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IM939-A
March, 2008
For use with machines having Code Numbers:
RETURN TO MAIN MENU
This
welder is built to
design specifications by Lincoln Electric.
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
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Table of Contents
Related Manuals for Lincoln Electric RED-D-ARC 11389
Summary of Contents for Lincoln Electric RED-D-ARC 11389
- Page 1 RETURN TO MAIN MENU This welder is built to design specifications by Lincoln Electric. 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.
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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
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- 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 LʼArc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 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.
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Page 7: 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 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 Gun Connections...A-5... -
Page 8: Installation
TECHNICAL SPECIFICATIONS – LN25 PRO (K2613-3) INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% RATED OUTPUT @ 104°F (40°C) DUTY CYCLE 60% rating 100% rating GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GEARING WFS RANGE 50 – 700 ipm Normal Speed (1.3 –... -
Page 9: 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 10: Cable Connections
• Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live electrical circuits. -
Page 11: 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 12: 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 13: Power Source To Ln25 Pro Extreme Cable Connection Diagrams
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) If the power source has a Remote/Local switch, place the switch in the Local position. Place the CV/CC switch in the feeder in the "CC" posi- tion. - Page 14 CV Power Sources with Stud Connectors and no Remote/Local Switch. (See Figure A.7) Place CV/CC switch in the feeder in the "CV" position. CV Power Source with Twist-Mate Connectors and Remote/Local Switch. (See Figure A.8) Place CV/CC switch in the feeder in the "CV" position. INSTALLATION FIGURE A.7 K2613-3...
- Page 15 CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) Place CV/CC switch in the feeder in the "CV" position. INSTALLATION FIGURE A.9 K2613-3 KP1695-XX KP1696-XX KP1697-XX See Magnum Literature K1841 K484 LN-25 PRO EXTREME Description LN25 PRO EXTREME Drive Roll Kit Welding Gun CV power Source...
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Page 16: 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 17: 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 LN25 PRO EXTREME is specially engineered to be the most rugged portable wire feeder available. -
Page 18: Case Front Controls
(See Customer Assistance Policy in the front of this Instruction Manual) CASE FRONT CONTROLS 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. - Page 19 2. WIRE FEED SPEED KNOB The large, calibrated wire feed speed knob makes for easy and accurate adjustment of the wire feed speed. The knob rotates 3/4 turn. Turn the knob clockwise to increase the wire feed speed, and counter clockwise to reduce the wire feed speed. Models with analog voltmeters have a calibrated scale printed around the wire feed speed knob using "in/min"...
- Page 20 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. POLARITY LED The Polarity LED lights when the wire feeder is connected for positive polarity.
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Page 21: Internal Controls
OPERATION INTERNAL CONTROLS FIGURE B.2 LN-25 PRO EXTREME... - Page 22 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.
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Page 23: 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 24: Rear Controls
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 25: 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) .040-.045" (1.0-1.2mm) Cored Wires: .052" (1.4mm) 1/16"... - Page 26 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: 1/0 Coaxial weld cable of length "xx". Ends of the weld cable have lug con- nections.
- Page 27 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 28 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.
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Page 29: Maintenance
SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off at the fuse box before working in the terminal strip. - Page 30 Wire Feed Speed Validation (See Figure D.1) Calibration of the LN25 PRO EXTREME may be required when the p.c. board, wire feed speed potentiometer or motor is replaced or serviced. Calibration matches the scale on the name plate to the actual wire feed speed. Tools required: •...
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Page 31: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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
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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed. - Page 33 (40psi or less). Replace the liner if worn. 4. Use only clean electrode. Use quality electrode, like L-50 or L-56 from Lincoln Electric. 5. Replace the contact tip. 6. Verify the proper parts are installed. 7. Adjust the tension arm per the Instruction Manual.
- Page 34 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 35 DIAGRAMS LN-25 PRO EXTREME...
- Page 36 DIAGRAMS LN-25 PRO EXTREME...
- Page 37 DIMENSION PRINT LN-25 PRO EXTREME...
- Page 38 NOTES LN-25 PRO EXTREME...
- Page 39 NOTES LN-25 PRO EXTREME...
- Page 40 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 41 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 42 • 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...