Lincoln Electric LN-25 PORTABLE CV-CC, IM620-B User Manual
LN-25 PORTABLE CV/CC
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SEMIAUTOMATIC WIRE FEEDER
For use with machines having Code Number 10556 11144
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
IM620-B
November, 2006
10557 11145
10558 11282
11283
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATING MANUAL
Copyright © 2006 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP
CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in
Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A
Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY
QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer,
birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the engine
and allow it to cool before refueling to prevent
spilled fuel from vaporizing on contact with hot
engine parts and igniting. Do not spill fuel when
filling tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position
and in good repair.Keep hands, hair, clothing and tools away from Vbelts, gears, fans and all other moving parts when starting, operating
or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on the throttle control rods while the engine is
running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-freegloves
to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition.
Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage of
both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
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.
vapors
to
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until they
fail.
6.h. Also see item 1.c.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et
les précautions de sûreté specifiques qui parraissent dans ce manuel
aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue ou
les vétements mouillés. Porter des gants secs et sans trous
pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans l e s
positions assis ou couché pour lesquelles une grande partie
du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension des
porte-électrodes connectés à deux machines à souder parce
que la tension entre les deux pinces peut être le total de la
tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la
masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la
zone de travail qu’il est pratique de le faire. Si on place la masse
sur la charpente de la construction ou d’autres endroits éloignés
de la zone de travail, on augmente le risque de voir passer le
courant de soudage par les chaines de levage, câbles de grue,
ou autres circuits. Cela peut provoquer des risques d’incendie ou
d’echauffement des chaines et des câbles jusqu’à ce qu’ils se
rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci
est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit
des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La chaleur
ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant
pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le
code “Code for safety in welding and cutting” CSA Standard W
117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand
on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au soudage
à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de soudage.
Se protéger avec des vêtements de protection libres de l’huile,
tels que les gants en cuir, chemise épaisse, pantalons sans
revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif de
montage ou la piece à souder doit être branché à une bonne
mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à
l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
v
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
Product Registration
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
TABLE OF CONTENTS
SAFETY ..............................................................................................................................................................i-iv
INSTALLATION ....................................................................................................................................SECTION A
Technical Specifications .................................................................................................................................A-1
Safety Precautions ..........................................................................................................................................A-2
Power Source Connections............................................................................................................................A-2
Gun Cable Connection to Feeder .................................................................................................................A-3
Weld Cable Connection ..................................................................................................................................A-4
Electrode Cable Connection......................................................................................................................A-4
Work Cable Connection .............................................................................................................................A-4
Wire Feed Drive Roll and Guide Tube Kits .................................................................................................A-4
OPERATION..........................................................................................................................................SECTION B
Safety Precautions ..........................................................................................................................................B-1
General Description.........................................................................................................................................B-1
Recommended Processes and Equipment..................................................................................................B-1
Welding Capability...........................................................................................................................................B-1
Controls and Settings......................................................................................................................................B-2
Sequence of Operation...................................................................................................................................B-4
Loading Electrode .......................................................................................................................................B-4
Loading Wire Drive .....................................................................................................................................B-5
Idle Roll Pressure Setting ..........................................................................................................................B-5
Presetting Wire Feed Speed .....................................................................................................................B-6
Making a Weld.............................................................................................................................................B-7
Procedure at End of Coil ................................................................................................................................B-8
Automatic Protection Shutdown.....................................................................................................................B-8
ACCESSORIES ....................................................................................................................................SECTION C
LN-25 Option Chart .........................................................................................................................................C-1
Options and Accessories................................................................................................................................C-2
K430-2 Gas Solenoid Kit ...........................................................................................................................C-2
K434-1 Gas Flow Timer Kit .......................................................................................................................C-2
K460-1 Pulse Power Adapter Kit..............................................................................................................C-3
K461 Pulse Power Control Cable Assembly...........................................................................................C-3
K443-2, K443-3 LN-25 Contactor Kits....................................................................................................C-3
Remote Output Control Options and Control Cable Assemblies..............................................................C-3
K431-1 Remote Output Control Kit ..........................................................................................................C-3
K433 Power Source Remote Box.............................................................................................................C-4
K432 Remote Control Cable Assembly ...................................................................................................C-4
K439 Remote Extension Cable Assembly...............................................................................................C-4
K624-1 42V Remote Output Control Module ..........................................................................................C-4
K625, K626, K626 Remote Control Cable Assembly ............................................................................C-4
K444, K444-1 or K444-2 Remote Voltage Control Kit...........................................................................C-5
K557-1 Rear Handle Kit.............................................................................................................................C-5
MAINTENANCE....................................................................................................................................SECTION D
Safety Precautions ..........................................................................................................................................D-1
Routine Maintenance ......................................................................................................................................D-1
Circuit Protection and Automatic Shutdown ................................................................................................D-1
Adjusting Speed Sensor Module...................................................................................................................D-1
Calibration of the LN-25 Wire Speed Dial ...................................................................................................D-2
TROUBLESHOOTING GUIDE............................................................................................................SECTION E
How to Use the Troubleshooting Guide .......................................................................................................E-1
Troubleshooting Guide....................................................................................................................................E-2
WIRING DIAGRAM...............................................................................................................................SECTION F
PHYSICAL DIMENSIONS....................................................................................................................SECTION F
PARTS MANUAL ..............................................................................................................................P333 SERIES
A-1
RATED CCURRENT
WIRE FFEED SSPEED
PHYSICAL DDIMENSIONS
ENVIRONMENTAL RRATING
WIRE DDIAMETERS
VOLTAGE
INSTALLATION
TECHNICAL SPECIFICATIONS – LN-25
A-1
OPERATING ARC VOLTAGE
Constant Voltage (CV)
or 15-40 VDC (110VDC Maximum OCV)
Constant Current (CC)
Rated current without contactor 500 Amps 60% Duty Cycle
Rated current with contactor 300 Amps 60% Duty Cycle
50 – 700 Inches Per Minute (IPM)
RECOMMENDED ELECTRODE WIRE SIZES
.023” to
.045” to
1
16” SOLID STEEL WIRE
5
64” CORED WIRE
RATED CURRENT
WIRE SPEED RANGE
.035” to 116” ALUMINUM WIRE
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
(Handle Down) w/o Options
14 Inches 7.4 Inches 21 Inches 28 lbs
(354 mm) (187 mm) (531 mm) (13 kg)
TEMPERATURE RANGE
OPERATION: - 40oC to +40oC (- 40oF to +104oF)
o
STORAGE: - 40
C to +85oC (- 40oF to +185oF)
IP23
LN-25
A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
WARNING
Unless an optional output control or contactor is used
with the LN-25, the electrode circuit (including welding
wire, wire drive and welding gun) is electrically hot
when the welding power source is on. The gun trigger
controls wire feed only.
Disconnect or shut off welding power source before
making connections or installations to the LN-25.
Welding gun should be stored in the insulated
gun holder, located near the rear on the top of the
LN-25 case, to avoid accidental arcing.
The LN-25 should be positioned upright on a
horizontal surface.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch metal portions
of the LN-25 lead clip when
welding power source is on.
WARNING
ELECTRIC SHOCK can kill.
• Do not operate with covers
removed.
• Turn off power source before
installing or servicing.
• Do not touch electrically
hot parts.
• Turn the input power to the
welding power source off at the
fuse box before working in the
terminal strip.
• Only qualified personnel should
install, use or service this
equipment.
DC-250
a. Connect a jumper from 2 to 4 on the power source
terminal strip so the output will be energized when
the DC-250 is turned on.
POWER SOURCE CONNECTION
The LN-25 can be used with most DC welding power
source. A constant voltage power source is
recommended; however, the LN-25 can also be used
with a constant current power source as long as the
open circuit voltage is less than 110V DC.
CAUTION
Do not use LN-25 models below Code 9200 with any
TIG or Square Wave welding power sources. Do not
use LN-25 models equipped with internal contactors
with non- Lincoln TIG or Square Wave welding power
sources. Damage to the LN-25 circuit can occur as a
result of the high output inductance typically
associated with these power sources. TIG high
frequency power should never be applied to the LN-25.
If not using an LN-25 Remote Output Control option
(See Remote Output Control Options and Cable
Assemblies Section), the power source output must
be electrically “hot” at all times when the power
source is turned on.
b. Connect electrode cable to the “Innershield/
GMAW” output terminal of polarity required by
electrode. Connect work lead to other
“Innershield/GMAW” output terminal.
c. Place “Set to CV Electrode Cable Polarity” switch
at appropriate position.
d. Place power source toggle switch in “Output
Control at DC-250” position, unless a Remote
Control is connected to 75, 76 and 77 on the DC250 terminal strip.
e. Place mode switch in “Innershield GMAW (CV)”
position. Set CV arc control to “2” (or “NORMAL”
on some machines). Initially set the output
control on “7”.
DC-400 AND CV-400
a. Connect a jumper from 2 to 4 on the power
source terminal strip so the output will be
energized when the power source is turned on.
NOTE: DC-400 machines above Code 9200 have
an output toggle switch to perform this function.
See the power source instruction manual for proper
power source connections and setting required.
LN-25
b. Connect the electrode cable to the output
terminal of polarity required by electrode.
Connect work lead to other output terminal.
A-3
INSTALLATION
A-3
c. Place “Set to Same Polarity As Electrode Cable
Connection” switch at appropriate position.
d. Place power source toggle switch in “Output
Control at DC(CV) -400” position, unless a
remote control is connected to 75, 76 and 77 on
the power source terminal strip.
e. If power source has a mode switch, set switch to
Constant Voltage Innershield. Initially set the
output control on “6”.
DC-600
a. Connect a jumper from 2 to 4 on the power
source terminal strip so the output will be
energized when the DC-600 is turned on. (For
DC-600 below Code 8200, also jumper N to S.)
b. Connect the electrode cable to the output
terminal of polarity required by electrode.
Connect work lead to other output terminal.
c. Place “Set to Same Polarity As Electrode Cable
Connection” switch at appropriate position.
d. Place power source toggle switch in “Output
Control at DC-600” position, unless a remote
control is connected to 75, 76 and 77 on the DC600 terminal strip.
e. Set mode switch to Constant Voltage Innershield.
Initially set output control on “4”.
R3S-325
a. Connect a jumper from 4 to 32 on the power
source terminal strip so that the output will be
energized when the R3S-325 is turned on.
c. Set ELECTRODE POLARITY switch to constant
voltage polarity required by electrode.
d. Set toggle switch to “Constant Voltage” and set
the Constant Voltage Control on welder and the
portable field control on #5 for initial start.
SA-200, —250 OR SAE-300, —400 (WITH
CV ADAPTER)
a. For electrode negative welding, connect the
electrode lead from the LN-25 to the output
terminal on the CV Adapter, and the work lead to
the power source output terminal labeled
“POSITIVE”. For electrode positive welding,
interchange the above lead connections so the
LN-25 electrode lead is then connected to the
positive power source terminal.
b. Place both switches on the CV Adapter to the CV
INNERSHIELD position and make appropriate
power source settings per the CV Adapter instructions provided for the power source being used.
c. The output voltage is set with the voltage control
on the CV Adapter.
NOTE: Refer to the Instruction Manual provided with
the machine for details on connection and operation
of the LN-25 with the power source.
INVERTEC, CV300 AND OTHER NEWER
LINCOLN POWER SOURCES
Refer to the instruction manual provided with the
power source for details on connection and operation
of the LN-25 with these newer machines.
b. Connect the electrode cable to the output
terminal of polarity required by electrode.
Connect work lead to other output terminal.
c. Set power source per its instruction manual.
NOTE: Use of the optional Line Voltage
Compensator available for the R3S-325 is
recommended if input line voltage variation
exceeds ±3%.
SAM-400, —650
a. Connect a jumper from 2 to C4 on the power
source terminal strip so the output will be
energized when the SAM power source is on.
b. Connect work lead to WORK stud. Connect
electrode to AUTO EQUIPMENT stud. Connect
SAM-650 “Tap” lead to the Innershield stud
desired.
LN-25
GUN CABLE CONNECTION
TO FEEDER
Lay the cable out straight. Insert the connector on the
welding conductor cable into the brass conductor
block on the front of the wire drive unit. Make sure it is
all the way in and tighten the hand wheel clamp. Keep
this connection clean and bright. Connect the control
cable polarized amphenol plug into the mating 5-cavity
receptacle on the front panel of the wire feeder case.
FOR GMA GUN AND CABLES:
Requires installation of K430-1 Gas Solenoid Kit
(factory installed on K446 and K449 models).
See K430-1 Gas Solenoid Kit Section (in Accessories
Section) for gas solenoid operation and gas supply
connection.
A-4
INSTALLATION
A-4
Install the barbed fitting and union nut to the 58-18
female inert gas fitting on the front panel of the
LN-25 case. Connect the 316” I.D. gas hose from the
gun cable to the barbed fitting.
When the gun is to be removed, this fitting can be
easily detached by loosening the union nut.
WELD CABLE CONNECTION
The size of the electrode cable and work cable must
be sufficient for the maximum weld current and total
cable length to be used. Refer to table A.1.
TABLE A.1
Weld Current
60% Duty Cycle 50’-100’ 100’-150’ 150’-200’ 200’-250’
200Amps 2 AWG 2 AWG 1 AWG 1/0
300Amps 1 AWG 1 AWG 1/0 2/0
400Amps 2/0 2/0 3/0 3/0
500Amps 2/0 3/0 3/0 4/0
ELECTRODE CABLE CONNECTION
Route the electrode cable through the oval hole in
the lower portion of the LN-25 rear panel. Connect
the electrode cable to the LN-25 input stud using the
1
2” nut provided.
Secure the cable with the strain relief clamp provided.
All units are supplied with an optional pigtail for
customers that prefer to make a taped and bolted
connection externally.
Total Cable Length
WIRE FEED DRIVE ROLL AND
GUIDE TUBE KITS
WARNING
Turn off power source before installing or changing
drive roll and/or guide tubes.
NOTE: The maximum wire sizes the LN-25 will
satisfactorily feed are
electrodes.
The electrode sizes that can be fed with each roll and
guide tube are stencilled
for proper components. See the instructions, included
with the drive roll kit, to install these parts on new
machines or replace them on used machines. Refer
to table A.2.
Steel Wire Sizes:
.068-564 Cored KP653-332 L9932
1
16 (.062) Cored or Solid -116
Steel
(Can also be used for .052)
.045 and .052 Solid Steel -.052
.045 and .052 Cored -.052C
.035 Solid Steel -.035S
.035 Cored -.035C
.030 Solid Steel -.030S
.025 Solid Steel -.025S
5
64” cored and 116” solid
(1)
on each part. Check the kit
TABLE A.2
Kit Instructions
WORK CABLE CONNECTION
Connect a work lead of sufficient size between
the proper output stud on the power source and
the work. Be sure the connection to the work
makes tight metal-to-metal electrical contact.
Poor work lead connections can result in poor
welding performance.
LN-25
Aluminum Wire Sizes:
1
16 KP654-
3
64 -364A
.035 -.035A
(1)
Drive rolls for only cored electrode sizes are stencilled with a
“C” suffix to the wire sizes.
Drive rolls for only solid electrode sizes are stencilled with an
“S” suffix to the wire sizes.
Drive rolls for aluminum wire sizes are stencilled with an “A” suffix
to the wire sizes.
1
16A L9932
B-1
OPERATION
B-1
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live
part or electrode with skin or
wet clothing.
• Insulate yourself from work
and ground.
• Always wear dry insulating
gloves.
FUMES AND GASSES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS can cause
fire or explosion.
GENERAL DESCRIPTION
The LN-25 is a lightweight portable semiautomatic
wire feeder designed for “across-the-arc” operation
without a control cable on most any DC welding
power source. Simply connect the LN-25 to the
electrode cable, clip it to Work and it is ready to weld,
using up to 30 lb. coils or spools.
The wire drive, controls and wire reel are fully
enclosed in a rugged molded plastic case providing
a compact and versatile welding package ideally
suited to “on-the-go” field welding applications in
virtually any environment.
RECOMMENDED PROCESSES
AND EQUIPMENT
When combined with the quality drive roll kits and
accessories available for use with the LN-25, a
versatile portable welding system can be provided to
meet the specific needs of Innershield, submerged
arc or gas metal arc welding applications within the
wire feed capabilities of the LN-25.
The LN-25 provides constant wire feed speed for use
with constant voltage (CV) power sources, and arcsensing wire feed speed for use with constant current
(CC) (formerly variable voltage) power sources. Wire
speed is presettable on a dual-range calibrated dial.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear and body protection.
The power sources recommended for use with the
LN-25 include the DC-250, -400, -600, CV-400 and
R3S type transformer machines, and the SAM-400,
-650 engine welders, as well as the SA-200, -250 or
SAE-300, -400 with CV Adapter and Pulse Power
500 with K460-1 LN-25 Kit.
WELDING CAPABILITY
The LN-25 will handle up to 500 Amp 60% duty cycle
welding currents. However, when equipped with a
K443-2 Contactor, the LN-25 will handle up to 300
Amp 60% duty cycle.
LN-25
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