Red-D-Arc LN-25x Operator's Manual
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Red-D-Arc LN-25x Operator's Manual

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RED-D-ARC
LN-25x
For use with machines having Code Numbers:
OPERATOR'S MANUAL
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.
North America's Largest Fleet of Welding Equipment
12504
IM10297
Dec, 2015
(

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Summary of Contents for Red-D-Arc LN-25x

  • Page 1 For use with machines having Code Numbers: OPERATOR’S MANUAL 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.
  • Page 2 LN-25X™ SAFETY THANK YOU FOR SELECTING A QUALITY PRODUCT BY KeeP your head out oF the Fumes. DON’T get too close to the arc. Use corrective lenses if necessary LINCOLN ELEC TRIC. to stay a reasonable distance away from the arc.

  • Page 3: Section A: Warnings

    LN-25X™ SAFETY SECTION A: 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from WARNINGS V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
  • Page 4 LN-25X™ SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 LN-25X™ SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If...
  • Page 6 TABLE OF CONTENTS LN-25X™...

  • Page 7: General Description

    LN-25X™ general desCriPtion equiPment limitations The LN-25x™ is a rugged, portable, across-the-arc wire feeder • The duty cycle of the wire feeder is 325A, 100% and 450A, equipped with CrossLinc™ technology. When used with a 60%. Duty cycle is based upon the amount of welding CrossLinc™...

  • Page 8: Technical Specifications

    LN-25X™ INSTALLATION TECHNICAL SPECIFICATIONS - MODEL SUMMARY Drive Roll Kit Gun Bushing Shipped Description Meters Gun Bushing Installed Included Loose K4326-1 LN-25X™ DIGITAL ---- K1500-2 K1500-1 INPUT - SINGLE PHASE Input Amperes @ Rated Input Voltage +/- 10% Output 15 - 110V DC...

  • Page 9: Installation

    Do not operate the wire feeder on an angled surface of more than 15 degrees. Do not submerge the LN-25x™. The LN-25x™ is rated IP23 and is suitable for outdoor use. The handle of the LN-25x™ is intended for moving the wire feeder about the work place only.

  • Page 10: Local/Remote Switch

    LN-25X™ INSTALLATION aCross the arC set-uP with CrosslinC™ (reCommended) Item K# Description K4267-1 LN-25x™ KP1695-xx Drive Roll Kit Place the power source Remote/Local switch in the Remote KP1696-xx position. KP1697-xx See Magnum PRO Welding Gun Literature CV power source K1841-xx...
  • Page 11 LN-25X™ INSTALLATION CV Power Sources with Stud Connectors and no Remote/Local Switch Item K# Description K4267-1 LN-25x™ KP1695-xx Drive Roll Kit KP1696-xx KP1697-xx See Magnum PRO Welding Gun Literature CV power source K1803-1 Welding Cables K484 Jumper Plug Kit* *Not Shown...

  • Page 12: Recommended Electrode And Work Cable Sizes For Arc Welding

    LN-25X™ INSTALLATION reCommended eleCtrode and worK Cable sizes For arC welding (See Table A.1) Tabulated 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.

  • Page 13: Coaxial Weld Cable

    LN-25X™ INSTALLATION Coaxial weld Cable A coaxial weld cable is constructed with multiple small leads (See Table A.2) wrapped around one large lead. The large inner lead connects to Coaxial welding cables are specially designed welding cables for the electrode stud on the power source and the electrode pulse welding or STT™...

  • Page 14: Trigger Connector

    LN-25X™ INSTALLATION trigger ConneCtor There is one circular connector for the gun trigger on the front of the LN-25x™ Picture Function Wiring 15 VOLT SUPPLY NOT USED 5 PIN TRIGGER CONNECTOR FOR TRIGGER PUSH-ONLY GUNS. 83% WFS SWITCH 15 VOLT SUPPLY WARNING ELECTRIC SHOCK CAN KILL.

  • Page 15: Tools Required

    LN-25X™ INSTALLATION Changing the gun adaPter 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"...

  • Page 16: Pressure Arm Adjustment

    LN-25X™ INSTALLATION ProCedure to install driVe rolls and Pressure arm adJustment wire guides WARNING WARNING ELECTRIC SHOCK CAN KILL. ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the welding • Turn the input power OFF at the welding power source power source before installation or before installation or changing drive rolls and/or guides.

  • Page 17: Gun Connection

    Shut off shielding gas supply when not in use. • See American National Standard The LN-25x™ comes with a K1500-2 gun adapter installed. To Z-49.1, "Safety in Welding and install a gun, Cutting” Published by the American Welding Society. 1. Turn power OFF.

  • Page 18: Operation

    Observe additional Safety Guidelines detailed SAFETY PRECAUTIONS in the beginning of this manual. The serviceability of a product or structure utilizing the LN-25x™ wirefeeder is and must be the sole responsibility of the WARNING builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the LN- ELECTRIC SHOCK can kill.

  • Page 19: Case Front Controls

    LN-25X™ OPERATION Case Front Controls Wire Feed Speed Digital Display The LN-25x™ has a digital display that shows the wire feed speed. This display is also capable of displaying amperage and the setup menu. Wire Feed Speed Knob Use the Wire Feed Speed Knob to set the rate of wire feed speed.
  • Page 20 LN-25X™ OPERATION CrossLinc™ LED The CrossLinc™ LED displays whether the feeder is connected to the power source. When the feeder has successfully connected to the power source, the LED will illuminate. Wire Feed Speed LED and Amperage LED The Wire Feed Speed and Amperage LEDs will communicate what is being displayed on the Wire Feed Speed Digital Display.

  • Page 21: Digital Meter Operation

    LN-25X™ OPERATION digital meter oPeration Power-up Welding The value in the left display will be either amps or actual wire feed All of the LED’s will briefly illuminate during power-up speed, depending upon the selection chosen in the set-up menu.
  • Page 22 LN-25X™ OPERATION set-uP menu Run-in To enter the set-up menu, use paper clip to press the small button “Run-in” refers to the wire feed speed during the time from when located below the Voltage Display on the case front. the trigger is pulled to when an arc is struck.
  • Page 23 LN-25X™ OPERATION WFS Calibration Left Display Selection To calibrate the wire feed speed, before entering the set-up The left display can show either amperage or actual WFS during menu: welding. Note that actual WFS is not the same as preset WFS. For example, the preset WFS may be set to 400 ipm, but the arc •...

  • Page 24: Hold Display

    OPERATION Arc Hours Hold Display The LN-25x™ can keep track of the number of hours in which the The LN-25x™ will display the actual wire feed speed or amperage unit has been welding. and voltage after welding has stopped. The hold display option will hold these values for either 10 seconds or 300 seconds.

  • Page 25: Internal Controls

    LN-25X™ OPERATION internal Controls Item Description 2 Step/Trigger Interlock Switch (not present on K2613-3 and K2613-4) Pressure Adjustment Knob Optional Timer Kit Spool Retainer Spindle Brake Gun Bushing Thumb Screw Socket Head Cap Screw for Gun Bushing Drive Hubs 10 Inlet Wire Guide...
  • Page 26 LN-25X™ OPERATION Internal Controls Description Preflow, Burnback and Postflow Timer Kit 2 Step - Trigger Interlock Switch The Preflow, Burnback and Postflow Timer Kit gives control over the shielding gas at the beginning and end of the weld and The 2 Step - Trigger Interlock switch prepares the end of the wire for the next arc start.

  • Page 27: Rear Controls

    LN-25X™ OPERATION rear Controls 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.
  • Page 28 LN-25X™ ACCESSORIES OPTIONS/ACCESSORIES The following options/accessories are available for your LN-25x™ from your local Lincoln Electric Distributor. DRIVE ROLL KITS, 2 ROLL DRIVE Steel Wire Drive Roll Kits KP1696-030S .023-.030 (0.6-0.8MM) KP1696-035S .035 (0.9MM) KP1696-045S .045 (1.2MM) INCLUDES: KP1696-052S .052 (1.4MM) 2 V GROOVE DRIVE ROLLS AND INNER WIRE GUIDE.

  • Page 29: Optional Kits & Accessories

    LN-25X™ ACCESSORIES Optional Kits & Accessories K910-1 & K910-2 Work Clamp Jaws open full 2-1/2 inches (63 K2330-2 mm). Welding cable lug bolts Preflow, Postflow and directly to the work clamp. 60% Burnback Timer Kit duty cycle. Select K910-1 for Provides adjustable delay of 300 Amp applications.
  • Page 30 LN-25X™ ACCESSORIES K489-7 Gun Receiver Bushing for Lincoln Fast-Mate guns.) Includes: Gun receiver bushing with trigger connector. K435 Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2 in (51 mm) spindles. Includes: Spindle Adapter made from 2 coil retainers.

  • Page 31: Routine Maintenance

    5. Connect the shielding gas hose to flow meter reference standard. 6. Orient the LN-25x™ in a vertical position. 7. Turn power ON. 8. Adjust the flow meter on the LN-25x™ to 40 scfh while pressing routine maintenanCe the GAS PURGE button.

  • Page 32: Troubleshooting

    LN-25X™ TROUBLE SHOOTING TROUBLESHOOTING HOW TO USE TROUBLESHOOTING WARNING Service and Repair should only be performed by Lincoln Electric 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.
  • Page 33 LN-25X™ TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEM POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Err 81 Motor overload, long The wire drive motor has 1. Check that the electrode slides easily through the gun and cable. term overheated.
  • Page 34 LN-25X™ TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION PROBLEM Inconsistent wire feeding or 6. Improper gun liner, tip, drive 6. Verify the proper parts are installed. wire not feeding but drive rolls and/or inner wire guide.
  • Page 35 LN-25X™ DIAGRAMS...
  • Page 36 LN-25X™ DIAGRAMS...
  • Page 37 Red-D-Arc LN-25X - 12504...
  • Page 38 Index of Sub Assemblies - 12504 PART NUMBER DESCRIPTION P-979-A Index of Sub Assemblies P-979-B.2 Miscellaneous Items P-979-C Front Panel Assembly P-979-D Control Box Assembly P-979-E Spindle & Mast Assembly P-979-F Wire Drive Assembly P-979-G Case Assembly Red-D-Arc LN-25X - 12504...
  • Page 39 Index of Sub Assemblies - 12504 P-979-A.jpg Red-D-Arc LN-25X - 12504...
  • Page 40 Miscellaneous Items PART NUMBER DESCRIPTION 9SG8565 WIRING DIAGRAM Red-D-Arc LN-25X - 12504...
  • Page 41 Miscellaneous Items No Image Red-D-Arc LN-25X - 12504...
  • Page 42 9ST13637-5 DIODE-BRIDGE35A800VF-W1-PH 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SS18581-2 BOOT 9SM25728 RECESSED BRACKET 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9ST14530-2 RECEPTACLE 9SS24287 STRAIN RELIEF CLAMP 9ST10082-29 SEMS SCREW 9SS17211-7 GROUND LEAD ASBLY 9SS18250-1100 PLUG & LEAD ASBLY 9SS9225-4 THREAD FORMING SCREW (ROLLING) Red-D-Arc LN-25X - 12504...
  • Page 43 Front Panel Assembly P-979-C.jpg Red-D-Arc LN-25X - 12504...
  • Page 44 9SM21005 BUS BAR ASBLY 9ST9860-4 LOCKWASHER 9ST15088 INSULATED FASTENER 9SS9262-98 PLAIN WASHER 9SS9225-99 SELF TAPPING SCREW 9SM21463-2 WELD CABLE 9SS31643-3 NYLON LOCKNUT 1" NPT 9SG8524 HARNESS 9SS26807 PUSH BUTTON SWITCH 9ST10642-262 FLEX TUBE 9ST13777-8 HOSE CLAMP Red-D-Arc LN-25X - 12504...
  • Page 45 DECAL FLOWMETER 9SS27028 FAN ASBLY 9SS8025-15 SELF TAPPING SCREW 9SM22570-1 DECAL MAST 9SS18504-6 CURRENT TRANSDUCER 9ST7028-181 INSULATING TUBE 9SCF000122 #10-24X1.50RHS 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SS28863 FILTER 9SM21011-2 CONTROL BOX COVER 9SS9225-99 SELF TAPPING SCREW 9ST12250-5 HOLE PLUG Red-D-Arc LN-25X - 12504...
  • Page 46 Control Box Assembly P-979-D.jpg Red-D-Arc LN-25X - 12504...
  • Page 47 SPINDLE MAST 9SM20990-1 SPINDLE SHAFTMACHINING 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9ST9860-6 LOCKWASHER 9SS9262-23 PLAIN WASHER 9ST12380-1 BUSHING 9SL10560-2 SPINDLE 9SS17435-3 FRICTION WASHER 9ST12965-2 KEYED WASHER 9ST11862-14 SPRING 9ST14813-A THUMB SCREW 9SS23811 RETAINING COLLAR ASBLY 9SS9262-192 PLAIN WASHER Red-D-Arc LN-25X - 12504...
  • Page 48 Spindle & Mast Assembly P-979-E.jpg Red-D-Arc LN-25X - 12504...
  • Page 49 9SM19870 DRIVE GEAR 9SS25414 COLLAR 9ST4291-A LOCKWASHER 9ST14731-47 METRIC PAN HD (PHILLIPS)M4 X 0.7 9SM19999 FEEDPLATE COVER 9SS9225-102 SELF TAPPING SCREW 9SS25638-1 DRIVE HUB ASBLY 9SS25403 DRIVE HUB RETAINER KP2071-3 WIRE GUIDE ASBLY OUTER 2 ROLL Red-D-Arc LN-25X - 12504...
  • Page 50 9SCF000021 1/2-13X1.00HHCS 9SE106A-15 LOCKWASHER 9SS9262-80 PLAIN WASHER 9SM22571-6 DECAL 9SM22571-4 DECAL 9SM22571-2 DECAL 9ST10800-38 SWITCH-TOGGLE 9SS26310 DECAL 9SS22905-2 GUN ADAPTER ASBLY 9ST13858 SCREW & HANDLE ASBLY 9SL13057 PLUG AND LEAD ASBLY 9SS25890-1 DECAL 9ST13086-130 CONFORMITY DECAL Red-D-Arc LN-25X - 12504...
  • Page 51 Wire Drive Assembly P-979-F.jpg Red-D-Arc LN-25X - 12504...
  • Page 52 9SS11893-8 DOOR LOGO DECAL 9ST13086-201 DECAL-CROSSED-OUT WHEELED BIN 9ST10397-6 PLUG BUTTON 9ST10397-19 PLUG BUTTON 9SS26924 GASKET 9ST15088-2 INSULATED FASTENER 9SS9225-102 SELF TAPPING SCREW 9SS18170 HANDLE ASBLY 9SS9262-98 PLAIN WASHER 9SS9262-113 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000013 1/4-20X.625HHCS Red-D-Arc LN-25X - 12504...
  • Page 53 Case Assembly P-979-G.jpg Red-D-Arc LN-25X - 12504...
  • Page 54 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish AVISO DE No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 55 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- AVISO DE Desconectar el cable de ali- No operar con panel abierto o...
  • Page 56 Customer assistanCe PoliCy The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products.

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