

(For Code 12164)

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-10

OPERATION

B-10

INTERNAL CONTROLS DESCRIPTION

(See Figure B.4)

1. 2 STEP - TRIGGER INTERLOCK SWITCH

The 2 Step - Trigger Interlock switch changes the function of the gun trigger. 2 Step trigger operation turns welding on and off in direct response to the trigger. Trigger Interlock operation allows welding to continue when the trigger is released for comfort on long welds.

Place the toggle switch in the DOWN position for 2 Step operation or in the UP position for Trigger Interlock operation.

2 Step Trigger

2 Step trigger operation is the most common. When the gun trigger is pulled, the welding power source energizes the electrode output and the wire feeder feeds wire for welding. The power source and wire feeder continue welding until the trigger is released.

Trigger Interlock

Trigger Interlock operation provides for operator comfort when making long welds. When the gun trigger is first pulled, the welding power source energizes the output and the wire feeder feeds wire for welding. The gun trigger is then released while the weld is made. To stop welding, the gun trigger is pulled again, and when it is released the welding power source output turns off and the wire feeder stops feeding wire.

2. CV/CC SWITCH

The CV/CC switch sets the wire feed speed control method for the wire feeder.

In the CV position, the wire feed speed remains constant during welding. A steady arc voltage is regulated by the power source by adjusting the arc current.

3. PRESSURE ARM

(See Installation Section)

4. OPTIONAL TIMER KIT

The optional Timer Kit provides control of preflow time, burnback, and postflow time.

5. SPOOL RETAINER

To release the spool retainer, squeeze the metal bar inwards. When securing the spool, verify the spool retainer is fully seated in place in one of the three grooves of the spindle.

6. SPOOL BRAKE

Adjust the spool brake to provide enough friction to stop wire overrun. Excessive brake force may cause motor thermal overloads or welding problems.

7. GUN BUSHING, THUMB SCREW AND SOCKET HEAD CAP SCREW (For Code 11750)

(SEE INSTALLATION SECTION)

7a. GUN BUSHING, THUMB SCREW AND

SET SCREW

(For Code 12164)

(SEE INSTALLATION SECTION)

8. DRIVE ROLLS AND WIRE GUIDES

(See Installation Section)

9. COLD FEED PUSHBUTTON

When cold feeding, the wire drive will feed electrode but neither the power source nor the gas solenoid will be energized. Adjust the speed of cold feeding by rotating the WFS knob. Cold feeding, or "cold inching" the electrode is useful for threading the electrode through the gun.

In the CC position, the wire feed speed varies during welding. The arc length is maintained by changing the wire feed speed.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-11

REAR CONTROLS:

OPERATION

FIGURE B.5

B-11

ITEM DESCRIPTION

1 Gas Purge Pushbutton

2 Flowmeter 3 Shielding Gas 4 Control Cable

5 Electrode Lead (electrode is a 4/0 cable)

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

B-12

OPERATION

1. GAS PURGE PUSHBUTTON

(See Figure B.5)

The gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on. The Gas Purge switch is useful for setting the proper flow rate of shielding gas. Flow meters should

always be adjusted while the shielding gas is flowing.

2. FLOW METER

(See Figure B.5)

The flowmeter shows the flow rate of shielding gas and has a valve to adjust the flow. The flow meter is scaled for CO

the ball indicates the flow rate of shielding gas.

Adjust the flow rate while depressing the GAS PURGE switch by turning the valve at the bottom of the meter. Most weld procedures require 25-40 scfh (11.8 - 18.9 lpm) for sufficient shielding gas coverage. Gun angle, nozzle diameter, joint configuration and wind conditions may effect the amount of shielding gas required.

, Ar, and Ar/CO2blends. The middle of

B-12

When using a wire feeder with a flow meter, adjust the regulator at the shield gas bottle or supply to a flow rate that is higher than the flow rate indicated on the feeder flow meter. Note that most regulators are calibrated based upon having low restrictions on the outlet. The valve on the feeder flow meter creates a high restriction and may cause errors in the readings at the supply regulator. Set the gas flow rate using the feeder flow meter reading and not the

Ball

Valve

supply regulator reading.

To achieve maximum flow rate, use a regulator with 30 psi or higher pressure compensation.

SCFH Liter/Min.

10 4.7 20 9.4 30 14.2 40 18.9 50 23.6 60 28.3 70 33.1 80 37.8

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

C-1

FACTORY INSTALLED EQUIPMENT

• K1500-2 Gun Receiver Bushing.

DRIVE ROLL KITS USED

• See Parts Pages

ACCESSORIES

C-1

K2330-2

K2596-2

K1796-xx

K2593-xx

K1803-1

K1840-xx

Timer Kit

Plastic Case

AWG 1/0 Co-Axial Power Cable

AWG #1 Coaxial Power Cable

Work and Feeder Cables Package

Weld Power Cable, Twist-Mate to

Lug

Includes: Panel and harness for adjusting preflow, burnback and postflow times.

Includes: a complete engineered plastic case.

Includes: 1/0 Coaxial weld

cable of length "xx". Ends of

the weld cable have lug con-

nections. Use for Pulse weld-

ing.

Includes: AWG #1 Coaxial

weld cable of length "xx".

Ends of the weld cable have

lug connections. Use for

Pulse or STT™ welding.

Includes: Twist-Mate to Lug

2/0 cable 14' (1.2m) long with

Ground Clamp, and Twist-

Mate to Lug 2/0 Cable 9'

(2.7m) long.

Includes: Twist-Mate to Lug,

1/0 cable of length "xx".

K1842-xx

Weld Power Cable, Lug to Lug

IIncludes: Lug to Lug, 3/0

Cable of length "xx" for lengths

up to 60' (18.3m). Lug to Lug,

4/0 Cable of length "xx" for

lengths greater than 60'

(18.3m).

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

C-2

K1797-xx

K2335-1

K484

ACCESSORIES

Control Cable

Adapter for Competitive Power

Sources

Jumper Plug Kit

C-2

Includes: 14 pin to 14 pin wire

feeder to power source control

cable.

Includes: Adapter control

cable for connecting a Lincoln

42 VAC wire feeder to a 24

VAC Miller power source.

Requires the digital

meter/remote voltage control

kit.

Includes: 14 pin circular con-

nector with jumper for leads 2-

4. For use in power sources

for turning the weld terminals

"ON" at all times.

K1520-1

K1798

42 Volt Transformer Kit

Adapter Cable for Control Cable to

Terminal Strip Power Sources

Includes: One transformer kit

for operating a 42 VAC wire

feeder on a power source sup-

plying only 115 VAC.

Includes: 14 circular connector

with leads to connect to a ter-

minal strip.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

C-3

ACCESSORIES

C-3

K910-1

K910-2

K1500-1

(For Code

11750 only)

K1500-2

(For Code

11750 only)

Ground Clamp

Gun Receiver Bushing (for guns

with K466-1 Lincoln gun connec-

tors; Innershield and Subarc guns)

Gun Receiver Bushing (for guns

with K466-2, K466-10 Lincoln gun connectors; Magnum 200/300/400 guns and compatible with Tweco®

#2-#4)

Includes: One 300 Amp

Ground Clamp.

Includes: One 500 Amp

Ground Clamp.

Includes: Gun receiver bush-

ing, set screw and hex key

wrench.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

K1500-3

(For Code

11750 only)

Gun Receiver Bushing (for guns

with K613-7 Lincoln gun connec-

tors; Magnum 550 guns and com-

patible with Tweco® #5)

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

C-4

ACCESSORIES

C-4

K1500-4

(For Code

11750 only)

K1500-5

(For Code

11750 only)

K489-7

K435

Gun Receiver Bushing (for gun

with K466-3 Lincoln gun connec-

tors; compatible with Miller® guns.)

Gun Receiver Bushing (compatible

with Oxo® guns.)

Gun Receiver Bushing (for Lincoln

Fast-Mate guns.)

Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2

in (51 mm) spindles.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

Includes: Gun receiver bushing with hose nipple, 4 guide tubes,

set screw and hex key wrench.

Includes: Gun receiver bushing

with trigger connector.

Includes: Spindle Adapter made

from 2 coil retainers. (Electrode

not included.)

K468

K590-6

K586-1

Spindle Adapter, for mounting 8in

(203mm) diameter spools on 2 in

(51 mm) spindles.

Water Connection Kit (for

European and Control cable mod-

els only)

Deluxe Adjustable Gas Regulator

Includes: 2 Spindle Adapters,

one for 2" wide spools and the

other for 3" wide spools.

Includes: 2 hoses with female

quick connectors at each end, 2

male connectors for 3/16" ID

hose, 2 male connectors for _" ID

hose, and mounting hardware.

Includes: Deluxe Gas Regulator

for Mixed Gases, Adapter for

CO2 and 1

0' (3.0m) Hose.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

D-1

SAFETY PRECAUTIONS

MAINTENANCE

the gun bushing.

D-1

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.

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

ROUTINE MAINTENANCE

• Check weld cables, control cables and gas hoses for cuts.

• Clean and tighten all weld terminals.

PERIODIC MAINTENANCE

5. Connect the shielding gas hose to flow meter reference standard.

6. Orient the RED-D-ARC LN25™ PRO EXTREME DUAL POWER in a vertical position.

7. Turn power ON.

8. Adjust the flow meter on the RED-D-ARC LN25™ PRO EXTREME DUAL POWER to 40 scfh while pressing the GAS PURGE button.

9. Measure the gas flow with the calibrated flow meter while pressing the GAS PURGE button.

10. The measured flow rate should be between 35

and 45 scfh.

The calibration on the RED-D-ARC LN25™ PRO EXTREME DUAL POWER flow meter is not adjustable. If the flow meter reads incorrectly, check for leaks or kinks in the gas hose. Replace the flow meter if necessary.

• Clean drive rolls and inner wire guide and replace if worn.

• Blow out or vacuum the inside of the feeder.

CALIBRATION SPECIFICATION

Flow Meter Validation

Tools required:

• Flow meter reference standard.

• Constant voltage DC welding power source (DC400, V-350, CV-400 or equivalent).

To verify the flow meter accuracy:

1. Turn power OFF.

2. Connect the RED-D-ARC LN25™ PRO EXTREME

DUAL POWER to the constant voltage DC welding power source. The work lead of the RED-D-ARC LN25™ PRO EXTREME DUAL POWER must be connected to the work terminal of the power source.

3. Connect a supply of CO

not exceed the maximum inlet pressure of the wire feeder.

to the wire feeder. Do

4. Disconnect the shielding gas hose that connects to

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

WARNING

ELECTRIC SHOCK can kill.

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

• Do not touch electrically live parts.

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

• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

• Only qualified personnel should perform maintenance work.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Fault Code

TROUBLESHOOTING

POSSIBLE

CAUSE

Digital Display Models Error Codes

Description

E-2

RECOMMENDED

COURSE OF ACTION

Possible Adjustments

Err 81 Motor overload, long term.

Err 82 Motor overload, short term.

1. The wire drive motor has overheated.

1. The wire drive motor current draw has exceeded limits, usually because the motor is in a locked rotor state.

1. Check that the electrode slides easily through the gun and cable.

2. Remove tight bends from the gun and cable.

3. Check that the spindle brake is not too tight.

4. Verify a high quality electrode is being used.

5. Wait for the error to reset and the motor to cool (approximately 1 minute).

1. Check that motor can turn freely when idle arm is open.

2. Verify that the gears are free of debris and dirt.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

E-3

ENHANCED DIAGRAM

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING

PROBLEMS

(SYMPTOMS)

The feeder does power up - no display, no cold feed.

1. The work sense lead is disconnected or is a poor electrical connection. (Across the arc models)

2. The power source is OFF.

3. The circuit breaker for the wire feeder on power source have tripped. (control cable models)

4. The control cable may be loose or damaged. (control cable models)

POSSIBLE

CAUSE

Output Problems

E-3

RECOMMENDED

COURSE OF ACTION

1. Connect the work sense lead to the work in a location free of dirt, rust and paint.

2. Turn ON the power source.

3. Reset the circuit breakers.

4. Tighten, repair or replace the control cable.

The wire feeder power up but there is no output when the trigger is pulled. The shielding gas is flowing and the drive rolls turn.

No shielding gas.

Inconsistent wire feeding or wire not feeding but drive rolls turning.

1. The contactor coil connections are loose.

2. The contactor has failed.

1. The gas supply is OFF or empty.

2. The gas hose is cut or crushed

3. The flow meter valve is closed.

4. Dirt or debris is in the solenoid.

5. There is a loose solenoid connection.

6. The solenoid has failed.

1. The gun cable is kinked and/or twisted

2. The wire is jammed in the gun and cable.

3. The gun liner is dirty or worn.

4. The electrode is rusty or dirty.

5. The contact tip is partially melted or has spatter.

6. Improper gun liner, tip, drive rolls and/or inner wire guide.

7. Incorrect tension arm pressure on the drive rolls.

8. The spindle brake is too tight.

9. Worn drive roll

1. Verify the contactor coil connections.

2. Replace the contactor.

1. Verify the gas supply is ON and flowing.

2. Route the gas hose so it avoids sharp corners and make sure nothing is on top of it. Repair or replace damaged hoses.

3. Open the flow meter valve.

4. Apply filtered shop at 80psi to the solenoid to remove dirt.

5. Remove the cover and check that all connections are in good condition.

1. Keep the gun cable as straight as possible. Avoid sharp corners or bends in the cable.

2. Remove the gun from the wire feeder and pull the jammed wire out of the gun and cable.

3. Blow dirt out of the liner with low pressure (40psi or less). Replace the liner if worn.

4. Use only clean electrode. Use quality electrode, like L-50 or L-56 from Lincoln Electric.

5. Replace the contact tip.

6. Verify the proper parts are installed.

7. Adjust the tension arm per the Instruction Manual. Most electrodes feed well at a tension arm setting of "3".

8. Verify the spool of wire moves with minimal effort.

9. Replace the drive rolls if worn or filled with dirt.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Wire feed speed consistently operates at the wrong value. The speed changes when the wire feed speed knob is adjusted.

TROUBLESHOOTING

POSSIBLE

CAUSE

Output Problems

1. The jumper lead for normal speed/extra torque is connected improperly.

2. The wrong gear is installed in the wire drive.

3. The brushes on the motor are worn.

E-4

RECOMMENDED

COURSE OF ACTION

1. Properly connect the normal speed/extra torque jumper.

2. Install the proper pinion gear in the wire drive.

3. Replace the motor/gearbox assembly.

The wire feed speed is fast (maximum) and there is no change when the wire feed speed knob is adjusted.

Variable or "hunting" arc.

When the trigger is pulled, the wire feeds slowly.

Poor arc starts with sticking or "blast-offs", weld porosity, narrow and ropy looking bead.

1. The tachometer is connected improperly.

2. The tachometer has failed.

1. Wrong size, worn and/or melted contact tip.

2. Worn work cable or poor work connection.

3. Wrong polarity.

4. The gas nozzle is extended beyond the contact tip or the wire stickout is too long.

5. Poor gas shielding on processes requiring gas.

1. The Run-In switch is "ON"

1. Improper procedures or techniques.

1. Verify all of the tachometer leads are properly connected.

2. Replace the motor and tachometer assembly.

1. Replace the contact tip.

2. Verify all work and electrode connections are tight and that the cables are in good condition. Clean/replace as necessary.

3. Adjust polarity to the recommended procedure.

4. Adjust the gas nozzle and shorten the stickout to 3/8 to 1/2 inches.

5. Check gas flow and mixture. Remove or block sources of drafts.

1. Place the Run-In switch to the "OFF" position.

1. See "Gas Metal Arc Welding Guide" (GS-100)

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

F-1

DIAGRAMS

F-1

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the

enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-2

DIMENSION PRINT

23.17

F-2

14.81

8.65

12” x 18” ELLIPSE

16” CIRCLE

17.19

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

NOTES

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

PARTS LIST FOR

™

Red-D-Arc LN25

PRO

Extreme Dual Power

P-670P-670

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs ofﬁcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs ofﬁcial Parts Book (BK-34) for the latest pages.

RED-D-ARC LN25™PRO EXTREME DUAL POWER

ILLUSTRATION OF SUB-ASSEMBLIES

P-670-AP-670-A

RED-D-ARC LN25™PRO EXTREME DUAL POWER

Oct-13

P-670-A.1P-670-A.1

Red-D-Arc LN25™ PRO Extreme Dual Power

For Codes: 11750 & 12164

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBL Y

PAGE NAME

Miscellaneous Items

PAGE NO.

CODE NO.

11750 111111

12164 • 11121

P-670-B.2

Case Front Assembly

P-670-C

Control Box Assembly

P-670-D

Spindle & Mast Assembly

P-670-E

Wire Drive Assembly

P-670-F

Case Assembly

P-670-G

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

P-670-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-670-B.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

DESCRIPTION PART NO. QTY. 123456789

Gun Adapter Bushing (Lincoln Adapted Guns) (Code 11750 Only)

S22774-1 1 X

RED-D-ARC LN25™PRO EXTREME DUAL POWER

Oct-13

NOTES

RED-D-ARC LN25™PRO EXTREME DUAL POWER

Case Front Assembly

20A

11A

11B

P-670-CP-670-C

11B

11A

20A

RED-D-ARC LN25™PRO EXTREME DUAL POWER

Oct-13

P-670-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Front Assembly (G6320-4), Includes: NSS 1X 1 Case Front G5578-1 1 X 2 Nameplate L15915 1 X 3A Preset P.C. Board Assembly S28438-[ ] 1 X 3B Sems Screw T10082-12 4 X 4 Connector & Lead Asbly, Includes: L13084-3 1 X 4A Connector (5 Socket) S12021-66 1 X 4B Self Tapping Screw (Not Shown) S8025-118 2 X 5 Remote Voltage Control Assembly M21286-2 1 X 6 Knob T10491 2 X 7A Diode Bridge T13637-5 2 X 7B #10-24 HLN (Not Shown) T9187-13 2 X 8 Grommet T9274-5 1 X 9 Ground Lead Assembly (Not Shown) S17211-6 1 X 11A Strain Relief Clamp S24287 1 X 11B Sems Screw T10082-29 2 X 12 Boot S18581-2 1 X 15 Thread Forming Screw (Not Shown) S9225-4 2 X 20A Thread Forming Screw S9225-99 1 X 20B #10-24 HLN (Not Shown) T9187-13 1 X 21 Thread Forming Screw S9225-99 1 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank as to eliminate errors, confusion and updates.

NSS - Not Sold Separately

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

Control Box Assembly

14A

17A

13A

20A

13B

16A

21A

25A

25B

12K

13C

22A

22B

22D

22C

11B

11C

10A

11D

12G

12F

12A

12B

11E

14A

P-670-DP-670-D

14A

16A

21A

14A

13C

13B

13A

22C

12K

20A

17A

25A

11E

RED-D-ARC LN25

22D

22B

11C

11B

10A

12F

12G

12A

12B

22A

™

PRO EXTREME DUAL POWER

11D

25B

Oct-13

P-670-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Control Box Assembly (G6321-3), Includes: NSS 1X 1 Control Box G5584-4 1 X 2 Control Box Decal M22570 1 X 3A Control P.C. Board Assembly S28442-[ ] 1 X 3B #10-24 HLN T9187-13 4 X 4A Motor Filter P.C. Board Assembly S27506-[ ] 1 X 4B Sems Screw T10082-12 4 X 5 Plug & Lead Assembly (Not Shown) M21926 1 X 6 Decal (M22571-1) (Part of M22571) NSS 1X 7A Gas Flow Meter Assembly S25565-2 1 X 7B Lock Washer (Not Shown) E106A-1 2 X 7C Flex Tube T10642-265 1 X 7D Hose Clamp (Not Shown) T13777-8 2 X 8A Fan Assembly S27028 1 X 8B Self Tapping Screw (Not Shown) S8025-15 2 X 9A Spindle & Mast Assembly (G5572-2) See P-670-E 1 X 9B #10-24 HLN T9187-13 4 X 9C Self Tapping Screw (Not Shown) S9225-99 1 X 9D Mast Decal (Not Shown) M22570-1 1 X 10A Insulated Mounting Block M21096 1 X 10B Self Tapping Screw (Not Shown) S9225-99 2 X 11A 1/2-13 HN (Not Shown) CF000027 1 X 11B Plain Washer S9262-80 1 X 11C Lock Washer E106A-15 1 X 11D 1/2-13 x 1.5 HHCS CF000052 1 X 12 Contactor Assembly , Includes: L12936-1 1 X 12A Contactor M15308-6 1 X 12B Contactor Bracket M21094-1 1 X 12C #10-32 x .25 RHS (Not Shown) CF000325 2 X 12D Lock Washer (Not Shown) E106A-1 2 X 12E Bus Bar Asbly M21010 1 X 12F Bus Bar Asbly M21005 1 X 12G Metric Hex Nut T14815-17 2 X 12H Insulated Fastener (Not Shown) T15088 1 X 12J Plain Washer (Not Shown) S9262-98 2 X 12K Self Tapping Screw S9225-99 2 X 13 Weld Cable, Includes: M21463-1 1 X 13A Twist Mate Welding Cable Plug M15479-1 1 X 13B Cord Grip Connector S19999 1 X 13C Conduit Lock Nut T14370-3 1 X 14 Harness, Includes: G5682-2 1 X 14A Push Button Switch S26807 1 X 16A Solenoid Assembly M17294-8 1 X 16B Plain Washer (Not Shown) S9262-149 1 X 16C Conduit Lock Nut (Not Shown) T14370-1 1 X 17A Control Box Panel S26587-7 1 X 17B #10-24 HLN (Not Shown) T9187-13 4 X 18 Bypass Jumper Assembly (Not Shown) S22969-11 1 X 19A #10-24 HN (Not Shown) CF000010 2 X 19B Lock Washer (Not Shown) E106A-1 1 X 19C Ground Reference (Not Shown) S26124 1 X

NSS - Not Sold Separately

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

P-670-D.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

20 Cable Connector Assembly, Includes: M21275 1 X 20A Cable Clamp S12024-21 1 X 21A Flex Tube T10642-262 1 X 21B Hose Clamp (Not Shown) T13777-8 2 X 22A Current Transducer S18504-6 1 X 22B Insulating Tube T7028-181 2 X 22C #10-24 x 1.50 RHS CF000122 2 X 22D #10-24 HLN T9187-13 2 X 23 Shielding Gas Filter S28863 1 X 25A Control Box Cover M21011-2 1 X 25B Thread Forming Screw S9225-99 4 X 26 Decal, Overcurrent M22571-7 1 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

NOTES

RED-D-ARC LN25™PRO EXTREME DUAL POWER

Spindle & Mast Assembly

P-670-EP-670-E

™

RED-D-ARC LN25

PRO EXTREME DUAL POWER

Oct-13

P-670-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Spindle & Mast Assembly (G5572-2), Includes: NSS 1X 1 Spindle Mast G5571-2 1 X 2 Spindle Shaft M20990-1 1 X 3A Thread Forming Screw S9225-102 2 X 3B External Tooth Lock Washer T9860-6 2 X 5 Bushing T12380-1 3 X 7 Spindle L10560-2 1 X 8 Friction Washer S17435-3 2 X 9 Keyed Washer T12965-2 1 X 10 Compression Spring T11862-14 1 X 11 Thumb Screw T14813-A 1 X 12 Retaining Collar Assembly S23811 1 X 13 Busing (Not Shown) T12380-1 2 X

NSS - Not Sold Separately

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

Wire Drive Assembly

15A

15B

19A

19B

19C

15A

P-670-FP-670-F

15B

19C

19B

19A

RED-D-ARC LN25™PRO EXTREME DUAL POWER

Oct-13

P-670-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Wire Drive Assembly, Includes: M21079-7 1 X •

Wire Drive Assembly, Includes: M21079-9 1 • X 1 Wire Drive Panel G5569-2 1 X X 2A Feed Plate Assembly, Includes: M19932 1 X • 2A Feed Plate Assembly, Includes: M19932-8 1 • X 2B Connection Bar M19611-1 1 X • 2C Socket Head Cap Screw T9447-112 1 X • 2D Plain Washer S9262-167 1 X • 2E Retaining Ring S9776-69 1 X • 2F Idle Arm NSS 1XX 2G Dowel Pin (Not Shown) NSS 1XX 2H Adjustment Arm Assembly M19179-1 1 X X 2J Roll Pin (Not Shown) NSS 2XX 2K Wire Guide Retaining Pin (Not Shown) NSS 2XX 2L Shaft NSS 2XX 2M Set Screw (Not Shown) S11604-47 1 X X 2N Self Tapping Screw (Not Shown) S9225-102 4 X X 3 Motor Gearbox Assembly, Includes: L12081-1 1 X X 3A Drive Motor NSS 1XX 3B Connector, Molex (Not Shown) S24018-8 1 X X 3C Locking Post (Not Shown) S24019-8 1 X X 3D Woodruff Key S24170-1 1 X X 3E Snap Ring S9776-27 1 X X 3F Motor Brush & Brush Cap (Not Shown) S28460 1 X X 3G Lock Washer (Not Shown) E106A-2 3 X X 3H M6 x 1.00 PPHS (Not Shown) T14731-18 3 X X 4A Drive Gear M19870 1 X X 4B Collar S25414 1 X X 4C Lock Washer T4291-A 1 X X 4D Metric Screw T14731-47 1 X X 5A Cover M19999 1 X X 5B Self Tapping Screw S9225-102 1 X X 6 Drive Roll Shaft Assembly, Includes: S25638 2 X X 6A Twist Lock Ring S25308 2 X X 7 Retainer S25403 2 X X 8 Wire Guide Assembly (Outer) KP2071-3 1 X X 9A Ball Housing M18946 1 X X 9B Set Screw S11604-21 1 X X 10A Timer Kit Panel S25706 1 X X 10B Thread Forming Screw S9225-99 2 X X 15A 1/2-13 x 1.00 HHCS CF000021 1 X X 15B Lock Washer E106A-15 1 X X 15C Plain Washer (Not Shown) S9262-80 1 X • 15C Plain Washer (Not Shown) S9262-1 1 • X 15D 1/2-13 HN (Not Shown) CF000027 1 • X 16 Decal, Toggle Switch (M22571-5) (Part of M22571) NSS 1XX 17 Decal, Option Panel (M22571-4) (Part of M22571) NSS 1XX 18 Decal, Serial Number (M22571-3) (Part of M22571) NSS 1XX 20 Toggle Switch T10800-38 1 X X 21 Decal, Maxtrac (Not Shown) S26310 1 X X

NSS - Not Sold Separately

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

P-670-F.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

23 Screw Stud T13858 1 X X 30 Gun Adapter S22905-2 1 X • 30 Gun Adapter (Left) (Tweco #2 to #4) S29807-2 1 • X 30A Set Screw (Not Shown) S11604-10 1 • X 30B Tab (Not Shown) M24893 1 • X 30C 1/2-13 HN (Not Shown) CF000027 1 • X 30D Lock Washer (Not Shown) E106A-15 1 • X 30E Plain Washer (Not Shown) S9262-1 1 • X

Plug & Lead Assembly (Not Shown), Includes: L13057 1 X X 32A Push Button Switch (Not Shown) S26807 1 X X 33 Decal, Pressure Arm (Not Shown) S25890-1 1 X X 34

Inner Wire Guide, .035/.045 (M18970-4) (Not Shown)

KP2178-6 1 X X

35 Drive Roll - Knurled (M18215-045) (Not Shown) NSS 2XX

NSS - Not Sold Separately

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

NOTES

RED-D-ARC LN25™PRO EXTREME DUAL POWER

Case Assembly

20A

P-670-GP-670-G

20A

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

P-670-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Assembly (G5900-1), Includes: NSS 1X 1A Plastic Case Asbly, Includes: G5660 1 X 1B Latch M20977-1 2 X 4 Warning Decal S20601-2A 1 X 5 Case Logo Decal S11893-11 1 X 6 Warning Decal S20601-2B 1 X 7 Warning Decal S25536-1 1 X 9 Door Logo Decal S11893-10 1 X 11 Decal - Crossed Out Wheeled Bin T13086-201 1 X 12 Plug Button T10397-6 2 X 13 Plug Button T10397-19 2 X 14 Gasket (Not Shown) S26924 1 X 15A Insulated Fastener T15088-2 6 X 15B Thread Forming Screw S9225-102 2 X 19 Decal (CC Mode) (Not Shown) M15242-2 1 X 20A Handle Assembly S18170 1 X 20B Plain Washer (Not Shown) S9262-113 1 X 20C Lock Washer (Not Shown) E106A-2 2 X 20D Insulated Fastener (Not Shown) T15088-1 2 X

NSS - Not Sold Separately

RED-D-ARC LN25

™

PRO EXTREME DUAL POWER

Oct-13

NOTES

RED-D-ARC LN25™PRO EXTREME DUAL POWER

NOTES

RED-D-ARC LN25™ PRO EXTREME DUAL POWER

WARNING

Spanish

AVISO DE

PRECAUCION

•

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

•

Insulate yourself from work and ground.

•

No toque las partes o los electrodos bajo carga con la piel o ropa mojada.

•

Aislese del trabajo y de la tierra.

•

Keep flammable materials away.

•

Mantenga el material combustible fuera del área de trabajo.

•

Wear eye, ear and body protection.

•

Protéjase los ojos, los oídos y el cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

•

Ne laissez ni la peau ni des vêtements mouillés entrer en contact avec des pièces sous tension.

•

Isolez-vous du travail et de la terre.

•

Berühren Sie keine stromführenden Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

•

Isolieren Sie sich von den Elektroden und dem Erdboden!

•

Não toque partes elétricas e electrodos com a pele ou roupa molhada.

•

Isole-se da peça e terra.

•

Gardez à l’écart de tout matériel inflammable.

•

Entfernen Sie brennbarres Material!

•

Mantenha inflamáveis bem guardados.

•

Protégez vos yeux, vos oreilles et votre corps.

•

Tragen Sie Augen-, Ohren- und Körperschutz!

•

Use proteção para a vista, ouvido e corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

•

Keep your head out of fumes.

•

Use ventilation or exhaust to remove fumes from breathing zone.

•

Turn power off before servicing.

•

Do not operate with panel open or guards off.

WARNING

•

Los humos fuera de la zona de respiración.

•

Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases.

•

Gardez la tête à l’écart des fumées.

•

Utilisez un ventilateur ou un aspirateur pour ôter les fumées des zones de travail.

•

Vermeiden Sie das Einatmen von Schweibrauch!

•

Sorgen Sie für gute Be- und Entlüftung des Arbeitsplatzes!

•

Mantenha seu rosto da fumaça.

•

Use ventilação e exhaustão para remover fumo da zona respiratória.

•

Desconectar el cable de alimentación de poder de la máquina antes de iniciar cualquier servicio.

•

Débranchez le courant avant l’entretien.

•

Strom vor Wartungsarbeiten abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

•

Não opere com as tampas removidas.

•

Desligue a corrente antes de fazer serviço.

•

Não toque as partes elétricas nuas.

•

No operar con panel abierto o guardas quitadas.

•

N’opérez pas avec les panneaux ouverts ou avec les dispositifs de protection enlevés.

•

Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in Betrieb setzen!

•

Mantenha-se afastado das partes moventes.

•

Não opere com os paineis abertos ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• 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

Lincoln Electric IM10080 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual