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Lincoln Electric PRO DUAL POWER LN-25 Operator's Manual

Lincoln electric welder user manual
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IM991-B
™
LN-25 PRO DUAL POWER
September, 2010
For use with machines having Code Number: 11534, 11617, 11720, 11726
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
IEC 60974-5
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• 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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Summary of Contents for Lincoln Electric PRO DUAL POWER LN-25

  • Page 1 RETURN TO MAIN MENU IM991-B ™ LN-25 PRO DUAL POWER September, 2010 For use with machines having Code Number: 11534, 11617, 11720, 11726 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 ...

  • 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 SAFETY...
  • Page 4 SAFETY...
  • Page 5 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 8 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 9: Table Of Contents

    TABLE OF CONTENTS –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation...Section A Technical Specifications ...A-1 Safety Precautions ...A-2 Location ...A-2 High Frequency Protection ...A-2 Weld cable Sizes ...A-2 Analog Control Cable ...A-3 Cable Connections and Control Cable Connector ...A-4 Shielding Gas Connection ...A-4 Wire Drive Configuration ...A-5 Changing The Gun Receiver Bushing ...A-5 Procedure to Install Drive Rolls and Wire Guides ...A-5 Pressure Arm Adjustment ...A-6...

  • Page 10: Installation

    TECHNICAL SPECIFICATIONS – LN-25™ PRO DUAL POWER (K2614-1 & -3) 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 GEARING WFS RANGE Standard Speed 50 –...

  • Page 11: Safety Precautions

    Table A.1 located below are copper cable sizes rec- ommended 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.

  • Page 12: Analog Control Cable

    ANALOG CONTROL CABLE K1797-xx he control cable connecting the wire feeder to the power source is specially made for the welding envi- ronment. The wire feeder power requires overcurrent protec- tion. Connect the wire feeder only to power sources where the overcurrent protection is no more than 15 amps.

  • Page 13: Shielding Gas Connection

    • Keep cylinder away from areas where it may be Not used damaged. Not used • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live electrical circuits.

  • Page 14: Wire Drive Configuration

    WIRE DRIVE CONFIGURATION (See Figure A.2) CHANGING BUSHING WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before instal- lation or changing drive rolls and/or guides. • Do not touch electrically live parts. •...

  • Page 15: Pressure Arm Adjustment

    PRESSURE ARM ADJUSTMENT WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- ing 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 Eagle 10,000 Plus Pipeliner 200D Without Wire Feed module SAE’s Without CV Adapter SAE 400 with CV adapter Engine Driven welder with Wire Feed Module If the power source has a Remote/Local switch, place the switch in the Local position.
  • Page 17 Eagle 10,000 Plus Pipeliner 200D Without Wire Feed module SAE’s Without CV Adapter SAE 400 with CV adapter Engine Driven welder with Wire Feed Module Place CV/CC switch in the feeder in the "CV" position. CV Power Source with Twist-Mate Connectors and Remote/Local Switch.
  • Page 18 CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) CV-250 CV-300 W o r k V - 4 5 0 V - 3 5 0 D C - 6 5 5 C V - 4 0 0 D C - 4 0 0 C V - 6 5 5 •...

  • Page 19: Operation

    SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. WARNING • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri- cally energized and could remain energized several sec- onds after the welding ceases..

  • Page 20: Definition Of Welding Terms

    DEFINITION OF WELDING TERMS • Wire Feed Speed • Constant Current • 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 DUAL POWER is specially engineered to be the most rugged portable wire feeder available.
  • Page 21 Wire Feed Speed, CV Operation When Across the Arc models are operated with CV power sources, the wire feed speed will remain a con- stant value, independent of arc voltage changes, as along as the arc voltage does not drop below the val- ues per the following table.

  • Page 22: Case Front Controls

    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. 8. VOLTAGE DISPLAY (See displays in Item 1 for Voltage functions) 9. VOLTAGE LED (See displays in Item 1 for LED functions.)
  • Page 23 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/AMPERAGE DISPLAY Idle The left display shows the wire feed speed. The right display is blank.

  • Page 24: Wfs Calibration With Digital Meters

    WFS CALIBRATION WITH DIGITAL METERS (K2613-4, K2614-1, -2 & -3 ) To calibrate the wire feed speed, before entering the set-up menu: Set the display to the desired wire feed speed (exam- ple: 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:...

  • Page 25: Internal Controls

    INTERNAL CONTROLS ITEM 2 Step Trigger Interlock Switch CV / CC Switch Pressure Adjustment Arm Optional Timer Kit (See Accessories Section) Spool Retainer Spindle Brake Gun Bushing Thumb Screw for securing the welding Gun Socket Head Cap Screw for securing the Gun Bushing Drive Hubs Inlet Wire Guide Cold Feed Pushbutton...
  • Page 26 INTERNAL CONTROLS DESCRIPTION (See Figure B.2) 2 Step - Trigger Interlock Switch The 2 Step - Trigger Interlock switch changes the function of the gun trigger. 2 Step trigger opera- tion turns welding on and off in direct response to the trigger. Trigger Interlock operation allows welding to continue when the trig- ger is released for comfort on long...

  • Page 27: Constant Current Wire Welding

    For these reasons, Lincoln Electric does NOT recom- mend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality requirements.

  • Page 28: Rear Controls

    B-10 REAR CONTROLS: ITEM Gas Purge Pushbutton Flow Meter Ball Flow Meter Valve Shielding Gas Inlet Electrode Lead Optional Water cooled gun connections Control Cable input OPERATION FIGURE B.4 DESCRIPTION LN-25™ PRO DUAL POWER B-10...
  • Page 29 B-11 1. GAS PURGE PUSHBUTTON (See Figure B.4) 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 30: Accessories

    FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS WIRE TYPE ELECTRODE SIzE Steel Wires: .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) Cored Wires: .040-.045" (1.0-1.2mm) .052" (1.4mm) 1/16"...
  • Page 31 K2330-2 Timer Kit K2596-1 Aluminum Case K2596-2 Plastic Case K1796-xx AWG 1/0 Co-Axial Power Cable K2593-xx AWG #1 Coaxial Power Cable K1803-1 Work and Feeder Cables Package K1840-xx Weld Power Cable, Twist-Mate to K1842-xx Weld Power Cable, Lug to Lug ACCESSORIES Includes: Panel and harness for adjusting preflow, burnback...
  • Page 32 Control Cable K1797-xx Adapter for Competitive Power K2335-1 Sources Jumper Plug Kit K484 42 Volt Transformer Kit K1520-1 Adapter Cable for Control Cable to K1798 Terminal Strip Power Sources ACCESSORIES Includes: 14 pin to 14 pin wire feeder to power source control cable.
  • Page 33 K910-1 Ground Clamp K910-2 Ground Clamp Gun Receiver Bushing (for guns K1500-1 with K466-1 Lincoln gun connec- tors; Innershield and Subarc guns) Gun Receiver Bushing (for guns with K466-2, K466-10 Lincoln gun K1500-2 connectors; Magnum 200/300/400 guns and compatible with Tweco® #2-#4) Gun Receiver Bushing (for guns K1500-3...
  • Page 34 Gun Receiver Bushing (for gun K1500-4 with K466-3 Lincoln gun connec- tors; compatible with Miller® guns.) K1500-5 Gun Receiver Bushing (compatible with Oxo® guns.) K489-7 Gun Receiver Bushing (for Lincoln Fast-Mate guns.) K435 Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2 in (51 mm) spindles.
  • Page 35 INSTALLATION OF THE K590-6 WATER COOLING KIT WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch before working on this equipment. • Do not touch electrically hot parts. • Only qualified personnel should install, use or service this equipment.

  • Page 36: Maintenance

    SAFETY PRECAUTIONS 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 37: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 38: Digital Display Models Error Codes

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Fault Code Err 81 Motor overload, long term. Err 82 Motor overload, short term. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 39 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The feeder does power up - no display, no cold feed. The wire feeder power up but there is no out- put when the trigger is pulled. The shielding gas is flowing and the drive rolls turn. No shielding gas.
  • Page 40 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Wire feed speed consistently oper- ates at the wrong value. The speed changes when the wire feed speed knob is adjusted. The wire feed speed is fast (maxi- mum) and there is no change when the wire feed speed knob is adjust- Variable or "hunting"...
  • Page 41 DIAGRAMS LN-25™ PRO DUAL POWER...
  • Page 42 DIMENSION PRINT LN-25™ PRO DUAL POWER...
  • Page 45 • 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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