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IM10084
October, 2010
LN- 25™ IRONWORKER
For use with machines having Code Number: 11752
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
IP23
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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 ARC RAYS can burn. ELECTRIC SHOCK can 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 and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a.Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mate
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln E
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vi vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions. If interference occurs, it may be necessary to take additional precautions such as filter
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask L
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viii viii TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ..............................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – LN-25™ IRONWORKER (K2614-9) 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 GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING WFS RANGE WIRE SIZES WFS RANGE WIRE SIZES Standard Speed 50 – 700 ipm .023 – 1/16" 50 – 700 ipm .030 - 5/64 K2614-5 (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 handle of the LN-25™ IRONWORKER is intended for moving the wire feeder about the work WARNING place only. When suspending a wire feeder, insulate the ELECTRIC SHOCK CAN KILL. hanging device from the wire feeder enclosure. • Turn the input power OFF at the disconnect switch or fuse box HIGH FREQUENCY PROTECTION before attempting to connect or disconnect input power lines, out- put cables or control cables. CAUTION • Only qualified personnel should
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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 LN-25™ IRONWORKER. 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 5 volt supply damaged. connector for B Not used • Never lift welder with cylinder attached. push-guns C Trigger • Never allow welding electrode to touch cylinder. onl
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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 LN-25™ IRONWORKER CABLE CONNECTION DIAGRAMS CV Power Sources with Stud Connectors and Remote/Local Switch (See Figure A.6) FIGURE A.6 CV-400 CV-655 DC-400 DC-600 LN-25™ IRONWORKER Electrode DC-655 (Across the Arc) V450-Pro SAE 400 with CV adapter Work clip Engine Driven welder with Wire Feed Module Work Ranger 250 GXT K# Description Place the power source Remote/Local switch in the K2614-9 LN-25™ IRONWORKER Local position. KP1695-XX KP1696-XX Drive Roll
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A-7 A-7 INSTALLATION CV Power Source with Twist-Mate Connectors and Remote/Local Switch. (See Figure A.8) FIGURE A.8 CV-305 Electrode LN-25™ IRONWORKER V350-Pro Work clip Work K# Description Place CV/CC switch in the feeder in the "CV" position. K2614-9 LN-25™ IRONWORKER KP1695-XX KP1696-XX Drive Roll Kit KP1697-XX See Magnum Literature Welding Gun CV power Source K1841 Welding Cables CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) FIGURE A.9 Jumper C
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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 450A, 60%. Duty cycle is based upon the amount of welding SMAW performed in a 10 minute period. • Shielded Meta
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B-3 B-3 OPERATION (See Customer Assistance Policy in the front of this WIRE FEED SPEED KNOB Instruction Manual) Wire Feed Speed, CV Operation When Across the Arc models are operated with CV CASE FRONT CONTROLS (See Figure B.1) power sources, the wire feed speed will remain a con- FIGURE B.1 stant value, independent of arc voltage changes, as along as the arc voltage does not drop below the val- 7 ues per the following table. 1 83% Wire Feed Speed 8 The 83% wire feed speed reduces the wire feed s
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B-4 B-4 OPERATION THERMAL LED, MOTOR OVERLOAD After Welding The display continues to hold the value of the amper- The thermal light illuminates when the wire age or WFS and arc voltage for five seconds after drive motor draws too much current. If the welding stops. The amperage or WFS and voltage thermal light illuminates, the wire drive will displays flash. automatically shutdown for up to 30 seconds to allow the motor to cool. To start welding again, release the Set-Up Menu gun trigger, ins
