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Red-D-Arc Welderentals LN25 PRO EXTREME DUAL POWER Operator's Manual

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IM10080-A
RED-D-ARC
August 2013
LN25™ PRO EXTREME DUAL POWER
For use with machines having Code Numbers: 11750, 12164
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 Red-D-Arc Welderentals LN25 PRO EXTREME DUAL POWER

  • Page 1 IM10080-A RED-D-ARC August 2013 LN25™ PRO EXTREME DUAL POWER For use with machines having Code Numbers: 11750, 12164 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 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 SAFETY SECTION A: with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until WARNINGS fumes have been eliminated. 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.
  • Page 4 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 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 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 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 lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
  • Page 8 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions.

  • Page 9: Table Of Contents

    viii viii 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 Analog Control Cable ......................A-3 Cable Connections and Control Cable Connector ...............A-4 Shielding Gas Connection ....................A-4 Wire Drive Configuration ......................A-5 Gun Receiver Bushing, Thumb Screw and Socket Head Cap Screw ......A-5, A-6 Procedure to Install Drive Rolls and Wire Guides ..............A-7...

  • Page 10: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – RED-D-ARC LN25™ PRO EXTREME DUAL POWER (K2614-7) INPUT VOLTAGE and CURRENT INPUT AMPERES INPUT VOLTAGE ± 10% Across the Arc configuration 15-110 VDC Control Cable configuration 24-42 VAC RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 60% rating GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW...

  • Page 11: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS The RED-D-ARC LN25™ PRO EXTREME DUAL POWER is rated IP23 and is suitable for outdoor use. WARNING The handle of the RED-D-ARC LN25™ PRO ELECTRIC SHOCK CAN KILL. EXTREME DUAL POWER is intended for moving • Turn the input power OFF at the the wire feeder about the work place only.

  • Page 12: Analog Control Cable

    INSTALLATION 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

    INSTALLATION TRIGGER CONNECTIONS SHIELDING GAS CONNECTION There is one circular connector for the gun trigger on the WARNING front of the RED-D-ARC LN25™ PRO EXTREME DUAL POWER. Note – if the gun trigger is already depressed when the CYLINDER may explode if damaged.

  • Page 14: Wire Drive Configuration

    INSTALLATION WIRE DRIVE CONFIGURATIONS 6. Remove the outer wire guide, and push the gun bushing out of the wire drive. Because of the pre- WARNING cision fit, light tapping may be required to remove the gun bushing. 7. Disconnect the shielding gas hose from the gun ELECTRIC SHOCK can kill.
  • Page 15 INSTALLATION GUN BUSHING, THUMB SCREW AND SET 10. Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate. SCREW Slide the gun bushing into the wire drive and verify (See Figure A.2a for Code 12164) the thumb screw holes are aligned.

  • Page 16: Procedure To Install Drive Rolls And Wire Guides

    INSTALLATION PRESSURE ARM ADJUSTMENT PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- • Turn the input power OFF at the ing power source before installation or welding power source before instal- changing drive rolls and/or guides.

  • Page 17: Gun Connections

    INSTALLATION 1. Squeeze the release bar on the retaining collar and The RED-D-ARC LN25™ PRO EXTREME DUAL remove it from the spindle. POWER comes with an S29807-2 gun adapter installed. (See Figure A.4a for Code 12164) 2. Place the spindle adapter on the spindle, aligning the spindle brake pin with the hole in the adapter.

  • Page 18: Diagrams

    INSTALLATION POWER SOURCE TO RED-D-ARC LN25™ PRO DUAL POWERR CABLE CONNECTION DIAGRAMS ACROSS THE ARC SET-UPS CC Power Sources with Output Terminals Always Hot (See Figure A.5) CC Power Source Classics Big Red’s Eagle 10,000 Plus Pipeliner 200D Without Wire Feed module SAE’s Without CV Adapter RED-D-ARC LN25™...
  • Page 19 A-10 A-10 INSTALLATION CV Power Sources with Stud Connectors and no Remote/Local Switch(See Figure A.7) FIGURE A.7 RANGER 250, 250 LPG RANGER 305G, 305D RANGER 10,000 RANGER 3 PHASE RANGER225, 225 GXT RED-D-ARC LN25™ COMMANDER 300 Electrode PRO EXTREME VANTAGE 300, 400, 500 DUAL POWER AIR VANTAGE 500 Work clip...
  • Page 20 A-11 A-11 INSTALLATION CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) FIGURE A.9 Jump er CV-250 RED-D-ARC LN25™ CV-300 Electrode PRO EXTREME DUAL POWER Work Wor k clip Description K2614-7 RED-D-ARC LN25™ PRO Place CV/CC switch in the feeder in the "CV" position. EXTREME DUAL POWER KP1695-XX KP1696-XX...

  • Page 21: Operation

    OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. INPUT POWER 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...

  • Page 22: Definition Of Welding Terms

    OPERATION DEFINITION OF WELDING TERMS General Functional Description The RED-D-ARC LN25™ PRO EXTREME DUAL POWER have adjustable WFS range for improving the knob sensitivi- • Wire Feed Speed ty. The low range is great for critical welds with Innershield wires, and the upper range is suitable for general purpose •...
  • Page 23 OPERATION The serviceability of a product or structure utiliz- To preset the wire feed speed on CC power sources: ing the RED-D-ARC LN25™ PRO EXTREME DUAL POWER wire feeder is and must be the sole 1. Set the Wire Feed Mode switch inside the LN25™ responsibility of the builder/user.

  • Page 24: Constant Current Wire Welding

    OPERATION CONSTANT CURRENT WIRE WELDING If the contact tip to work distance is properly main- (See Figure B.2) tained, a satisfactory operating voltage range may be achieved, and a sound weld may result. However, Most semiautomatic welding processes perform better when a welder uses a longer contact tip to work dis- using constant voltage power sources.

  • Page 25: Case Front Controls

    OPERATION CASE FRONT CONTROLS POWER-UP SEQUENCE Figure B.3 All of the LEDʼs will briefly illuminate during power-up. 1. WIRE FEED SPEED/AMPERAGE DISPLAY Idle The left display shows the preset wire feed speed. The right display shows OCV. The wire feed speed LED is lit.
  • Page 26 OPERATION 5. SET-UP MENU 2. WIRE FEED SPEED KNOB Use the Wire Feed Speed Knob to adjust the rate of Preparation for WFS Calibration: wire feed speed. • Place the CV/CC switch in CV. Because the wire feeder is powered by the arc volt- age, the full range of wire feed speed may not be •...
  • Page 27 OPERATION RUN-IN WFS CALIBRATION “Run-in” refers to the wire feed speed during the time Measurements for adjusting the WFS calibration must from when the trigger is pulled to when an arc is be made before entering the set-up menu. When first struck.
  • Page 28 OPERATION AMPERAGE CALIBRATION LEFT DISPLAY SELECTION Measurements for adjusting the Amperage calibration The left display can show either amperage or actual must be made before entering the set-up menu. WFS during welding. Note that actual WFS is not the same as preset WFS. For example, the preset WFS When first entering Amperage Calibration, the calibra- may be set to 400 ipm, but the arc voltage is only 15V.
  • Page 29 OPERATION INTERNAL CONTROLS FIGURE B.4 (For Code 11750) (For Code 12164) ITEM DESCRIPTION 2-Step Trigger Interlock Switch CV / CC Switch Pressure Adjustment Arm Optional Timer Kit (See Accessories Section) Spool Retainer Spool Brake Gun Bushing, Thumb Screw and Socket Head Cap Screw(For Code 11750) Gun Bushing, Thumb Screw and Socket Set Screw(For Code 12164) Drive Hubs Cold Feed Pushbutton...
  • Page 30 B-10 B-10 OPERATION 3. PRESSURE ARM INTERNAL CONTROLS DESCRIPTION (See Installation Section) (See Figure B.4) 4. OPTIONAL TIMER KIT The optional Timer Kit provides control of preflow 1. 2 STEP - TRIGGER time, burnback, and postflow time. INTERLOCK SWITCH 5. SPOOL RETAINER The 2 Step - Trigger Interlock switch changes the function of the To release the spool retainer, squeeze the metal bar...
  • Page 31 B-11 B-11 OPERATION REAR CONTROLS: FIGURE B.5 ITEM DESCRIPTION Gas Purge Pushbutton Flowmeter Shielding Gas Control Cable Electrode Lead (electrode is a 4/0 cable) RED-D-ARC LN25™ PRO EXTREME DUAL POWER...
  • Page 32 B-12 B-12 OPERATION 1. GAS PURGE PUSHBUTTON (See Figure B.5) 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 33: Accessories

    ACCESSORIES FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS USED • See Parts Pages K2330-2 Timer Kit Includes: Panel and harness for adjusting preflow, burnback and postflow times. K2596-2 Plastic Case Includes: a complete engi- neered plastic case. K1796-xx AWG 1/0 Co-Axial Power Cable Includes: 1/0 Coaxial weld...
  • Page 34 ACCESSORIES Includes: 14 pin to 14 pin wire Control Cable feeder to power source control K1797-xx cable. Includes: Adapter control cable for connecting a Lincoln 42 VAC wire feeder to a 24 Adapter for Competitive Power VAC Miller power source. K2335-1 Sources Requires the digital...
  • Page 35 ACCESSORIES K910-1 Ground Clamp Includes: One 300 Amp Ground Clamp. K910-2 Ground Clamp Includes: One 500 Amp Ground Clamp. K1500-1 Gun Receiver Bushing (for guns Includes: Gun receiver bush- (For Code with K466-1 Lincoln gun connec- ing, set screw and hex key 11750 only) tors;...
  • Page 36 ACCESSORIES K1500-4 Gun Receiver Bushing (for gun Includes: Gun receiver bush- (For Code with K466-3 Lincoln gun connec- ing with hose nipple, set screw 11750 only) 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, (For Code...

  • Page 37: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS the gun bushing. WARNING 5. Connect the shielding gas hose to flow meter refer- ence standard. ELECTRIC SHOCK can kill. • Turn the input power OFF at the 6. Orient the RED-D-ARC LN25™ PRO EXTREME welding power source before DUAL POWER in a vertical position.

  • Page 38: 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 39: 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 Fault Code Description Possible Adjustments 1. The wire drive motor has over- 1. Check that the electrode slides Err 81 Motor overload, long term.
  • Page 40 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Output Problems The feeder does power up - no display, no 1. The work sense lead is disconnected or is 1. Connect the work sense lead to the work in cold feed.
  • Page 41 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 42 ENHANCED DIAGRAM DIAGRAMS RED-D-ARC LN25™ PRO EXTREME DUAL POWER...
  • Page 43 DIMENSION PRINT RED-D-ARC LN25™ PRO EXTREME DUAL POWER...
  • Page 44 NOTES RED-D-ARC LN25™ PRO EXTREME DUAL POWER...
  • Page 45 NOTES RED-D-ARC LN25™ PRO EXTREME DUAL POWER...
  • Page 46 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 •...
  • Page 47 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- •...
  • Page 48 • 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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