Page 1
RED-D-ARC
LN-25™ PRO EXTREME
IM960-A
March, 2010
Red-D-Arc Spec-Built Welding Equipment
This
RED-D-ARC
welder is built to
RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
For use with machines having Code Numbers: 11391, 11718
North America’s Largest Fleet of Welding Equipment
1-800-245-3660
OPERATOR’S MANUAL
Page 2
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
i
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 a dd 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 som e case s it may be necessar y 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
Page 3
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-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
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09
Page 4
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Us e only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Jan ‘09
Page 5
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.
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
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.
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
Page 6
Thank You
vv
for selecting a QUALITY product. We want you to take pride in
operating this product ••• as much pride as we have in bringing
this product to you!
The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products. We
respond to our customers based on the best information in our possession at that time. We are not in a position to warrant or guarantee such
advice, and assume no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration,
we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.
We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the control of, and remains the
sole responsibility of the customer. Many variables beyond our control affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing.
CUSTOMER ASSISTANCE POLICY
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code (if available)______________________________________________________
Serial Number (if available)__________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
Page 7
vi
TABLE OF CONTENTS
Page
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Location................................................................................................................................A-2
High Frequency Protection...................................................................................................A-2
Weld cable Sizes..................................................................................................................A-2
Cable Connections ...............................................................................................................A-3
Shielding Gas Connection....................................................................................................A-3
Wire Drive Configuration ......................................................................................................A-4
Changing The Gun Receiver Bushing................................................................................A-4
Procedure to Install Drive Rolls and Wire Guides ..............................................................A-4
Pressure Arm Adjustment ....................................................................................................A-5
Loading Spools of Wire ........................................................................................................A-5
Gun Connections..................................................................................................................A-5
Power Source to LN-25™ PRO EXTREME Cable Connection Diagrams ...........A-6 thru A-8
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Graphic Symbols that appear on this Machine or in this Manual .........................................B-1
Definition of Welding Terms .................................................................................................B-2
General Description..............................................................................................................B-2
Recommended Processes, Equipment Limitations, Recommended Power Sources ..........B-2
Case Front Controls ...............................................................................................B-3 thru B-5
Internal Controls ...................................................................................................................B-7
Internal Controls Description ................................................................................................B-8
Constant Current Wire Welding............................................................................................B-9
Rear Controls .....................................................................................................................B-10
Gas Purge Pushbutton .......................................................................................................B-10
________________________________________________________________________________
Accessories ....................................................................................................................Section C
Factory Installed Equipment.................................................................................................C-1
Drive Roll Kits used, Accessories Used .................................................................C-1 thru C-3
________________________________________________________________________________
Maintenance....................................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Calibration Specification’s ....................................................................................................D-2
________________________________________________________________________________
Troubleshooting .............................................................................................................Section E
How to Use Troubleshooting Guide .....................................................................................E-1
Digital Display Models Error Codes......................................................................................E-2
Troubleshooting Guide .................................................................................................E-3, E-4
________________________________________________________________________________
vi
Wiring Diagram & Dimension Prints .............................................................................Section F
________________________________________________________________________________
Parts Pages ................................................................................................................P-562 Series
_______________________________________________________________________
________
Page 8
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS –
INPUT VOLTAGE and CURRENT
INPUT VOLTAGE ± 10%
15-110 VDC
RATED OUTPUT @ 104°F (40°C)
DUTY CYCLE
60% rating
100% rating
GEARING - WIRE FEED SPEED RANGE-WIRE SIZE
GMAW
GEARING
WFS RANGE
Normal Speed
50 – 700 ipm
(1.3 – 17.7m/min)
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
LN-25™ PRO EXTREME WITH DIGITAL METERS
(K2613-4)
INPUT AMPERES
4A
INPUT AMPERES
450
325
FCAW
WIRE SIZES
.023 – 1/16"
(0.6 – 1.6mm)
WFS RANGE
50 – 700 ipm
(1.3 – 17.7m/min)
WIRE SIZES
.030 - 5/64
(0.8 - 2.0mm)
14.8 Inches 8.7 Inches 22.2 Inches 36 lbs
(376 mm) ( 221 mm) (589 mm) (16 kg)
Handle folded down
TEMPERATURE RANGE
OPERATION: -40°F to 104°F (-40°C to 40°C)
STORAGE: -40°F to 185°F (-40°C to 85°C)
RED-D-ARC LN-25™ PRO EXTREME
Page 9
A-2
SAFETY PRECAUTIONS
WARNING
INSTALLATION
The LN-25™ PRO EXTREME is rated IP23 and is
suitable for outdoor use.
A-2
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 LN-25™ PRO
EXTREME 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 EXTREME 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.
The handle of the LN-25™ PRO EXTREME 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 EXTREME away from
radio controlled machinery. The normal operation of
the LN-25™ PRO EXTREME may adversely affect
the operation of RF controlled equipment, which
may result in bodily injury or damage to the equipment.
------------------------------------------------------------------------
WELD CABLE SIZE
Table A.1 located below are copper cable sizes recommended for different currents and duty cycles.
Lengths stipulated are the distance from the welder to
work and back to the welder again. Cable sizes are
increased for greater lengths primarily for the purpose
of minimizing cable drop.
Do not submerge the LN-25™ PRO EXTREME .
TABLE A.1
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES
200
200
225
225
250
250
250
250
300
325
350
400
400
500
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).
PERCENT
DUTY
CYCLE
60
100
20
40 & 30
30
40
60
100
60
100
60
60
100
60
0 to 50Ft.
(0 to15m)
2
2
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
50 to 100Ft.
(15 to 30m)
2
2
3
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
100 to 150 Ft.
(30 to 46m)
2
2
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
150 to 200 Ft.
(46 to 61m)
1
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
200 to 250 Ft.
(61 to 76m)
1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
RED-D-ARC LN-25™ PRO EXTREME
Page 10
A-3
INSTALLATION
A-3
CABLE CONNECTIONS
There is one circular connector for the gun trigger on
the front of the LN-25™ PRO EXTREME .
Function
5-pin trigger
connector for
push-guns
only.
C
Pin
A
B
C
D
E
Wiring
Trigger
Not used
Common
Not used
Not used
B
E
D
A
SHIELDING GAS CONNECTION
WARNING
CYLINDER may explode if
damaged.
• Keep cylinder upright and
chained to support.
• Keep cylinder away from areas where it may be
damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live
electrical circuits.
• BUILD UP OF SHIELDING GAS MAY
HARM HEALTH OR KILL.
• Shut off shielding gas supply when not
in use.
• See American National Standard Z-49.1, "Safety
in Welding and Cutting” Published by the
American Welding Society.
------------------------------------------------------------------------
Maximum inlet pressure is 100 psi. (6.9 bar.)
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
2. Remove the cylinder cap. Inspect the cylinder valves
and regulator for damaged threads, dirt, dust, oil or
grease. Remove dust and dirt with a clean cloth. DO
NOT ATTACH THE REGULATOR IF OIL, GREASE
OR DAMAGE IS PRESENT! Inform your gas supplier
of this condition. Oil or grease in the presence of high
pressure oxygen is explosive.
3. Stand to one side away from the outlet and open the
cylinder valve for an instant. This blows away any dust
or dirt which may have accumulated in the valve outlet.
4. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench. Note:
if connecting to 100% CO2cylinder, insert regulator
adapter between regulator and cylinder valve. If
adapter is equipped with a plastic washer, be sure it is
seated for connection to the CO2cylinder.
5. Attach one end of the inlet hose to the outlet fitting of
the flow regulator. Attach the other end to the welding
system shielding gas inlet. Tighten the union nuts with
a wrench.
6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.
7. Standing to one side, open the cylinder valve slowly a
fraction of a turn. When the cylinder pressure gage
stops moving, open the valve fully.
8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making a weld.
RED-D-ARC LN-25™ PRO EXTREME
Page 11
A-4
INSTALLATION
A-4
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.
------------------------------------------------------------------------
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.
------------------------------------------------------------------------
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
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN TIGHTEN
OUTER WIRE GUIDE
RED-D-ARC LN-25™ PRO EXTREME
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.
Page 12
A-5
PRESSURE ARM ADJUSTMENT
INSTALLATION
1. Squeeze the release bar on the retaining collar and
remove it from the spindle.
A-5
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the welding power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several seconds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform maintenance work.
------------------------------------------------------------------------
The pressure arm controls the amount of force the
drive rolls exert on the wire. Proper adjustment of the
pressure arm gives the best welding performance.
Set the pressure arm as follows:
(See Figure A.3)
Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6
FIGURE A.3
ALUMINUM WIRES
CORED WIRES
STEEL, STAINLESS WIRES
6
Al
Fe, CrNi
Fe, CrNi
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.
2. Place the spindle adapter on the spindle, aligning
the spindle brake pin with the hole in the adapter.
3. Place the spool on the spindle and align the
adapter brake tab with one of the holes in the back
side of the spool. An indicator mark on the end of
the spindle shows the orientation of the brake tab.
Be certain the wire feeds off of the spool in the
proper direction.
4. Re-install the retaining collar. Make sure that the
release bar snaps out and that the retaining collar
fully engages the groove on the spindle.
GUN CONNECTION
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the welding power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several seconds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform maintenance work.
------------------------------------------------------------------------
The LN-25™ PRO EXTREME 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
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.
RED-D-ARC LN-25™ PRO EXTREME
Page 13
A-6
INSTALLATION
POWER SOURCE TO LN-25™ PRO EXTREME
CABLE CONNECTION DIAGRAMS
ACROSS THE ARC SET-UPS
CC Power Sources with Output Terminals Always
Hot (See Figure A.5)
FIGURE A.5
®
®
®
®
®
®
®
A-6
-
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)
Place the power source Remote/Local switch in the
Local position.
Place CV/CC switch in the feeder in the "CV" position.
K#
K2613-4
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum® Literature
K1803-1
FIGURE A.6
-
K#
K2613-4
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum
® Literature
K1803-1
Description
LN-25™ PRO EXTREME
WITH DIGITAL METERS
Drive Roll Kit
Welding Gun
CC power Source
Welding Cables
Description
LN-25™ PRO EXTREME
WITH DIGITAL METERS
Drive Roll Kit
Welding Gun
CV power Source
Welding Cables
RED-D-ARC LN-25™ PRO EXTREME
Page 14
A-7
CV Power Sources with Stud Connectors and no
Remote/Local Switch. (See Figure A.7)
INSTALLATION
A-7
FIGURE A.7
-
Place CV/CC switch in the feeder in the "CV" position.
CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.8)
K#
K2613-4
KP484
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum® Literature
K1803-1
FIGURE A.8
Description
LN-25™ PRO EXTREME
WITH DIGITAL METERS
Jumper Plug Kit
Drive Roll Kit
Welding Gun
CC power Source
Welding Cables
Place CV/CC switch in the feeder in the "CV" position.
-
K#
K2613-4
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum® Literature
K1841-XX
K852-95
RED-D-ARC LN-25™ PRO EXTREME
Description
LN-25™ PRO EXTREME
WITH DIGITAL METERS
Drive Roll Kit
Welding Gun
CV power Source
Welding Cables
Twist-Mate Cable Plug
Page 15
A-8
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.9)
INSTALLATION
A-8
FIGURE A.9
-
Place CV/CC switch in the feeder in the "CV" position.
K#
K2613-4
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum® Literature
K1841
K852-95
K484
Description
LN-25™ PRO EXTREME
WITH DIGITAL METERS
Drive Roll Kit
Welding Gun
CV power Source
Welding Cables
Twist-mate Cable Plug
Jumper Plug kit
RED-D-ARC LN-25™ PRO EXTREME
Page 16
B-1
OPERATION
B-1
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
WARNING
• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive
mechanism are always electrically energized and could
remain energized several seconds after the welding ceases..
• Do not touch electrically live part or electrode
with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards
removed or open.
---------------------------------------------------------------------
• FUMES AND GASSES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
---------------------------------------------------------------------
• WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
---------------------------------------------------------------------ARC RAYS can burn.
• Wear eye, ear and body protec-
tion.
---------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MANUAL.
----------------------------------------------------------------------
The serviceability of a product or structure utilizing the
LN-25™ PRO EXTREME wirefeeder is and must be
the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric
Company affect the results obtained in using the LN25™ PRO EXTREME wirefeeder. These variables
include, but are not limited to, welding procedure,
plate chemistry and temperature, weldment design,
fabrication methods and service requirements. The
available range of the LN-25™ PRO EXTREME
wirefeeder may not be suitable for all applications,
and the builder/user is and must be solely responsible
for welding settings.
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
INPUT POWER
ON
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
INPUT POWER
DIRECT CURRENT
U
U
U
I
I
0
1
2
1
2
OPEN CIRCUIT
VOLTAGE
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVE
GROUND
WARNING OR
CAUTION
RED-D-ARC LN-25™ PRO EXTREME
Page 17
B-2
OPERATION
B-2
DEFINITION OF WELDING TERMS
WFS
• Wire Feed Speed
CC
• Constant Current
CV
• Constant Voltage
GMAW
• Gas Metal Arc welding
SMAW
• Shielded Metal Arc welding
FCAW
• Flux Core Arc Welding
GENERAL DESCRIPTION
General Physical Description
The LN-25™ PRO EXTREME is specially engineered
to be the most rugged portable wire feeder available.
The plastic case is molded from a high impact, flame
retardant plastic for durability and low weight. The
patent pending design keeps the internal components
protected and dry.
The heart of the LN-25™ PRO EXTREME is the 2
roll MAXTRAC™ drive. The patented features on the
wire drive offer tool-less changing of the drive rolls
and wire guides for quick spool changes. A tachometer controlled motor powers the patent pending drive
rolls for smooth, steady feeding without slippage.
The LN-25™ PRO EXTREME is designed to be simple, reliable and easy to service. The Control P.C.
board is mounted with Lincoln’s leading environmental
design protection by mounting the board in a plastic
tray and potting it with epoxy.
RECOMMENDED PROCESSES
• GMAW
• FCAW
PROCESS LIMITATIONS
• GMAW-P procedures must be qualified by the customer.
• Across-the-Arc models are not recommended for
stitch or spot welding.
EQUIPMENT LIMITATIONS
• The duty cycle of the wire feeder is 325A, 100% and
450A, 60%. Duty cycle is based upon the amount of
welding performed in a 10 minute period.
• The maximum spool size is 45 lb, 12" diameter.
• Maximum FCAW gun length is 15 ft.
• Maximum GMAW gun length is 25 ft.
• Push-pull guns do not work with the LN-25™ PRO
EXTREME.
RECOMMENDED POWER SOURCES
• CV-305
• CV-400
• CV-655
• DC-400
• DC-600
• DC-655
• Invertec® V-350 PRO
• Invertec® V-450 PRO
• Multi-Weld® 350
• Ranger® 10,000
• Ranger
• Ranger® GXT
• Ranger® 250
• Ranger® 305
• SAE-400
• Pipeliner® 200G
• Classic® 300
• Vantage® 300
• Vantage® 400
• Vantage® 500
® 3 Phase
With a 450 amp, 60% duty cycle rating, this feeder is
ready for heavy duty welding.
General Functional Description
The LN-25™ PRO EXTREME as designed is a simple, robust feeder. Standard features include a calibrated wire feed speed dial, CV-CC switch, Gas
Purge and Cold Feed.
RED-D-ARC LN-25™ PRO EXTREME
Page 18
B-3
OPERATION
B-3
(See Customer Assistance Policy in the front of this
Instruction Manual)
CASE FRONT CONTROLS (See Figure B.1)
FIGURE B.1
5
1
2
3
6
7
8
LN25
4
9
POWER-UP SEQUENCE
All of the LED’s will briefly illuminate during power-up.
If the gun trigger is activated during power up, the
feeder will not operate until the gun trigger is released.
1. WIRE FEED SPEED DISPLAY
Idle
The left display shows the wire feed speed. The right
display is blank. The wire feed speed LED is lit.
WFS
AVERTISSEMENT
V
Welding
The left display shows the WFS and the right display
shows the arc voltage. If the wire feeder is connected
for electrode negative welding, then the voltage display shows a minus sign. The WFS and voltage LEDs
are lit.
ITEM DESCRIPTION
1 Wire Feed Speed Display
2 Wire Feed Speed LED
3 Wire Feed Speed Knob
4 5-pin gun trigger connector
5 Thermal LED
6 Voltage Display
7 Voltage LED
8 Set-up Push Button
9 Work Clip Connection
83% FUNCTIONALITY (for Innershield®
Pipeline welding)
With a special Gun, the LN-25™ Pro incorporates
83% functionality. This feature allows for the reduction
of the wire feed speed to 83% of the original set value
when activated with a second switch (usually in the
gun). The 100% wire feed is adjusted using the wire
feed speed knob on the front of the machine, and is
displayed on the right LED. When the reduced wire
speed switch (mounted on the gun handle) is in
Position No. 1, the wire speed feed will be that figure
indicated on the display. In Position No. 2, the wire
feed speed will be 83% of the figure indicated on the
display.
WFS
AV
After Welding
The display continues to hold the value of the WFS
and arc voltage for five seconds after welding stops.
The WFS and voltage displays flash.
Set-Up Menu
To enter the set-up menu, use paper clip to press the
small button located on the case front.
VOLTAGE
AVERTISSEMENT
V
BUTTON
LN25
RED-D-ARC LN-25™ PRO EXTREME
Page 19
B-4
OPERATION
B-4
WIRE FEED SPEED UNITS
Rotate the WFS knob to
the left to use “inch-
S
es/minute” for the wire
feed speed units.
U
OO
WFS
OO
A
Rotate the WFS knob to
the right to use
r
o
E
“meters/minute” for the
U
OO
A
wire feed speed units.
OOWFS
Press the set-up button again.
WFS CALIBRATION WITH DIGITAL
METERS
3. WIRE FEED SPEED KNOB
The large, calibrated wire feed speed knob makes
for easy and accurate adjustment of the wire feed
speed. The knob rotates 3/4 turn. Turn the knob
clockwise to increase the wire feed speed, and
counter clockwise to reduce the wire feed speed.
The digital displays show the wire feed speed on
the display.
Wire Feed Speed, CV Operation
When Across the Arc models are operated with CV
power sources, the wire feed speed will remain a constant value, independent of arc voltage changes, as
along as the arc voltage does not drop below the values per the following table:
CV Operation
Maximum WFS Minimum Arc Volts
280 15 V
340 17 V
440 21 V
520 24 V
600 27 V
To calibrate the wire feed speed, before entering the
set-up menu:
Set the display to the desired wire feed speed (example: 400 inches per minute)
Measure the actual wire feed speed (example: 405
inches per minute)
While in the set-up menu, adjust the calibration factor
as follows:
Actual WFS 405
Set WFS 400
=
Calibration Factor Example=1.01
Press the set-up button to exit the set-up menu.
RED-D-ARC LN-25™ PRO EXTREME
Page 20
B-5
OPERATION
Wire Feed Speed, CC Operation
When Across the Arc models are operated with CC
power sources, the wire feed speed changes as the
arc voltage changes. When the arc voltage increases,
the wire feed speed will increase; and when the arc
voltage decreases, the wire feed speed will decrease.
To preset the wire feed speed on CC power sources:
1. Set the Wire Feed Mode switch inside the LN25™ PRO EXTREME to "CC".
2. Refer to the Figure B.1a graph for the setting for
the wire feed speed knob setting. Select the horizontal line representing the Desired Wire Feed
Speed. (See Figure B.1a arrow for 375 in/min.)
3. Select the diagonal line representing the Arc
Volts. (See Figure B.1a for 29 volts.)
4. Determine the vertical line representing the CC
Wire Feed Speed setting where the above two
lines cross. (See Figure B.1a arrow line for 450.)
Set the LN-25™ PRO EXTREME wire feed
speed knob to this value.
B-5
CC WFS dial setting = desired WFS x 35
(See Figure B.1a)
700
650
600
550
500
450
400
350
300
250
200
150
100
50
50 100 150 200 250 300 350 400 450 500 550
FIGURE B.1a
CC
Arc Volts
600
650 700
35
V
33
31
29
27
25
23
21
19
17
15
A constant voltage (CV) power
source is recommended for fluxcored arc welding (FCAW) and
gas metal arc welding (GMAW)
to obtain code quality results.
However, this wire feeder may
also be used with a constant current (CC) power source to obtain
passable results for noncritical
quality applications.
RED-D-ARC LN-25™ PRO EXTREME
Page 21
B-6
OPERATION
4. 5-PIN GUN TRIGGER CONNECTOR
(See Figure B.1 for Location)
5. THERMAL LED, MOTOR OVERLOAD
The thermal light illuminates when the
wire drive motor draws too much current.
If the thermal light illuminates, the wire
drive will automatically shutdown for up to
30 seconds to allow the motor to cool. To start
welding again, release the gun trigger, inspect the
gun cable, liner (and conduit). Clean and make
repairs as necessary. Start welding again when the
problem has been safely resolved.
For best results, keep the gun cable and conduit as
straight as possible. Perform regular maintenance
and cleaning on the gun liner, conduit and gun.
Always use quality electrode, such as L-50 or L-56
from Lincoln Electric.
6. VOLTAGE DISPLAY
(See Item 2 for Details)
7. VOLTAGE LED
}
B-6
RED-D-ARC LN-25™ PRO EXTREME
Page 22
B-7
INTERNAL CONTROLS
OPERATION
FIGURE B.2
B-7
RED-D-ARC LN-25™ PRO EXTREME
Page 23
B-8
OPERATION
CV/CC SWITCH
(See Figure B.2)
The CV/CC switch sets the wire
feed speed control method for the
wire feeder.
In the CV position, the wire feed
speed remains constant during
welding. A steady arc voltage is
regulated by the power source by
adjusting the arc current.
In the CC position, the wire feed
speed varies during welding. The
arc length is maintained by changing the wire feed speed.
COLD FEED PUSHBUTTON
(See Figure B.2)
When cold feeding, the wire
drive will feed electrode but neither the power source nor the
gas solenoid will be energized.
Adjust the speed of cold feeding by rotating the WFS knob.
Cold feeding, or "cold inching"
the electrode is useful for
threading the electrode through
the gun.
B-8
CC
CV
RED-D-ARC LN-25™ PRO EXTREME
Page 24
B-9
OPERATION
CONSTANT CURRENT WIRE WELDING
(See Figure B.3)
Most semiautomatic welding processes perform better
using constant voltage power sources.
Welding codes usually do not address the power
source selection or specifically, whether the welding
process is to be operated in the constant voltage or
constant current mode. Instead, codes typically specify limitations on the current, voltage, heat input and
preheat temperature based on the material to be
welded. The intention is to assure that proper weld
material properties will develop.
Welding is sometimes performed using constant current power sources. The operation can be more convenient because it may allow the use of an existing
stick (SMAW) power source and the power source
can be placed at a distant location without any provision for adjusting the output settings.
B-9
If the contact tip to work distance is properly maintained, a satisfactory operating voltage range may be
achieved, and a sound weld may result. However,
when a welder uses a longer contact tip to work distance, an arc-sensing wire feeder compensates by
increasing the wire feed speed to regulate the voltage.
Even if the voltage and current remain unchanged, the
increased wire feed speed may result in a deposition
rate well beyond the specified range of the electrode.
Under these conditions, the specified weld metal properties may not be achieved.
Constant voltage power sources deliver large current
surges to stabilize the arc when the electrode is shorted or the arc length is very short. However, a constant
current power source does not provide such a
response to stabilize the arc. It may be difficult to
achieve required weld metal properties, or to achieve
the required quality of welds needed to pass nondestructive tests, when such welds are made under constant current operation.
For constant current operation, the power source is
set to deliver the specified current. The power source
regulates this current regardless of changes in the
welding circuit, including cable length, electrode diameter, wire feed speed, contact tip to work distance,
etc.
Changes in the wire feed speed (WFS) or contact tip
to work distance (CTWD) affect the arc voltage when
constant current power sources are used. Lowering
the wire feed speed raises the voltage, raising the
wire feed speed lowers the voltage. Lengthening the
contact tip to work distance raises the voltage, shortening the contact tip to work distance lowers the voltage.
FIGURE B-3
Current
+
Constant Current
Power Source
For these reasons, Lincoln Electric does NOT
mend constant current semiautomatic welding for
applications which need to meet specified weld metal
chemical or mechanical property requirements or weld
quality requirements.
recom-
Wire
Feede r
CTWD
WFS
-
Current
RED-D-ARC LN-25™ PRO EXTREME
Page 25
B-10
REAR CONTROLS:
OPERATION
B-10
GAS PURGE PUSHBUTTON
The gas solenoid valve will energize but neither the
power source output nor the drive motor will be turned
on. The Gas Purge switch is useful for setting the
proper flow rate of shielding gas. Flow meters should
always be adjusted while the shielding gas is flowing.
RED-D-ARC LN-25™ PRO EXTREME
Page 26
C-1
FACTORY INSTALLED EQUIPMENT
• K1500-2 Gun Receiver Bushing.
DRIVE ROLL KITS
ACCESSORIES
C-1
WIRE TYPE
Steel Wires:
Cored Wires:
Aluminum Wires:
ELECTRODE SIZE
.023-.030 (0.6-0.8mm)
.035 (0.9mm)
.045 (1.2mm)
.052 (1.4mm)
1/16 (1.6mm)
.035,.045 (0.9, 1.2mm)
.040 (1.0mm)
.030-.035" (0.8-0.9mm)
.040-.045" (1.0-1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
.068-.072" (1.7-1.8mm)
5/64" (2.0mm)
3/32” (2.4mm)
.035" (0.9 mm)
.040" (1.0mm)
3/64" (1.2mm)
1/16" (1.6mm)
KP KIT
KP1696-030S
KP1696-035S
KP1696-045S
KP1696-052S
KP1696-1/16S
KP1696-1
KP1696-2
KP1697-035C
KP1697-045C
KP1697-052C
KP1697-1/16C
KP1697-068
KP1697-5/64
KP1697-3/32
KP1695-035A
KP1695-040A
KP1695-3/64A
KP1695-1/16A
Includes: 2 V groove
drive rolls and inner
wire guide.
Includes: 2 Knurled
drive rolls and inner
wire guide.
Includes: 2 polished
U groove drive rolls,
outer wire guide and
inner wire guide.
K2330-2
K1803-1
K1840-xx
K1842-xx
Timer Kit
Work and Feeder Cables Package
Weld Power Cable, Twist-Mate to
Lug
Weld Power Cable, Lug to Lug
Includes: Panel and harness
for adjusting preflow, burnback
and postflow times
Includes: Twist-Mate to Lug
2/0 cable 14' (1.2m) long with
Ground Clamp, and Twist-
Mate to Lug 2/0 Cable 9'
(2.7m) long.
Includes: Twist-Mate to Lug,
1/0 cable of length "xx".
IIncludes: Lug to Lug, 3/0
Cable of length "xx" for lengths
up to 60' (18.3m). Lug to Lug,
4/0 Cable of length "xx" for
lengths greater than 60'
(18.3m).
RED-D-ARC LN-25™ PRO EXTREME
Page 27
C-2
K484
Jumper Plug Kit
ACCESSORIES
Includes: 14 pin circular
connector with jumper for
leads 2-4. For use in power
sources for turning the weld
terminals “ON” at all times.
C-2
K910-1
K910-2
K1500-1
K1500-2
Ground Clamp
Ground Clamp
Gun Receiver Bushing (for guns
with K466-1 Lincoln gun connec-
guns)
®
and Subarc
®
tors; Innershield
Gun Receiver Bushing (for guns
with K466-2, K466-10 Lincoln gun
connectors; Magnum
200/300/400 guns and compatible
with Tweco® #2-#4)
Includes: One 300 Amp
Ground Clamp.
Includes: One 500 Amp
Ground Clamp.
Includes: Gun receiver bush-
ing, set screw and hex key
wrench.
Includes: Gun receiver bush-
ing with hose nipple, set screw
and hex key wrench.
Gun Receiver Bushing (for guns
K1500-3
with K613-7 Lincoln gun connec-
tors; Magnum
patible with Tweco® #5)
®
Includes: Gun receiver bush-
550 guns and com-
RED-D-ARC LN-25™ PRO EXTREME
ing with hose nipple, set screw
and hex key wrench.
Page 28
C-3
ACCESSORIES
C-3
K1500-4
K1500-5
K489-7
K435
Gun Receiver Bushing (for gun
with K466-3 Lincoln gun connec-
tors; compatible with Miller® guns.)
Gun Receiver Bushing (compatible
with Oxo® guns.)
Gun Receiver Bushing (for Lincoln
Fast-Mate guns.)
Spindle Adapter, for mounting 14
lb. (6.4 kg) Innershield
in (51 mm) spindles.
®
Coils on 2
Includes: Gun receiver bush-
ing with hose nipple, set screw
and hex key wrench.
Includes: Gun receiver bushing
with hose nipple, 4 guide tubes,
set screw and hex key wrench.
Includes: Gun receiver bushing
with trigger connector.
Includes: Spindle Adapter made
from 2 coil retainers. (Electrode
not included.)
K468
K586-1
K590-6
K283
Spindle Adapter, for mounting 8in
(203mm) diameter spools on 2 in
(51 mm) spindles.
Deluxe Adjustable Gas Regulator
Water Connection Kit (for
European and Control cable
models only)
Wire Feed Speed Meter
Includes: 2 Spindle Adapters,
one for 2" wide spools and the
other for 3" wide spools.
Includes: Deluxe Gas Regulator
for Mixed Gases, Adapter for
CO2 and 1
IIncludes: 2 hoses with female
quick connectors at each end, 2
male connectors for 3/16” ID
hose, 2 male connectors for ¼”
ID hose, and mounting hard-
Includes: A wire feed speed
meter with digital display.
0' (3.0m) Hose.
ware.
RED-D-ARC LN-25™ PRO EXTREME
Page 29
D-1
SAFETY PRECAUTIONS
MAINTENANCE
4. Turn power ON.
D-1
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.
----------------------------------------------------------------------
ROUTINE MAINTENANCE
• Check weld cables, control cables and gas hoses
for cuts.
• Clean and tighten all weld terminals.
PERIODIC MAINTENANCE
• Clean drive rolls and inner wire guide and replace if
worn.
• Blow out or vacuum the inside of the feeder.
5. Energize the output circuit of the power source.
Adjust the power source output to 20±1 VDC as
measured on the reference meter.
6. Verify that LN-25™ PRO EXTREME voltmeter
reads between 19 and 21 volts.
If the voltmeter reading is out of range, check for
loose connections or replace the voltmeter. There is
no calibration adjustment for the LN-25™ PRO
EXTREME voltmeter.
CALIBRATION SPECIFICATION
The voltmeter and flow meter are not calibrated and
are for reference purposes only.
Voltmeter Validation, Across the Arc Meter Models
Tools required:
• DC voltmeter reference standard
• Constant voltage DC welding power source with
adjustable no-load voltage (DC-400, V-350, CV-400
or equivalent).
To verify the voltmeter accuracy:
1. Turn power OFF.
2. Connect the LN-25™ PRO EXTREME to the constant voltage DC welding power source. The work
lead of the LN-25™ PRO EXTREME must be
connected to the work terminal of the power
source.
3. Connect the reference voltmeter between the
brass block of the LN-25™ PRO EXTREME and
the work lead.
RED-D-ARC LN-25™ PRO EXTREME
Page 30
D-2
MAINTENANCE
D-2
Wire Feed Speed Validation
(See Figure D.1)
Calibration of the LN-25™ PRO EXTREME may be
required when the p.c. board, wire feed speed potentiometer or motor is replaced or serviced. Calibration
matches the scale on the name plate to the actual wire
feed speed.
Tools required:
• RPM meter
• Constant voltage DC welding power source (DC-400,
V-350, CV-400 or equivalent)
• 7/16" open end wrench
To verify if calibration is necessary:
1. Turn power OFF.
2. Set the wire feed speed per the table.
Model gearing Wire Feed Speed Acceptable Range
Normal Speed 400 in/min 69 - 77 rpm
3. Remove the plastic cover from the lower portion of the
wire drive with a 7/16" wrench.
4. Connect the LN-25™ PRO EXTREME to the constant voltage DC welding power source. The work
lead of the LN-25™ PRO EXTREME must be connected to the work terminal of the power source.
5. Turn power ON.
6. Measure the motor rpm when the COLD FEED button
is pressed.
To change the wire feed speed calibration:
(See Figure D.2)
Tools required:
• 5/16" nut driver
• RPM meter
• Shorting plug. The shorting plug shorts pins 1 & 5 of
connector J2 on the p.c. board. J2 is a 6 pin molex
connector.
1. Turn power OFF.
2. Remove the 4 screws holding the rear cover inside
the feeder and remove the cover.
3. Open the idle arm.
4. Set the wire feed speed per the table.
Model gearing Wire Feed Speed
Normal Speed 400 in/min
5. Connect the LN-25™ PRO EXTREME to the con-
stant voltage DC welding power source. The work
lead of the LN-25™ PRO EXTREME must be connected to the work terminal of the power source.
6. Turn power ON.
7. Insert the shorting plug into connector J2 on the p.c.
board. The shorting plug shorts pins 1 & 5.
8. Remove the shorting plug.
9. Turn power OFF.
7. Verify the rpm is within the acceptable range.
FIGURE D.1
MOTOR
SHAFT
COVER
RED-D-ARC LN-25™ PRO EXTREME
10. Replace the cover and secure with the screws.
FIGURE D.2
COVER
P.C. BOARD
Page 31
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will
invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all
safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
E-1
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the welding power source before installation or changing
drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and drive mechanism are "hot" to work
and ground and could remain energized several seconds after the gun trigger is
released.
• Welding power source must be connected to system ground per the National Electrical
Code or any applicable local codes.
• Only qualified personnel should perform maintenance work.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Authorized Field Service Facility.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
RED-D-ARC LN-25™ PRO EXTREME
Page 32
E-2
PROBLEMS
(SYMPTOMS)
Fault Code
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE
CAUSE
Digital Display Models Error Codes
Description
RECOMMENDED
COURSE OF ACTION
Possible Adjustments
E-2
Err 81 Motor overload, long term.
Err 82 Motor overload, short term.
1. The wire drive motor has overheated.
1. The wire drive motor current draw
has exceeded limits, usually
because the motor is in a locked
rotor state.
1. Check that the electrode slides
easily through the gun and cable.
2. Remove tight bends from the gun
and cable.
3. Check that the spindle brake is
not too tight.
4. Verify a high quality electrode is
being used.
5. Wait for the error to reset and the
motor to cool (approximately 1
minute).
1. Check that motor can turn freely
when idle arm is open.
2. Verify that the gears are free of
debris and dirt.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
RED-D-ARC LN-25™ PRO EXTREME
Page 33
E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
The feeder does power up - no display, no cold feed.
TROUBLESHOOTING
POSSIBLE
CAUSE
Output Problems
1. The work sense lead is disconnected or is a poor electrical connection. (Across the arc models)
2. The power source is OFF.
3. The circuit breaker for the wire
feeder on power source have
tripped. (control cable models)
4. The control cable may be loose or
damaged. (control cable models)
E-3
RECOMMENDED
COURSE OF ACTION
1. Connect the work sense lead to
the work in a location free of dirt,
rust and paint.
2. Turn ON the power source.
3. Reset the circuit breakers.
4. Tighten, repair or replace the control cable.
No shielding gas.
Inconsistent wire feeding or wire not
feeding but drive rolls turning.
1. The gas supply is OFF or empty.
2. The gas hose is cut or crushed
3. The flow meter valve is closed.
4. Dirt or debris is in the solenoid.
5. There is a loose solenoid connection.
6. The solenoid has failed.
1. The gun cable is kinked and/or
twisted
2. The wire is jammed in the gun and
cable.
3. The gun liner is dirty or worn.
4. The electrode is rusty or dirty.
5. The contact tip is partially melted
or has spatter.
6. Improper gun liner, tip, drive rolls
and/or inner wire guide.
7. Incorrect tension arm pressure on
the drive rolls.
8. The spindle brake is too tight.
9. Worn drive roll
1. Verify the gas supply is ON and
flowing.
2. Route the gas hose so it avoids
sharp corners and make sure
nothing is on top of it. Repair or
replace damaged hoses.
3. Open the flow meter valve.
4. Apply filtered shop at 80psi to the
solenoid to remove dirt.
5. Remove the cover and check that
all connections are in good condition.
1. Keep the gun cable as straight as
possible. Avoid sharp corners or
bends in the cable.
2. Remove the gun from the wire
feeder and pull the jammed wire
out of the gun and cable.
3. Blow dirt out of the liner with low
pressure (40psi or less). Replace
the liner if worn.
4. Use only clean electrode. Use
quality electrode, like L-50 or L-56
from Lincoln Electric.
5. Replace the contact tip.
6. Verify the proper parts are
installed.
7. Adjust the tension arm per the
Instruction Manual. Most electrodes feed well at a tension arm
setting of "3".
8. Verify the spool of wire moves
with minimal effort.
9. Replace the drive rolls if worn or
filled with dirt.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
RED-D-ARC LN-25™ PRO EXTREME
Page 34
E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
Wire feed speed consistently operates at the wrong value. The speed
changes when the wire feed speed
knob is adjusted.
TROUBLESHOOTING
POSSIBLE
CAUSE
Output Problems
1. The jumper lead for normal
speed/extra torque is connected
improperly.
2. The wrong gear is installed in the
wire drive.
3. The brushes on the motor are
worn.
E-4
RECOMMENDED
COURSE OF ACTION
1. Properly connect the normal
speed/extra torque jumper.
2. Install the proper pinion gear in
the wire drive.
3. Replace the motor/gearbox
assembly.
The wire feed speed is fast (maximum) and there is no change when
the wire feed speed knob is adjusted.
Variable or "hunting" arc.
(Digital display models)
When the trigger is pulled, the wire
feeds slowly.
(Digital display models)
The preset voltage does not match
the power source voltage.
1. The tachometer is connected
improperly.
2. The tachometer has failed.
1. Wrong size, worn and/or melted
contact tip.
2. Worn work cable or poor work
connection.
3. Wrong polarity.
4. The gas nozzle is extended
beyond the contact tip or the wire
stickout is too long.
5. Poor gas shielding on processes
requiring gas.
1. The Run-In switch is "ON"
1. The preset voltage calibration in
the feeder has been selected for a
different power source.
1. Verify all of the tachometer leads
are properly connected.
2. Replace the motor and tachometer assembly.
1. Replace the contact tip.
2. Verify all work and electrode connections are tight and that the
cables are in good condition.
Clean/replace as necessary.
3. Adjust polarity to the recommended procedure.
4. Adjust the gas nozzle and shorten
the stickout to 3/8 to 1/2 inches.
5. Check gas flow and mixture.
Remove or block sources of
drafts.
1. Place the Run-In switch to the
"OFF" position.
1. Use the set-up menu to change
the preset voltage calibration in
the feeder to match the power
source.
Poor arc starts with sticking or
"blast-offs", weld porosity, narrow
and ropy looking bead.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
1. Improper procedures or techniques.
1. See "Gas Metal Arc Welding
CAUTION
RED-D-ARC LN-25™ PRO EXTREME
Guide" (GS-100)
Page 35
F-1
DIAGRAMS
F-1
RED-D-ARC LN-25™ PRO EXTREME
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
Page 36
F-2
DIMENSION PRINT
23.17
F-2
14.81
8.65
12" x 18" ELLIPSE
16" CIRCLE
17.19
RED-D-ARC LN-25™ PRO EXTREME
Page 37
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 38
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Não toque as partes elétricas nuas.
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Page 39
• 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
Loading...