RETURN TO MAIN MENU |
IM901-A |
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LN-25™ PRO |
January, 2010 |
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For use with machines having Code Number: 11387, 11388, 11507, 11508
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.
IP23
IEC 60974-5
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
•World's Leader in Welding and Cutting Products •
•Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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WARNING
CALIFORNIA PROPOSITION 65 WARNINGS |
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
ARC WELDING CAN bE HAzARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIbLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR bEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
bE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY bY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
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1.c. Do not add the fuel near an open flame welding arc or when the engine is running.
Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
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1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods
while the engine is running.
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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
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SAFETY |
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ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full 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 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 vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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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 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.
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.
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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1.Protegez-vous contre la secousse électrique:
a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b.Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher 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 l’eau pour le refroidir.
e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3.Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a.Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b.Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc.
c.Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables.
4.Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5.Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8.S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1.Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2.Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3.Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4.Garder tous les couvercles et dispositifs de sûreté à leur place.
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Thank You
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric 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. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes 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.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric 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. Please refer to www.lincolnelectric.com for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEb SITE at www.lincolnelectric.com. Choose “Quick Links” and then “Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TAbLE OF CONTENTS |
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Installation....................................................................................................................... |
Section A |
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Technical Specifications....................................................................................................... |
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A-1 |
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Safety Precautions ............................................................................................................... |
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Location................................................................................................................................ |
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High Frequency Protection................................................................................................... |
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Weld cable Sizes.................................................................................................................. |
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Cable Connections ............................................................................................................... |
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A-3 |
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Shielding Gas Connection.................................................................................................... |
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Wire Drive Configuration ...................................................................................................... |
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A-4 |
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Changing The Gun Receiver Bushing................................................................................ |
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A-4 |
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Procedure to Install Drive Rolls and Wire Guides .............................................................. |
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Pressure Arm Adjustment .................................................................................................... |
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A-5 |
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Loading Spools of Wire ........................................................................................................ |
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A-5 |
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Gun Connections.................................................................................................................. |
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A-5 |
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Power Source to LN-25™ Pro Cable Connection Diagrams .................................. |
A-6 thru A-8 |
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Operation......................................................................................................................... |
Section b |
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Safety Precautions ............................................................................................................... |
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B-1 |
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Graphic Symbols that appear on this Machine or in this Manual ......................................... |
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B-1 |
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Definition of Welding Terms ................................................................................................. |
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B-2 |
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General Description.............................................................................................................. |
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B-2 |
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Recommended Processes, Equipment Limitations, Recommended Power Sources |
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Case Front Controls ............................................................................................... |
B-3 thru B-5 |
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Internal Controls ................................................................................................................... |
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B-6 |
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Internal Controls Decription.................................................................................................. |
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B-7 |
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Constant Current Wire Welding............................................................................................ |
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B-8 |
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Rear Controls ....................................................................................................................... |
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B-9 |
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Gas Purge Pushbutton ....................................................................................................... |
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B-10 |
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Flow Meter.......................................................................................................................... |
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Power-Up Sequence .......................................................................................................... |
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B-10 |
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Accessories .................................................................................................................... |
Section C |
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Factory Installed Equipment................................................................................................. |
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C-1 |
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Drive Roll Kits used.............................................................................................................. |
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C-1 |
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Accessories Used .................................................................................................. |
C-2 thru C-5 |
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Installation of Water Cooling Kit ........................................................................................... |
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C-6 |
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Maintenance.................................................................................................................... |
Section D |
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Safety Precautions ............................................................................................................... |
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D-1 |
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Routine Maintenance ........................................................................................................... |
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D-1 |
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Periodic Maintenance........................................................................................................... |
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D-1 |
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Calibration Specification................................................................................................ |
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D-1,D-2 |
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Troubleshooting ............................................................................................................. |
Section E |
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How to Use Troubleshooting Guide ..................................................................................... |
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E-1 |
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Digital Display Models Error Codes...................................................................................... |
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E-2 |
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Troubleshooting Guide ................................................................................................. |
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E-3, E-4 |
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Wiring Diagram & Dimension Prints ............................................................................. |
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Section F |
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Parts Pages ................................................................................................................ |
P-557 Series |
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A-1 |
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INSTALLATION |
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A-1 |
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TECHNICAL SPECIFICATIONS – LN-25™ PRO ACROSS THE ARC MODEL |
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(K2613-1, K2613-2) |
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INPUT VOLTAGE and CURRENT |
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INPUT VOLTAGE ± 10% |
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INPUT AMPERES |
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15-110 VDC |
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4A |
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RATED OUTPUT @ 104°F (40°C) |
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DUTY CYCLE |
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INPUT AMPERES |
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60% rating |
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450 |
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100% rating |
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325 |
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GEARING - WIRE FEED |
SPEED RANGE-WIRE SIzE |
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GEARING |
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GMAW |
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FCAW |
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WFS RANGE |
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WIRE SIzES |
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WFS RANGE |
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WIRE SIzES |
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Extra torque |
30 – 400 ipm |
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.023 – 1/16" |
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30 – 400 ipm |
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.030 - 3/32” |
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K2613-2 |
(0.8 – 10.1m/min) |
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(0.6 – 1.6mm) |
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(0.8 – 10.1m/min) |
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(10.3 – 2.4mm) |
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Standard Speed |
50 – 700 ipm |
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.023 – 1/16" |
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50 – 700 ipm |
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.030 - 5/64 |
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K2613-1 |
(1.3 – 17.7m/min) |
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(0.6 – 1.6mm) |
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(1.3 – 17.7m/min) |
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(0.8 - 2.0mm) |
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PHYSICAL DIMENSIONS |
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HEIGHT |
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WIDTH |
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DEPTH |
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WEIGHT |
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14.8 Inches |
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8.7 Inches |
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22.2 Inches |
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36 lbs |
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(376 mm) |
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( 221 mm) |
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(589 mm) |
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(16 kg) |
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Handle folded down |
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TEMPERATURE RANGE |
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OPERATION: |
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-40°F to 104°F |
(-40°C to 40°C) |
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STORAGE: |
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-40°F to 185°F |
(-40°C to 85°C) |
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LN-25™ PRO ACROSS THE ARC MODEL
A-2 |
INSTALLATION |
A-2 |
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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 LN25™ PRO 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 LN-25™ PRO.
The LN-25™ PRO is rated IP23 and is suitable for outdoor use.
The handle of the LN-25™ PRO 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 LN-25™ PRO away from radio controlled machinery. The normal operation of the LN-25™ PRO may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.
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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)**
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CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES |
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AMPERES |
PERCENT |
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DUTY |
0 to 50Ft. |
50 to 100Ft. |
100 to 150 Ft. |
150 to 200 Ft. |
200 to 250 Ft. |
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CYCLE |
(0 to15m) |
(15 to 30m) |
(30 to 46m) |
(46 to 61m) |
(61 to 76m) |
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200 |
60 |
2 |
2 |
2 |
1 |
1/0 |
200 |
100 |
2 |
2 |
2 |
1 |
1/0 |
225 |
20 |
4 or 5 |
3 |
2 |
1 |
1/0 |
225 |
40 & 30 |
3 |
3 |
2 |
1 |
1/0 |
250 |
30 |
3 |
3 |
2 |
1 |
1/0 |
250 |
40 |
2 |
2 |
1 |
1 |
1/0 |
250 |
60 |
1 |
1 |
1 |
1 |
1/0 |
250 |
100 |
1 |
1 |
1 |
1 |
1/0 |
300 |
60 |
1 |
1 |
1 |
1/0 |
2/0 |
325 |
100 |
2/0 |
2/0 |
2/0 |
2/0 |
3/0 |
350 |
60 |
1/0 |
1/0 |
2/0 |
2/0 |
3/0 |
400 |
60 |
2/0 |
2/0 |
2/0 |
3/0 |
4/0 |
400 |
100 |
3/0 |
3/0 |
3/0 |
3/0 |
4/0 |
500 |
60 |
2/0 |
2/0 |
3/0 |
3/0 |
4/0 |
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** 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).
LN-25™ PRO ACROSS THE ARC MODEL
A-3 INSTALLATION A-3
CAbLE CONNECTIONS |
SHIELDING GAS CONNECTION |
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There is one circular connector for the gun trigger on the front of the LN-25™ PRO.
Function |
Pin |
Wiring |
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5-pin trigger |
A |
Trigger |
connector for |
B |
Not used |
push-guns |
C |
Common |
only. |
D |
Not used |
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E |
Not used |
C B
D E A
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.
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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% CO2 cylinder, 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 CO2 cylinder.
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.
LN-25™ PRO ACROSS THE ARC MODEL
A-4 |
INSTALLATION |
A-4 |
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WIRE DRIVE CONFIGURATION
(See Figure A.2)
CHANGING THE GUN RECEIVER bUSHING
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.
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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.
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.
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.
7.Disconnect the shielding gas hose from the gun bushing, if required.
FIGURE A.2
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.
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.
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1.Turn power off at the welding power source.
2.Release the idle roll pressure arm.
3.Remove the outer wire guide by turning the knurled thumbscrews counter-clockwise to unscrew them from the feed plate.
4.Rotate the triangular lock and remove the drive rolls.
THUMB SCREW
GUN RECEIVER BUSHING
OUTER WIRE GUIDE
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN TIGHTEN
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.
LN-25™ PRO ACROSS THE ARC MODEL
A-5 |
INSTALLATION |
A-5 |
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PRESSURE ARM ADJUSTMENT
1.Squeeze the release bar on the retaining collar and remove it from the spindle.
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.
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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.
Set the pressure arm as follows: |
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(See Figure A.3) |
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Aluminum wires |
between 1 and 3 |
Cored wires |
between 3 and 4 |
Steel, Stainless wires |
between 4 and 6 |
FIGURE A.3
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Al |
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ALUMINUM WIRES |
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Fe, CrNi |
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CORED WIRES |
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6 |
Fe, CrNi |
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STEEL, STAINLESS WIRES |
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LOADING SPOOLS OF WIRE
WARNING
•Keep hands, hair, clothing and tools away from rotating equipment.
•Do not wear gloves when threading wire or changing wire spool.
•Only qualified personnel should install, use or service this equipment.
------------------------------------------------------------------------
Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.
A K468 spindle adapter is required for loading 2" (51mm) wide spools on 2" (51mm) spindles. Use a K468 spindle adapter for loading 2-1/2" (64mm) wide spools.
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.
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The LN-25™ PRO ACROSS THE ARC MODEL comes with a K1500-2 gun adapter installed. (See Figure A.4)
To install a gun,
1.Turn power OFF.
2.Remove the thumb screw.
3.Push the gun the completely into the gun bushing.
4.Secure the gun in place with the thumb screw.
5.Connect the trigger cable from the gun to the trigger connector on the front of the feeder.
Note: Not all gun bushings require the use of the thumb screw.
FIGURE A.4
THUMB
SCREW
GUN 
LN-25™ PRO ACROSS THE ARC MODEL
A-6 |
INSTALLATION |
A-6 |
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POWER SOURCE TO LN-25™ PRO
CAbLE CONNECTION DIAGRAMS
ACROSS THE ARC SET-UPS
CC Power Sources with Output Terminals Always
Hot (See Figure A.5)
CC Power Source
Ranger 250, 250 LPG
Ranger 305G, 305D
Commander 300 |
FIGURE A.5 |
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Vantage 300, 400, 500
Air Vantage 500
Electrode
Work clip
Work
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)
K# |
Description |
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K2613-1 |
LN-25™ PRO |
K2613-2 |
LN-25™ PRO Extra Torque |
KP1695-XX |
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KP1696-XX |
Drive Roll Kit |
KP1697-XX |
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See Magnum Literature |
Welding Gun |
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CC power Source |
K1803-1 |
Welding Cables |
FIGURE A.6
CV-655 DC-400 DC-600 DC-655 V450-Pro
Electrode
LN-25™ PRO
(Across the Arc)
Work clip
Work
Place the power source Remote/Local switch in the Local position.
Place CV/CC switch in the feeder in the "CV" position.
K# |
Description |
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K2613-1 |
LN-25™ PRO |
K2613-2 |
LN-25™ PRO Extra Torque |
KP1695-XX |
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KP1696-XX |
Drive Roll Kit |
KP1697-XX |
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See magnum Literature |
Welding Gun |
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CV power Source |
K1803-1 |
Welding Cables |
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LN-25™ PRO ACROSS THE ARC MODEL
A-7 |
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INSTALLATION |
A-7 |
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CV Power Sources with Stud Connectors and no |
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Remote/Local Switch. (See Figure A.7) |
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CV-400 |
Jumper |
FIGURE A.7 |
LN-25™ PR0 |
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Electrode |
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CV-655 |
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(Across The Arc) |
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Work |
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Work clip |
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Place CV/CC switch in the feeder in the "CV" position. |
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K# |
Description |
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K2613-1 |
LN-25™ PRO |
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K2613-2 |
LN-25™ PRO Extra Torque |
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KP484 |
Jumper Plug Kit |
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KP1695-XX |
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KP1696-XX |
Drive Roll Kit |
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KP1697-XX |
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See Magnum Literature |
Welding Gun |
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CC power Source |
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K1803-1 |
Welding Cables |
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CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.8)
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FIGURE A.8 |
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V350-Pro |
Electrode |
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LN-25™ PRO |
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(Across the Arc) |
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Work clip |
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Work |
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Place CV/CC switch in the feeder in the "CV" position. |
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K# |
Description |
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K2613-1 |
LN-25™ PRO |
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K2613-2 |
LN-25™ PRO Extra Torque |
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KP1695-XX |
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KP1696-XX |
Drive Roll Kit |
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KP1697-XX |
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See Magnum Literature |
Welding Gun |
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CC power Source |
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K1841 |
Welding Cables |
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LN-25™ PRO ACROSS THE ARC MODEL
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