Lincoln Electric LN-25x Service Manual
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Lincoln Electric LN-25x Service Manual

Lincoln Electric LN-25x Service Manual

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LINCOLN ELECTRIC
LN-25x™
Service Manual SVM269
Last update: 2016/05/01
LN-25X™ .................................................................................................................................................. 1
Service Manual............................................................................................................................................................. 1
Theory of Operation .................................................................................................................................................. 3
INPUT SECTION ....................................................................................................................................... 3
USER INTERFACE BOARD AND CROSSLINC™ TECHNOLOGY ....................................................................... 4
FLEXIBLE POWER SUPPLY BOARD, SWITCHES AND WIREFEED .................................................................. 5
OPTIONAL TIMER KIT ............................................................................................................................... 6
Troubleshooting & Repair ....................................................................................................................................... 7
HOW TO USE TROUBLESHOOTING GUIDE ................................................................................................ 7
PC BOARD TROUBLESHOOTING PROCEDURES .......................................................................................... 8
Troubleshooting guide ............................................................................................................................................. 9
Test Procedures ....................................................................................................................................................... 12
D1 RECTIFIER TEST PROCEDURE ............................................................................................................. 15
WIRE DRIVE MOTOR TEST PROCEDURE .................................................................................................. 17
USER INTERFACE BOARD TEST PROCEDURE............................................................................................ 20
GAS SOLENOID TEST PROCEDURE .......................................................................................................... 23
CONTACTOR TEST PROCEDURE .............................................................................................................. 25
FLEXIBLE POWER SUPPLY BOARD TEST PROCEDURE ............................................................................... 27
Removal And Replacement Procedures .......................................................................................................... 31
LN-25x™ Service Manual
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Summary of Contents for Lincoln Electric LN-25x

  • Page 1: Table Of Contents

    LINCOLN ELECTRIC LN-25x™ Service Manual LN-25x™ Service Manual SVM269 Last update: 2016/05/01 LN-25X™ ..............................1 Service Manual................................1 Theory of Operation ..............................3 INPUT SECTION ............................3 USER INTERFACE BOARD AND CROSSLINC™ TECHNOLOGY ............... 4 FLEXIBLE POWER SUPPLY BOARD, SWITCHES AND WIREFEED ..............5 OPTIONAL TIMER KIT ..........................
  • Page 2 LINCOLN ELECTRIC LN-25x™ Service Manual CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE ..............31 D1 RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE ..............34 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE ............36 USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE ............ 39 GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE ..............42 CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE ..............

  • Page 3: Theory Of Operation

    The LN-25x is an across-the-arc wire feeder that is equipped with CrossLinc™ technology. The DC input is applied to the LN-25x wire feeder from the power source via the electrode cable and the work sensing clip lead. This input voltage is applied to a bridge rectifier (D1) and also to the user interface board and the flexible power supply board.

  • Page 4: User Interface Board And Crosslinc™ Technology

    Flextec 350x. When this feature is available the preset welding voltage can be adjusted from the LN-25x by using the right hand encoder control. This can be accomplished without the use of a separate control cable. The CrossLinc™ function will operate during an open circuit voltage...

  • Page 5: Flexible Power Supply Board, Switches And Wirefeed

    LINCOLN ELECTRIC LN-25x™ Service Manual Figure E.3 – Flexible power supply board, switches and wirefeed Flexible Power Supply Board, Switches and Wirefeed The flexible power supply board creates several power supplies from the arc voltage. It communicates with and supplies regulated power to the user interface board. The electronic circuitry in the flexible power supply board creates a 50 VDC bus that is used to power the gas solenoid and the contactor.

  • Page 6: Optional Timer Kit

    LINCOLN ELECTRIC LN-25x™ Service Manual Figure E.4 – Optional timer kit Optional Timer Kit The optional timer kit allows for control of the gas preflow time, gas postflow time and wire burnback time. The gas preflow time is from zero to 10 seconds. Gas preflow is used to purge the welding gun with shielding gas and helps to minimize porosity at the start of a weld.

  • Page 7: Troubleshooting & Repair

    Troubleshooting & Repair HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only 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 8: Pc Board Troubleshooting Procedures

    ELECTRIC SHOCK can kill. • If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will • Have an electrician install and service this prevent further damage and allow proper failure analysis.

  • Page 9: Troubleshooting Guide

    3. Make sure the OCV is at least 60 VDC. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 10 Motor Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 11 3. Perform the Wire Drive Motor Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 12: Test Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 13 LINCOLN ELECTRIC LN-25x™ Service Manual NOTE: Some mild leverage will have to be applied to the top of the case so the wire drive assembly will “clear” for removal. The harness will still be attached to the wire drive motor and trigger interlock switch.
  • Page 14 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.1 – Control box cover and wire drive panel mounting screw locations Figure F.2 – Wire drive assembly mounting screw locations...

  • Page 15: D1 Rectifier Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 16 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.3 – D1 rectifier location Figure F.4 – D1 rectifier lead locations...

  • Page 17: Wire Drive Motor Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 18 3. Locate the wire drive motor, on the rear of the wire drive panel, and plug P53. See Figure F.5. See Wiring Diagram. 4. Carefully apply the correct input voltage (15 – 110 VDC) to the LN-25x. 5. With the gun trigger activated and the motor running check the motor armature current. Normal armature current is less than 3 amps.
  • Page 19 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.5 – Wire drive motor location Figure F.6 – Wire drive motor plug P53 lead locations...

  • Page 20: User Interface Board Test Procedure

    5. Carefully apply the correct input voltage to the LN-25x. 6. With the proper input voltage applied to the LN-25x, LED 10 should be flashing indicating the microcontroller on the board is operating. LED 11 should be steady green indicating +5 VDC is present on the board.
  • Page 21 LINCOLN ELECTRIC LN-25x™ Service Manual Table F.2 - User interface board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS (POS) (NEG) READING INPUT VOLTAGE PLUG J35 PIN 2 PLUG J35 PIN 3 15 TO 110 VDC ELECTRODE FROM POWER...
  • Page 22 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.8 – User interface board plug and LED locations Figure F.9 – User interface board lead locations...

  • Page 23: Gas Solenoid Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 24 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.10 – Gas solenoid location Figure F.11 – Gas solenoid coil lead locations...

  • Page 25: Contactor Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 26 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.12 – Contactor location Figure F.13 – Black contactor coil lead locations...

  • Page 27: Flexible Power Supply Board Test Procedure

    4. Locate LED 1 on the flexible power supply board. See Figure F.15. 5. Carefully apply the correct input voltage to the LN-25x. 6. With the proper input voltage applied to the LN-25x, LED 1 should be flashing indicating the microcontroller on the board is operating.
  • Page 28 LINCOLN ELECTRIC LN-25x™ Service Manual Table F.3 - Flexible power supply board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS (POS) (NEG) READING INPUT VOLTAGE PLUG J5 PIN 7 PLUG J5 PIN 6 15 TO 110 VDC ELECTRODE FROM POWER...
  • Page 29 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.14 – Flexible power supply board location Figure F.15 – Flexible power supply board plug and LED locations...
  • Page 30 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.16 – Flexible power supply board lead locations...

  • Page 31: Removal And Replacement Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 32 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.17 – Left side control box mounting screw locations Figure F.18 – Top and bottom control box mounting screw locations...
  • Page 33 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.19 – Handle mounting hardware location Figure F.20 – Cord grip connector location...

  • Page 34: D1 Rectifier Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 35 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.21 – D1 rectifier lead locations Figure F.22 – D1 rectifier mounting nut location...

  • Page 36: Wire Drive Motor Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 37 LINCOLN ELECTRIC LN-25x™ Service Manual 7. Perform the Wire Drive Assembly And Control Box Cover Replacement Procedure. 8. Perform the Retest After Repair Procedure. Figure F.23 – Feedplate cover mounting screw location Figure F.24 – Drive gear mounting hardware locations...
  • Page 38 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.25 – Drive motor mounting screw locations...

  • Page 39: User Interface Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 40 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.26 – User interface board plug locations Figure F.27 – Wire feed speed knob and voltage knob locations...
  • Page 41 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.28 – User interface board mounting screw locations...

  • Page 42: Gas Solenoid Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 43 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.29 – Control box cover mounting screw locations Figure F.30 – Gas solenoid leads and gas hose connection location...
  • Page 44 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.31 – Gas solenoid mounting nut location...

  • Page 45: Contactor Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 46 LINCOLN ELECTRIC LN-25x™ Service Manual 2. Carefully position the contactor with bus bars into the machine. Carefully slide the bus bar into position in the insulated mounting block where the input cable can bus bar are joined. Take note of all lead placements.
  • Page 47 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.33 – Contactor mounting screw location Figure F.34 – Copper bus bar mounting nut locations...

  • Page 48: Flexible Power Supply Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 49 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.35 – Flexible power supply board plug locations Figure F.36 – Flexible power supply board mounting nut locations...

  • Page 50: Current Transducer Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 51 LINCOLN ELECTRIC LN-25x™ Service Manual Figure F.37 – Current transducer mounting hardware locations...

  • Page 52: Retest After Repair

    WIRE FEED SPEED 35 THROUGH 715 INCHES PER MINUTE GAS SOLENOID MUST OPERATE WHEN GUN TRIGGER IS ACTIVATED CONTACTOR MUST OPERATE WHEN GUN TRIGGER IS ACTIVATED CROSSLINC LED MUST ILLUMINATE WHEN LN-25x IS CONNECTED TO A COMPATIBLE LINCOLN POWER SOURCE (FLEXTEC 350X).

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