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Lincoln Electric RED-D-ARC LN-25 PRO EXTREME Operator's Manual

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Download this manual See also: Service Manual, Operator's Manual
IM960-A
March, 2010
RED-D-ARC
LN-25™ PRO EXTREME
For use with machines having Code Numbers: 11391, 11718
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.
1-800-245-3660
North America's Largest Fleet of Welding Equipment

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Summary of Contents for Lincoln Electric RED-D-ARC LN-25 PRO EXTREME

  • Page 1 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 ...

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    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”...
  • Page 4 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.
  • Page 5 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 l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
  • Page 6 Thank You 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! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our cus- tomers and to exceed their expectations.

  • Page 7: Table Of Contents

    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...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – LN-25™ PRO EXTREME WITH DIGITAL METERS (K2613-4) INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 15-110 VDC RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 60% rating 100% rating GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING...

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS The LN-25™ PRO EXTREME is rated IP23 and is suitable for outdoor use. WARNING The handle of the LN-25™ PRO EXTREME is ELECTRIC SHOCK CAN KILL. intended for moving the wire feeder about the work • Turn the input power OFF at the place only.

  • Page 10: Cable Connections

    INSTALLATION SHIELDING GAS CONNECTION CABLE CONNECTIONS WARNING There is one circular connector for the gun trigger on the front of the LN-25™ PRO EXTREME . CYLINDER may explode if damaged. Function Wiring • Keep cylinder upright and chained to support. 5-pin trigger Trigger connector for...

  • Page 11: Wire Drive Configuration

    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 RECEIVER aligns with the thumb screw hole in the feed plate. BUSHING Slide the gun receiver bushing into the wire drive WARNING...

  • Page 12: Pressure Arm Adjustment

    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. •...

  • Page 13: Power Source To Ln-25™ Pro Extreme Cable Connection Diagrams

    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 ® ® ® ® ® ® ® Description If the power source has a Remote/Local switch, K2613-4 LN-25™...
  • Page 14 INSTALLATION CV Power Sources with Stud Connectors and no Remote/Local Switch. (See Figure A.7) FIGURE A.7 Description Place CV/CC switch in the feeder in the "CV" position. K2613-4 LN-25™ PRO EXTREME WITH DIGITAL METERS KP484 Jumper Plug Kit KP1695-XX KP1696-XX Drive Roll Kit KP1697-XX See Magnum...
  • Page 15 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. Description K2613-4 LN-25™ PRO EXTREME WITH DIGITAL METERS KP1695-XX KP1696-XX Drive Roll Kit KP1697-XX See Magnum Literature Welding Gun...

  • Page 16: Operation

    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 vari- ables beyond the control of The Lincoln Electric OUTPUT CURRENT Company affect the results obtained in using the LN- 25™...

  • Page 17: Definition Of Welding Terms

    OPERATION RECOMMENDED PROCESSES DEFINITION OF WELDING TERMS • GMAW • FCAW • Wire Feed Speed PROCESS LIMITATIONS • Constant Current • GMAW-P procedures must be qualified by the cus- tomer. • Constant Voltage • Across-the-Arc models are not recommended for GMAW stitch or spot welding.

  • Page 18: Case Front Controls

    OPERATION (See Customer Assistance Policy in the front of this POWER-UP SEQUENCE Instruction Manual) All of the LED’s will briefly illuminate during power-up. If the gun trigger is activated during power up, the CASE FRONT CONTROLS (See Figure B.1) feeder will not operate until the gun trigger is released. FIGURE B.1 1.
  • Page 19 OPERATION 3. WIRE FEED SPEED KNOB WIRE FEED SPEED UNITS The large, calibrated wire feed speed knob makes Rotate the WFS knob to for easy and accurate adjustment of the wire feed the left to use “inch- speed. The knob rotates 3/4 turn. Turn the knob es/minute”...
  • Page 20 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.
  • Page 21 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...

  • Page 22: Internal Controls

    OPERATION INTERNAL CONTROLS FIGURE B.2 RED-D-ARC LN-25™ PRO EXTREME...
  • Page 23 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.

  • Page 24: Constant Current Wire Welding

    For constant current operation, the power source is For these reasons, Lincoln Electric does NOT recom- set to deliver the specified current. The power source mend constant current semiautomatic welding for...

  • Page 25: Rear Controls

    B-10 B-10 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. Flow meters should always be adjusted while the shielding gas is flowing.

  • Page 26: Accessories

    ACCESSORIES FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS WIRE TYPE ELECTRODE SIZE KP KIT Steel Wires: .023-.030 (0.6-0.8mm) KP1696-030S .035 (0.9mm) KP1696-035S Includes: 2 V groove .045 (1.2mm) KP1696-045S drive rolls and inner .052 (1.4mm) KP1696-052S 1/16 (1.6mm) KP1696-1/16S wire guide.
  • Page 27 ACCESSORIES Includes: 14 pin circular connector with jumper for Jumper Plug Kit leads 2-4. For use in power K484 sources for turning the weld terminals “ON” at all times. K910-1 Ground Clamp Includes: One 300 Amp Ground Clamp. K910-2 Ground Clamp Includes: One 500 Amp Ground Clamp.
  • Page 28 ACCESSORIES Gun Receiver Bushing (for gun Includes: Gun receiver bush- K1500-4 with K466-3 Lincoln gun connec- ing with hose nipple, set screw tors; compatible with Miller® guns.) and hex key wrench. Includes: Gun receiver bushing K1500-5 Gun Receiver Bushing (compatible with hose nipple, 4 guide tubes, with Oxo®...

  • Page 29: Maintenance

    MAINTENANCE 4. Turn power ON. SAFETY PRECAUTIONS 5. Energize the output circuit of the power source. WARNING Adjust the power source output to 20±1 VDC as measured on the reference meter. ELECTRIC SHOCK can kill. • Do not operate with covers 6.
  • Page 30 MAINTENANCE To change the wire feed speed calibration: Wire Feed Speed Validation (See Figure D.2) (See Figure D.1) Tools required: Calibration of the LN-25™ PRO EXTREME may be required when the p.c. board, wire feed speed poten- • 5/16" nut driver tiometer or motor is replaced or serviced.

  • Page 31: Troubleshooting

    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.

  • Page 32: Digital Display Models Error Codes

    TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Digital Display Models Error Codes Description Possible Adjustments Fault Code Err 81 Motor overload, long term. 1. The wire drive motor has over- 1.
  • Page 33 4. The electrode is rusty or dirty. 4. Use only clean electrode. Use quality electrode, like L-50 or L-56 from Lincoln Electric. 5. The contact tip is partially melted 5. Replace the contact tip. or has spatter.
  • Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Output Problems Wire feed speed consistently oper- 1. The jumper lead for normal 1. Properly connect the normal ates at the wrong value. The speed speed/extra torque is connected speed/extra torque jumper.
  • Page 35 DIAGRAMS RED-D-ARC LN-25™ PRO EXTREME...
  • Page 36 DIMENSION PRINT RED-D-ARC LN-25™ PRO EXTREME...
  • Page 37 ● ● ● 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 ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 38 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • 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...

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