Lincoln Electric pmn User Manual

LN-25 PORTABLE CV/CC

SEMIAUTOMATIC WIRE FEEDER

OPERATING MANUAL

IM359-G

February, 1998

For use with machines having Code Number 10231

10232
10233

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.

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

RETURN TO MAIN MENU

FOR ENGINE
powered equipment.

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

____________________________________________________

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

____________________________________________________

1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill
fuel when filling tank. If fuel is spilled, wipe it up
and do not start engine until fumes have been
eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in position
and in good repair.Keep hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts when starting,
operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler by
pushing on the throttle control rods while the
engine is running.

___________________________________________________

1.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.

i

SAFETY

i

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.

WARNING

Mar ‘95

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.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

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 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 Diesel Engines

The Above For Gasoline Engines

ii

SAFETY

ii

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.

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.

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. 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.c. 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.d. 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.e. Also see item 1.b.

Mar ‘95

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.

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.

iii

SAFETY

iii

Mar ‘95

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.

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
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.

Mar. ‘93

LN-25

Thank You

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!

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.

This statement appears where the information must be followed to avoid minor personal injury or dam-

age to this equipment.

CAUTION

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.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

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

LN-25

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

K430-1 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

K443-1 LN-25 Contactor Kit........................................................................................................... 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-3

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..................................................................................................................P 175 SERIES

TABLE OF CONTENTS

TEMPERATURE RANGE

OPERATION: - 40oC to +40oC (- 40oF to +104oF)
STORAGE: - 40oC to +85oC (- 40oF to +185oF)

LN-25

A-1

OPERATING ARC VOLTAGE

Constant Voltage (CV)

or 15-40 VDC (110VDC Maximum OCV)

Constant Current (CC)

RATED CURRENT

Rated current without contactor 500 Amps 60% Duty Cycle

Rated current with contactor 300 Amps 60% Duty Cycle

WIRE SPEED RANGE

50 – 700 Inches Per Minute (IPM)

RECOMMENDED ELECTRODE WIRE SIZES

.023” to

1

⁄16” SOLID STEEL WIRE

.045” to

5

⁄64” CORED WIRE

.035” to 1⁄16” 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)

RRAATTEEDD CCUURRRREENNTT

WWIIRREE FFEEEEDD SSPPEEEEDD

PPHHYYSSIICCAALL DDIIMMEENNSSIIOONNSS

EENNVVIIRROONNMMEENNTTAALL RRAATTIINNGG

WWIIRREE DDIIAAMMEETTEERRSS

VVOOLLTTAAGGEE

INSTALLATION

TECHNICAL SPECIFICATIONS – LN-25

IP23 (IEC529)

MAR97

LN-25

A-2

INSTALLATION

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.

b. Connect electrode cable to the “Innershield/

GMAW” output terminal of polarity required by
electrode. Connect work lead to other
“Innershield/GMAW” output terminal.

c. Place “Set to CV Electrode Cable Polarity” switch

at appropriate position.

d. Place power source toggle switch in “Output

Control at DC-250” position, unless a Remote
Control is connected to 75, 76 and 77 on the DC­250 terminal strip.

e. Place mode switch in “Innershield GMAW (CV)”

position. Set CV arc control to “2” (or “NORMAL”
on some machines). Initially set the output
control on “7”.

DC-400 AND CV-400

a. Connect a jumper from 2 to 4 on the power

source terminal strip so the output will be
energized when the power source is turned on.

NOTE: DC-400 machines above Code 9200 have

an output toggle switch to perform this function.

b.Connect the electrode cable to the output

terminal of polarity required by electrode.
Connect work lead to other output terminal.

SAFETY PRECAUTIONS

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.

ELECTRIC SHOCK can kill.

• Do not touch metal portions
of the LN-25 lead clip when
welding power source is on.

POWER SOURCE CONNECTION

The LN-25 can be used with any 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.

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.

See the power source instruction manual for proper
power source connections and setting required.

WARNING

WARNING

WARNING

CAUTION

MAR97

LN-25

A-3

c. Set ELECTRODE POLARITY switch to constant

voltage polarity required by electrode.

d. Set toggle switch to “Constant Voltage” and set

the Constant Voltage Control on welder and the
portable field control on #5 for initial start.

SA-200, —250 OR SAE-300, —400 (WITH
CV ADAPTER)

a. For electrode negative welding, connect the

electrode lead from the LN-25 to the output
terminal on the CV Adapter, and the work lead to
the power source output terminal labeled
“POSITIVE”. For electrode positive welding,
interchange the above lead connections so the
LN-25 electrode lead is then connected to the
positive power source terminal.

b. Place both switches on the CV Adapter to the CV

INNERSHIELD position and make appropriate
power source settings per the CV Adapter instruc­tions provided for the power source being used.

c. The output voltage is set with the voltage control

on the CV Adapter.

NOTE: Refer to the Instruction Manual provided with
the machine for details on connection and operation
of the LN-25 with the power source.

INVERTEC, CV300 AND OTHER NEWER
LINCOLN POWER SOURCES

Refer to the instruction manual provided with the
power source for details on connection and operation
of the LN-25 with these newer machines.

GUN CABLE CONNECTION
TO FEEDER

Lay the cable out straight. Insert the connector on the
welding conductor cable into the brass conductor
block on the front of the wire drive unit. Make sure it is
all the way in and tighten the hand wheel clamp. Keep
this connection clean and bright. Connect the control
cable polarized amphenol plug into the mating 5-cavity
receptacle on the front panel of the wire feeder case.

FOR GMA GUN AND CABLES:

Requires installation of K430-1 Gas Solenoid Kit
(factory installed on K446 and K449 models).

See K430-1 Gas Solenoid Kit Section (in Accessories
Section) for gas solenoid operation and gas supply
connection.

c. Place “Set to Same Polarity As Electrode Cable

Connection” switch at appropriate position.

d. Place power source toggle switch in “Output

Control at DC(CV) -400” position, unless a
remote control is connected to 75, 76 and 77 on
the power source terminal strip.

e. If power source has a mode switch, set switch to

Constant Voltage Innershield. Initially set the
output control on “6”.

DC-600

a. Connect a jumper from 2 to 4 on the power

source terminal strip so the output will be
energized when the DC-600 is turned on. (For
DC-600 below Code 8200, also jumper N to S.)

b.Connect the electrode cable to the output

terminal of polarity required by electrode.
Connect work lead to other output terminal.

c. Place “Set to Same Polarity As Electrode Cable

Connection” switch at appropriate position.

d. Place power source toggle switch in “Output

Control at DC-600” position, unless a remote
control is connected to 75, 76 and 77 on the DC­600 terminal strip.

e. Set mode switch to Constant Voltage Innershield.

Initially set output control on “4”.

R3S-325

a. Connect a jumper from 4 to 32 on the power

source terminal strip so that the output will be
energized when the R3S-325 is turned on.

b. Connect the electrode cable to the output

terminal of polarity required by electrode.

Connect work lead to other output terminal.
c. Set power source per its instruction manual.
NOTE: Use of the optional Line Voltage

Compensator available for the R3S-325 is

recommended if input line voltage variation

exceeds ±3%.

SAM-400, —650

a. Connect a jumper from 2 to C4 on the power

source terminal strip so the output will be

engergized 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.

INSTALLATION

LN-25

A-4

INSTALLATION

Install the barbed fitting and union nut to the 5⁄8-18

female inert gas fitting on the front panel of the

LN-25 case. Connect the 3⁄16” I.D. gas hose from the

gun cable to the barbed fitting.

When the gun is to be removed, this fitting can be

easily detached by loosening the union nut.

WELD CABLE CONNECTION

The size of the electrode cable and work cable must

be sufficient for the maximum weld current and total

cable length to be used. Refer to table A.1.

TABLE A.1

Total Cable Length

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

On units without an internal contactor route the

electrode cable through the oval hole in the LN-25

rear panel, then along the case floor behind the reel

support and around the door side of the wire drive.

Connect the electrode cable to the LN-25 using the

1

⁄2” bolt on the front of the wire drive.

On units with an internal contactor connect the

electrode cable to the LN-25 electrode input cable

with the nut and bolt provided. Tape the bolted

connection.

WORK CABLE CONNECTION

Connect a work lead of sufficient size between

the proper output stud on the power source and

the work. Be sure the connection to the work

makes tight metal-to-metal electrical contact.

Poor work lead connections can result in poor

welding performance.

WIRE FEED DRIVE ROLL AND
GUIDE TUBE KITS

Turn off power source before installing or changing
drive roll and/or guide tubes.

NOTE: The maximum wire sizes the LN-25 will
satisfactorily feed are 5⁄64” cored and 1⁄16” solid
electrodes.

The electrode sizes that can be fed with each roll and
guide tube are stencilled

(1)

on each part. Check the kit
for proper components. See the instructions, included
with the drive roll kit, to install these parts on new
machines or replace them on used machines. Refer
to table A.2.

TABLE A.2

Kit Instructions

Steel Wire Sizes:

.068-5⁄64 Cored KP653-3⁄32 L9932

1

⁄16 (.062) Cored or Solid -1⁄16
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

Aluminum Wire Sizes:

1

⁄16 KP654-

1

⁄16A L9932

3

⁄64 -3⁄64A
.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.

WARNING

4/96