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IM939-A
March, 2008
LN-25PROEXTREME
ForusewithmachineshavingCodeNumbers:
11389,11523
OPERATOR’SMANUAL
Red-D-ArcSpec-BuiltWeldingEquipment
ThisRED-D-ARC welder is built toRED-D-ARCExtremeDuty
design specifications by Lincoln Electric.
SafetyDependsonYou
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
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All ho
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque dʼincendie dû aux étincelles
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v v for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing Thank You this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about t
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vi vi TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ..................................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – LN25 PRO (K2613-3) INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 15-110 VDC 4A RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 60% rating 450 100% rating 325 GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING WFS RANGE WIRE SIZES WFS RANGE WIRE SIZES Normal Speed 50 – 700 ipm .023 – 1/16" 50 – 700 ipm .030 - 5/64 (1.3 – 17.7m/min) (0.6 – 1.6mm) (1.3 – 17.7m/min) (0.8 - 2.0mm) PHYSICAL DIMENSIONS HEIGHT WIDTH D
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS The LN25 PRO EXTREME is rated IP23 and is suitable for outdoor use. WARNING The handle of the LN25 PRO EXTREME is intended ELECTRIC SHOCK CAN KILL. for moving the wire feeder about the work place • Turn the input power OFF at the only. disconnect switch or fuse box before attempting to connect or When suspending a wire feeder, insulate the disconnect input power lines, out- hanging device from the wire feeder enclosure. put cables or control cables.
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A-3 A-3 INSTALLATION SHIELDING GAS CONNECTION CABLE CONNECTIONS WARNING There is one circular connector for the gun trigger on the front of the LN25 PRO EXTREME. CYLINDER may explode if damaged. •Keep cylinder upright and chained to support. Function Pin Wiring • Keep cylinder away from areas where it may be 5-pin trigger A Trigger damaged. connector for B Not used • Never lift welder with cylinder attached. push-guns C Common • Never allow welding electrode to touch cylinder. only. D Not
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A-4 A-4 INSTALLATION WIRE DRIVE CONFIGURATION 8. Connect the shielding gas hose to the new gun bushing, if required. (See Figure A.2) 9. Rotate the gun bushing until the thumb screw hole CHANGING THE GUN RECEIVER aligns with the thumb screw hole in the feed plate. BUSHING Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned. WARNING 10. Tighten the socket head cap screw. 11. Insert the welding gun into the gun bushing and ELECTRIC SHOCK can kill. tig
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A-5 A-5 INSTALLATION 1. Squeeze the release bar on the retaining collar and PRESSURE ARM ADJUSTMENT remove it from the spindle. WARNING 2. Place the spindle adapter on the spindle, aligning the spindle brake pin with the hole in the adapter. ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- 3. Place the spool on the spindle and align the ing power source before installation or adapter brake tab with one of the holes in the back changing drive rolls and/or guides. side of the s
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A-6 A-6 INSTALLATION POWER SOURCE TO LN25 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 K# Description If the power source has a Remote/Local switch, place the switch in the Local position. K2613-3 LN25 PRO EXTREME KP1695-XX Drive Roll Kit Place the CV/CC switch in the feeder in the "CC" posi- KP1696-XX tion. KP1697-XX See Magnum Literature Welding Gun CC power Source K1803-1 Welding Cables CV Power
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A-7 A-7 INSTALLATION CV Power Sources with Stud Connectors and no Remote/Local Switch. (See Figure A.7) FIGURE A.7 K# Description Place CV/CC switch in the feeder in the "CV" position. K2613-3 LN25 PRO EXTREME KP484 Jumper Plug Kit KP1695-XX KP1696-XX Drive Roll Kit KP1697-XX See Magnum Literature Welding Gun CC power Source K1803-1 Welding Cables CV Power Source with Twist-Mate Connectors and Remote/Local Switch. (See Figure A.8) FIGURE A.8 K# Description Place CV/CC switch in the feeder in
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A-8 A-8 INSTALLATION CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) FIGURE A.9 Place CV/CC switch in the feeder in the "CV" position. K# Description K2613-3 LN25 PRO EXTREME KP1695-XX KP1696-XX Drive Roll Kit KP1697-XX See Magnum Literature Welding Gun CV power Source K1841 Welding Cables K484 Jumper Plug kit LN-25 PRO EXTREME
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B-1 B-1 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION THIS MACHINE OR IN THIS MANUAL BEFORE OPERATING MACHINE. INPUT POWER WARNING • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ON ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri- OFF cally energized and could remain energized several sec- onds after the welding ceases.. • Do not touch electrically live part or electrode WIRE FEEDER with skin or w
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B-2 B-2 OPERATION RECOMMENDED PROCESSES DEFINITION OF WELDING TERMS • GMAW • FCAW WFS • Wire Feed Speed PROCESS LIMITATIONS CC • Constant Current • GMAW-P procedures must be qualified by the cus- tomer. CV • Across-the-Arc models are not recommended for • Constant Voltage stitch or spot welding. GMAW EQUIPMENT LIMITATIONS • Gas Metal Arc welding • The duty cycle of the wire feeder is 325A, 100% and 450A, 60%. Duty cycle is based upon the amount of SMAW welding performed in a 10 minute period.
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B-3 B-3 OPERATION (See Customer Assistance Policy in the front of this Instruction Manual) CASE FRONT CONTROLS (See Figure B.1) FIGURE B.1 1 5 6 2 3 4 ITEM DESCRIPTION 1 Analog Voltmeter 2 Wire Feed Speed Knob 3 5-pin gun trigger connector 4 Work sense lead 5 Thermal LED, MOTOR OVERLOAD 6 Polarity LED 1. ANALOG VOLTMETER The analog voltmeter shows the voltage between electrode and work. On across the arc models, the voltmeter shows open circuit voltage when the wire feeder is not welding.
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B-4 B-4 OPERATION Wire Feed Speed, CC Operation 2. WIRE FEED SPEED KNOB The large, calibrated wire feed speed knob makes When Across the Arc models are operated with CC for easy and accurate adjustment of the wire feed power sources, the wire feed speed changes as the speed. The knob rotates 3/4 turn. Turn the knob arc voltage changes. When the arc voltage increases, clockwise to increase the wire feed speed, and the wire feed speed will increase; and when the arc counter clockwise to reduce th
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B-5 B-5 OPERATION 3. 5-PIN GUN TRIGGER CONNECTOR 4. WORK SENSE LEAD 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
