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Operator's Manual
LN-25 WIRE FEEDER
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code:
(ex: 10859)
Serial:
(ex: U1060512345)
IM620-B
| Issue D ate 5-Sep
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
10556, 11144, 10557, 11145, 10558,
11282, 11283

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Troubleshooting

   Summary of Contents for Lincoln Electric LN-25

  • Page 1

    Operator’s Manual LN-25 WIRE FEEDER For use with machines having Code Numbers: 10556, 11144, 10557, 11145, 10558, 11282, 11283 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345)

  • Page 2

    THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...

  • Page 3

    MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).

  • Page 4: Electric Shock Can Kill

    S FETY 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

    S FETY 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 and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Safety

    SAFETY PRÉCAUTIONS DE SÛRETÉ 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffe- Pour votre propre protection lire et observer toutes les instructions et ment et un risque d’incendie. les précautions de sûreté...

  • Page 7: Table Of Contents

    Safety Precautions ............................D-1 Routine Maintenance ............................D-1 Circuit Protection and Automatic Shutdown ....................D-1 Adjusting Speed Sensor Module ........................D-1 Calibration of the LN-25 Wire Speed Dial ....................D-2 TROUBLESHOOTING GUIDE ......................SECTION E How to Use the Troubleshooting Guide .......................E-1 Troubleshooting Guide............................E-2 WIRING DIAGRAM ..........................SECTION F PHYSICAL DIMENSIONS........................SECTION F...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – LN-25 VOLTAGE OPERATING ARC VOLTAGE Constant Voltage (CV) 15-40 VDC (110VDC Maximum OCV) Constant Current (CC) RATED C C URRENT RATED CURRENT Rated current without contactor 500 Amps 60% Duty Cycle Rated current with contactor 300 Amps 60% Duty Cycle...

  • Page 9: Safety Precautions

    DC-250 is turned on. POWER SOURCE CONNECTION b. Connect electrode cable to the “Innershield/ GMAW” output terminal of polarity required by The LN-25 can be used with most DC welding power electrode. Connect work lead other source.

  • Page 10: Gun Cable Connection To Feeder

    Constant Voltage Innershield. Initially set the output control on “6”. a. For electrode negative welding, connect the electrode lead from the LN-25 to the output DC-600 terminal on the CV Adapter, and the work lead to the power source output terminal labeled a.

  • Page 11: Weld Cable Connection

    Cored KP653- ⁄ L9932 ⁄ (.062) Cored or Solid ⁄ the electrode cable to the LN-25 input stud using the Steel ⁄ ” nut provided. (Can also be used for .052) .045 and .052 Solid Steel -.052 .045 and .052 Cored -.052C...

  • Page 12: Operation

    • Wear eye, ear and body protec- tion. WELDING CAPABILITY The LN-25 will handle up to 500 Amp 60% duty cycle welding currents. However, when equipped with a K443-2 Contactor, the LN-25 will handle up to 300 Amp 60% duty cycle.

  • Page 13

    OPERATION LN-25 INSTRUMENTS AND NOTE: CONTROLS 1. The Voltmeter will read zero if the LN-25 work clip lead is not connected to work, even if the Refer to Figure B.1 for control locations. electrode is electrically “hot” to work. REMOTE 2.

  • Page 14

    NOTE: The clip lead also serves as a work sensing procedure arc voltage of at least 17V would be lead for the LN-25 Voltmeter (if installed). If the clip required to obtain the 400 in/min. wire feed speed. lead is extended by the user beyond the standard 15 ft.

  • Page 15: Sequence Of Operation

    ® COILS spool in a clockwise direction when dereeled from the bottom of the coil. The LN-25 will require an optional K363-P Readi- c. Replace and tighten the locking collar. Reel ® Adapter which is required to load Lincoln 22 to 30 lb Readi-Reel coils.

  • Page 16: Loading Wire Drive

    CAUTION the outgoing guide tube causing a “bird nest”.) Keep gun in LN-25 gun holder when not feeding wire c. Insert the free end through the incoming guide to prevent accidental arcing.

  • Page 17: Presetting Wire Feed Speed

    PRESETTING WIRE FEED SPEED The LN-25 permits accurate presetting of the desired wire feed speed, before welding, in both CV and CC wire feed modes. SETTING CONSTANT WIRE FEED SPEED (CV MODE) a.

  • Page 18: Making A Weld

    NOTE: If the K460-1 Pulse Power Adapter Kit is 668 612 566 526 490 460 432 installed but the LN-25 is to be used without the K461 Pulse Power Control Cable Assembly, then the 700 642 592 550 514 482 452...

  • Page 19: Procedure At End Of Coil

    POWER SOURCE WARNING WARNING ARC RAYS can burn. The LN-25 should be used with a constant current • Do not touch metal por- machine only upon non-critical weldments and after tions of the LN-25 lead Clip testing is done to assure quality is adequate for the...

  • Page 20: Automatic Protection Shutdown

    MOTOR OVERLOAD SHUTDOWN To aid in stabilizing the arc voltage when welding on CC power sources the LN-25 is provided with a VV If excessive motor overload occurs (due to prolonged (CC) wire feed mode. This arc voltage sensing feed...

  • Page 21: Accessories

    How to use Table C.1. Determine which Kit No. is to be used. Locate that Kit No. in the left hand vertical column. Scan horizontally to determine which LN-25 model is required and what additional kits may be required. TABLE C.1 LN-25 OPTION CHART O = CANNOT BE USED WITH X = REQUIRED ➀...

  • Page 22: Options And Accessories

    LN-25. delay before the wire feeder and welding output Install by connecting a supply hose from the gas flow...

  • Page 23: K460-1 Pulse Power Adapter Kit

    K461 Pulse Power Control Cable.)(No Longer Available) This kit can only be used with LN-25’s Code 10500- This kit enables the LN-25 to pulse weld with a Pulse 10558. To prevent possible damage to the LN-25 with Power 500 power source above Code 9300 (or lower internal contactor, do not connect to non-Lincoln TIG Codes updated with Kit).

  • Page 24: K433 Power Source Remote Box

    NOTE: If the K431-1 Remote Output Control Kit is total extension), the maximum welding current used installed but the LN-25 is to be used without the should be less than 350 amps. K432 Remote Control Cable Assembly, then the Re-...

  • Page 25: K444, K444-1 Or K444-2 Remote Voltage Control Kit

    ACCESSORIES The cable assembly end with the socket pin K577-1 REAR HANDLE KIT connector connects to the LN-25 per the Instructions (M17253) included with the K624-1 Kit. (For LN-25 model codes above 9383) The fold-down handle mounts to the rear of the LN-...

  • Page 26

    LN-25. GUN CABLE CONNECTOR REQUIREMENTS TO PERMIT PROPER CONNECTION TO LINCOLN LN-25 WIRE FEEDER. LN-25 Cable Connector for .023 through .052 Wire (For all other dimensions, see above) FIGURE C.1 NOTE: Connector part with .749/.747 diameter...

  • Page 27: Maintenance

    Drive rolls for .023 through .052 solid electrode and The LN-25 Speed Sensor Module is a three lead Hall aluminum sizes have no teeth but use two grooves Effect switch device encased in an externally so they also can be reversed for additional life.

  • Page 28: Calibration Of The Ln-25 Wire Speed Dial

    MAINTENANCE 1. Be sure all power to the LN-25 is shut off at the WARNING power source. 2. Check that the module mounting plate is screwed Electrode will be electrically “hot”. Do not allow fed securely to the side of the gearbox.

  • Page 29: How To Use The Troubleshooting Guide

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

  • Page 30: Troubleshooting

    1. Power source must be on pulled and open circuit voltage (OCV) present at weld terminals. 2. LN-25 work clip may not be connected. 3. LN-25 polarity switch must match electrode polarity. 4. Jumper plug on control or option board may be loose or missing.

  • Page 31

    11. Wire reel brake tension set too high. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized field service facility for technical troubleshooting assistance before you proceed. LN-25...

  • Page 32

    2. Check speed sensor - see maintenance section. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized field service facility for technical troubleshooting assistance before you proceed. LN-25...

  • Page 33: Wiring Diagram

    WIRING DIAGRAM LN-25...

  • Page 34

    WIRING DIAGRAM LN-25...

  • Page 35: Ln-25 Physical Dimensions

    DIMENSIONS LN-25 PHYSICAL DIMENSIONS 16.60 14.00 21.00 7.40 LN-25...

  • Page 36

    NOTES LN-25...

  • Page 37

    NOTES LN-25...

  • Page 38

    ● ● ● 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 39

    ● ● ● 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 40

    • 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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