Lincoln Electric LN-25 PRO DUAL POWER Service Manual
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Lincoln Electric LN-25 PRO DUAL POWER Service Manual

Lincoln Electric LN-25 PRO DUAL POWER Service Manual

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LN-25
PRO DUAL POWER
™
For use with machines having Code Numbers:
11534, 11617, 11720, 11726
SERVICE MANUAL
SVM206-A
| Issue D ate 11-Jan
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.
®

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  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. LN-25 PRO DUAL POWER ™ ® For use with machines having Code Numbers: 11534, 11617, 11720, 11726 SERVICE MANUAL SVM206-A | Issue D ate 11-Jan...
  • Page 2 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 ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 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. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 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 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 INSTALLATION TECHNICAL SPECIFICATIONS – LN-25™ PRO DUAL POWER (K2614-1 & -3) INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 15-110 VDC RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 60% rating 100% rating GEARING - WIRE FEED SPEED RANGE-WIRE SIzE GMAW FCAW GEARING...

  • Page 11: Installation

    INSTALLATION SAFETY PRECAUTIONS The handle of the LN-25™ PRO DUAL POWER is intended for moving the wire feeder about the work place only. WARNING When suspending a wire feeder, insulate the ELECTRIC SHOCK CAN KILL. hanging device from the wire feeder enclosure. •...

  • Page 12: Shielding Gas Connections

    INSTALLATION CABLE CONNECTIONS SHIELDING GAS CONNECTION WARNING There is one circular connector for the gun trigger on the front of the LN-25™ PRO DUAL POWER. CYLINDER may explode if Picture Function Wiring damaged. 5-pin trigger Trigger • Keep cylinder upright and connector for Not used chained to support.

  • Page 13: Wire Drive Configuration

    INSTALLATION WIRE DRIVE CONFIGURATION 8. Connect the shielding gas hose to the new gun bushing, if required. (See Figure A.2) 9. Rotate the gun bushing until the thumb screw hole CHANGING THE GUN RECEIVER aligns with the thumb screw hole in the feed plate. BUSHING Slide the gun receiver bushing into the wire drive WARNING...

  • Page 14: Pressure Arm Adjustment

    INSTALLATION 1. Squeeze the release bar on the retaining collar and PRESSURE ARM ADJUSTMENT remove it from the spindle. WARNING 2. Place the spindle adapter on the spindle, aligning the spindle brake pin with the hole in the adapter. ELECTRIC SHOCK can kill. •...
  • Page 15 INSTALLATION POWER SOURCE TO LN™-25 PRO CABLE CONNECTION DIAGRAMS ACROSS THE ARC SET-UPS CC Power Sources with Output Terminals Always FIGURE A.5 Hot (See Figure A.5) CC Power Source Ranger 250, 250 LPG Ranger 305G, 305D Commander 300 Vantage 300, 400, 500 Air Vantage 500 Ranger 10,000 LN-25™...
  • Page 16 INSTALLATION CC Power Sources with Output Terminals always Hot Stud Connectors and no Remote/Local Switch. FIGURE A.7 (See Figure A.7) Jumper CV-400 LN-25™ PRO Electrode CV-655 DUAL POWER Work clip Work Place CV/CC switch in the feeder in the "CV" position. Description K2613-1 LN-25™...
  • Page 17 INSTALLATION CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) FIGURE A.9 Jump er CV-250 CV-300 LN-25™ PRO Electrode CV-305 DUAL POWER Wor k clip Work Description K2614-1, -3 LN-25™ PRO Dual Power Place CV/CC switch in the feeder in the "CV" position. KP1695-XX KP1696-XX Drive Roll Kit...
  • Page 18 NOTES A-10 A-10 LN-25™ PRO DUAL POWER...
  • Page 19 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 20: 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...

  • Page 21: Definition Of Welding Terms

    OPERATION DEFINITION OF WELDING TERMS RECOMMENDED PROCESSES • GMAW • FCAW • Wire Feed Speed PROCESS LIMITATIONS • Constant Current • GMAW-P procedures must be qualified by the cus- • Constant Voltage tomer. GMAW • Across-the-Arc models are not recommended for •...
  • Page 22 OPERATION Wire Feed Speed, CV Operation To preset the wire feed speed on CC power sources: When Across the Arc models are operated with CV 1. Set the Wire Feed Mode switch inside the LN™- power sources, the wire feed speed will remain a con- 25 Pro to "CC".

  • Page 23: Case Front Controls

    Voltage Display Always use quality electrode, such as L-50 or L-56 Voltage LED from Lincoln Electric. Set-up Push Button Remote Voltage Control Knob 8. VOLTAGE DISPLAY (See displays in Item 1 for Voltage functions) 83% FUNCTIONALITY (for Innershield®...

  • Page 24: Power-Up Sequence

    OPERATION Wire Feed Speed Units POWER-UP SEQUENCE All of the LED’s will briefly illuminate during power-up. Rotate the WFS knob to If the gun trigger is activated during power up, the feed- the left to use er will not operate until the gun trigger is released. “inches/minute”...

  • Page 25: Wfs Calibration With Digital Meter

    OPERATION 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 26: Internal Controls

    OPERATION INTERNAL CONTROLS FIGURE B.2 ITEM DESCRIPTION 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 27 OPERATION INTERNAL CONTROLS DESCRIPTION CV/CC SWITCH (See Figure B.2) (See Figure B.2) The CV/CC switch sets the wire feed speed control method for the 2 Step - Trigger Interlock Switch wire feeder. The 2 Step - Trigger Interlock In the CV position, the wire feed switch changes the function of the speed remains constant during gun trigger.

  • Page 28: Constant Current Wire Welding

    The power source reg- ulates this current regardless of changes in the weld- For these reasons, Lincoln Electric does NOT recom- ing circuit, including cable length, electrode diameter, mend constant current semiautomatic welding for wire feed speed, contact tip to work distance, etc.

  • Page 29: Rear Controls

    OPERATION B-11 B-11 FIGURE B.4 - REAR CONTROLS ITEM DESCRIPTION Gas Purge Pushbutton Flow Meter Ball Flow Meter Valve Shielding Gas Inlet Electrode Lead Optional Water cooled gun connections Control Cable input LN-25™ PRO DUAL POWER...
  • Page 30 OPERATION B-12 B-12 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 31 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Factory Installed Equipment .
  • Page 32 ACCESSORIES FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS WIRE TYPE ELECTRODE SIzE KP KIT Steel Wires: .023-.030 (0.6-0.8mm) KP1696-030S .035 (0.9mm) KP1696-035S Includes: 2 V groove .045 (1.2mm) KP1696-045S drive rolls and inner .052 (1.4mm) KP1696-052S 1/16 (1.6mm) KP1696-1/16S wire guide.
  • Page 33 ACCESSORIES K2330-2 Timer Kit Includes: Panel and harness for adjusting preflow, burnback and postflow times. K2596-1 Aluminum Case Includes: a complete engi- neered aluminum case. 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 cable of length "xx".
  • 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. Gun Receiver Bushing (for guns Includes: Gun receiver bush- K1500-1 with K466-1 Lincoln gun connec- ing, set screw and hex key tors;...
  • Page 36 ACCESSORIES Gun Receiver Bushing (for gun Includes: Gun receiver bush- K1500-4 with K466-3 Lincoln gun connec- ing with hose nipple, set tors; compatible with Miller® screw and hex key wrench. guns.) Includes: Gun receiver bushing K1500-5 Gun Receiver Bushing (compatible with hose nipple, 4 guide tubes, with Oxo®...
  • Page 37 ACCESSORIES INSTALLATION OF THE K590-6 WATER 4. Use a 5/16" nutdriver to remove the screws holding the water cooling cover on the case front of the inner COOLING KIT module and on the rear of the case. WARNING ELECTRIC SHOCK can kill. •...
  • Page 38 NOTES LN-25™ PRO DUAL POWER...
  • Page 39 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
  • Page 40 MAINTENANCE SAFETY PRECAUTIONS 3. Connect a supply of CO 2 to the wire feeder. Do not exceed the maximum inlet pressure of the wire WARNING feeder. ELECTRIC SHOCK can kill. 4. Disconnect the shielding gas hose that connects to • Turn the input power OFF at the the gun bushing.
  • Page 41 MAINTENANCE Wire Feed Speed Validation To change the wire feed speed calibration: (See Figure D.1) (See Figure D.2) Calibration of the LN-25™ PRO DUAL POWER may Tools required: be required when the p.c. board, wire feed speed potentiometer or motor is replaced or serviced. •...
  • Page 42 MAINTENANCE 1. Front Panel Assembly 2. Control Box Assembly 3. Spindle & Mast Assembly 4. Wire Drive Assembly 5. Case Assembly FIGURE D.3 - MAJOR COMPONENT LOCATION LN-25™ PRO DUAL POWER...
  • Page 43 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .
  • Page 44 THEORY OF OPERATION FIGURE E.2 - GENERAL DESCRIPTION ELECTRODE INPUT CURRENT TRANSDUCER CONTACTOR FEEDPLATE INPUT SOLENOID POLARITY TIMER OPTION TACH MOTOR MOTOR OVERLOAD ARMATURE CONTROL BOARD TACH FEEDBACK POWER SUPPLY 14 PIN AMPHENOL GUN TRIGGER REMOTE VOLTAGE WIRE SPEED COLD TRIGGER FEED INTERLOCK...
  • Page 45 THEORY OF OPERATION FIGURE E.3 - INPUT POWER ELECTRODE INPUT CURRENT TRANSDUCER CONTACTOR FEEDPLATE INPUT SOLENOID POLARITY TIMER OPTION TACH MOTOR MOTOR OVERLOAD ARMATURE CONTROL BOARD TACH FEEDBACK POWER SUPPLY 14 PIN AMPHENOL GUN TRIGGER REMOTE VOLTAGE WIRE SPEED COLD TRIGGER FEED INTERLOCK...
  • Page 46 THEORY OF OPERATION FIGURE E.4 - PRESET BOARD (DISPLAY) ELECTRODE INPUT CURRENT TRANSDUCER CONTACTOR FEEDPLATE INPUT SOLENOID POLARITY TIMER OPTION TACH MOTOR MOTOR OVERLOAD ARMATURE CONTROL BOARD TACH FEEDBACK POWER SUPPLY 14 PIN AMPHENOL GUN TRIGGER REMOTE VOLTAGE WIRE SPEED COLD TRIGGER FEED...
  • Page 47 THEORY OF OPERATION FIGURE E.5 - TRIGGER CIRCUIT ELECTRODE INPUT CURRENT TRANSDUCER CONTACTOR FEEDPLATE INPUT SOLENOID POLARITY TIMER OPTION TACH MOTOR MOTOR OVERLOAD ARMATURE CONTROL BOARD TACH FEEDBACK POWER SUPPLY 14 PIN AMPHENOL GUN TRIGGER REMOTE VOLTAGE WIRE SPEED COLD TRIGGER FEED INTERLOCK...
  • Page 48 THEORY OF OPERATION FIGURE E.6 - FEEDBACK AND CONTROL CIRCUITS ELECTRODE INPUT CURRENT TRANSDUCER CONTACTOR FEEDPLATE INPUT SOLENOID POLARITY TIMER OPTION TACH MOTOR MOTOR OVERLOAD ARMATURE CONTROL BOARD TACH FEEDBACK POWER SUPPLY 14 PIN AMPHENOL GUN TRIGGER REMOTE VOLTAGE WIRE SPEED COLD TRIGGER...
  • Page 49 THEORY OF OPERATION FIGURE E.7 - OPTIONAL CIRCUITS ELECTRODE INPUT CURRENT TRANSDUCER CONTACTOR FEEDPLATE INPUT SOLENOID POLARITY TIMER OPTION TACH MOTOR MOTOR OVERLOAD ARMATURE CONTROL BOARD TACH FEEDBACK POWER SUPPLY 14 PIN AMPHENOL GUN TRIGGER REMOTE VOLTAGE WIRE SPEED COLD TRIGGER FEED INTERLOCK...
  • Page 50 NOTES LN-25™ PRO DUAL POWER...
  • Page 51 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 52: Troubleshooting And Repair

    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 53: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 54 (Across the arc models) CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-25™ PRO DUAL POWER...
  • Page 55 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-25™ PRO DUAL POWER...
  • Page 56 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-25™ PRO DUAL POWER...
  • Page 57 Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-25™ PRO DUAL POWER...
  • Page 58 NOTES LN-25™ PRO DUAL POWER...

  • Page 59: Gas Solenoid Test

    GAS SOLENOID TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 60 TROUBLESHOOTING AND REPAIR F-10 F-10 GAS SOLENOID TEST (continued) FIGURE F.1 – GAS SOLENOID GAS SOLENOID GAS HOSE CONTROL BOX ASSEMBLY LOCK NUT CONTROL BOX COVER CONTROL BOX COVER SCREWS PROCEDURE 1. Remove the input power from the LN-25™ PRO 6.

  • Page 61: Contactor Test

    CONTACTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 62 TROUBLESHOOTING AND REPAIR F-12 F-12 CONTACTOR TEST (continued) FIGURE F.2 – CONTACTOR LOCATION CONTROL BOX ASSEMBLY CONTACTOR PROCEDURE 1. Remove power from the LN-25™ PRO DUAL 5. Check for the correct voltage at leads 507 and POWER wire drive unit. 578 at the contactor.

  • Page 63: Drive Motor And Tach Feedback Test

    DRIVE MOTOR AND TACH FEEDBACK TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 64 TROUBLESHOOTING AND REPAIR F-14 F-14 DRIVE MOTOR AND TACH FEEDBACK TEST (continued) FIGURE F.3 – CONTROL BOX ASSEMBLY CONTROL BOX ASSEMBLY CASE COVER PROCEDURE 1. Remove power from the LN-25™ PRO DUAL 7. With the trigger activated and the motor running POWER wire drive unit.

  • Page 65: Motor Overload Test

    MOTOR OVERLOAD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 66 TROUBLESHOOTING AND REPAIR F-16 F-16 MOTOR OVERLOAD TEST (continued) FIGURE F.4 – CONTROL BOX ASSEMBLY CONTROL BOX ASSEMBLY CASE COVER PROCEDURE 1. Remove power from the LN-25™ PRO DUAL 6. If the amperage exceeds 3.2 amps for more POWER wire drive unit. than 8 seconds the motor will be disabled.

  • Page 67: Display Pcb Test

    PRESET (DISPLAY) PCB TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 68 TROUBLESHOOTING AND REPAIR F-18 F-18 PRESET (DISPLAY) PCB TEST (continued) FIGURE F.5 – FRONT PANEL FRONT PANEL PROCEDURE 1. Remove the input power from the LN-25™ PRO DUAL POWER unit. 2. Perform Case Cover And Control Box Removal Procedure. 3. Perform Front Panel Removal Procedure. 4.
  • Page 69 TROUBLESHOOTING AND REPAIR F-19 F-19 PRESET (DISPLAY) PCB TEST (continued) FIGURE F.6 – PRESET (DISPLAY) PCB PROCEDURE 5. Check for the following voltages from the chart below. Description Positive Lead (RED) Negative Lead (BLACK) Expected Value J8 (Pin 1) J8 (Pin 10) +15VDC Supply power for Preset (Display) PCB...
  • Page 70 NOTES F-20 F-20 LN-25™ PRO DUAL POWER...

  • Page 71: Bridge Rectifier Test

    BRIDGE RECTIFIER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 72 TROUBLESHOOTING AND REPAIR F-22 F-22 BRIDGE RECTIFIER TEST (continued) FIGURE F.7 – FRONT PANEL FRONT PANEL PROCEDURE 1. Remove the input power from the LN-25™ PRO DUAL POWER unit. 2. Perform Case Cover And Control Box Removal Procedure. 3. Perform Front Panel Removal Procedure. 4.
  • Page 73 TROUBLESHOOTING AND REPAIR F-23 F-23 BRIDGE RECTIFIER TEST (continued) FIGURE F.8 – BRIDGE RECTIFIER PROCEDURE To test either bridge rectifier (located on the back- 4. If test results do not match the table, the Bridge side of the front nameplate) follow the procedure Rectifier may be faulty.
  • Page 74 NOTES F-24 F-24 LN-25™ PRO DUAL POWER...

  • Page 75: Case Cover And Control Box Removal And Replacement

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 76 TROUBLESHOOTING AND REPAIR F-26 F-26 CASE COVER AND CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.9 – CASE COVER SCREWS AND CORD GRIP CONNECTOR LOCATIONS CASE COVER SCREWS (8) CORD GRIP CONNECTOR REMOVAL PROCEDURE 1. Remove input power from the LN-25™ PRO DUAL POWER unit.
  • Page 77 TROUBLESHOOTING AND REPAIR F-27 F-27 CASE COVER AND CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.10 – CONTROL BOX ASSEMBLY REMOVAL CONTROL BOX ASSEMBLY CASE COVER REPLACEMENT PROCEDURE 1. Slide control box assembly back into case cover. See Figure F.10. 2.
  • Page 78 NOTES F-28 F-28 LN-25™ PRO DUAL POWER...

  • Page 79: Wire Drive Motor And Gear Box Removal And Replacement

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 80 TROUBLESHOOTING AND REPAIR F-30 F-30 WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.11 – BUSS BAR AND GAS HOSE REMOVAL PLASTIC DRIVE WIRE DRIVE GEAR COVER CONTROL BOX PANEL SCREWS COVER SCREWS PHILLIPS SCREW GAS HOSE BUS BAR CONTROL BOX WIRE DRIVE...
  • Page 81 TROUBLESHOOTING AND REPAIR F-31 F-31 WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.12 – WIRE DRIVE PANEL REMOVAL CONTROL BOX ASSEMBLY DRIVE GEAR 7/16” NUT WIRE DRIVE PANEL ASSEMBLY DRIVE GEAR MOUNTING SCREW PLASTIC DRIVE GEAR COVER REPLACEMENT PROCEDURE 1.
  • Page 82 NOTES F-32 F-32 LN-25™ PRO DUAL POWER...
  • Page 83 FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 84 TROUBLESHOOTING AND REPAIR F-34 F-34 FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – FRONT PANEL PHILLIPS HEAD PHILLIPS HEAD SCREW SCREW 5/16” NUT REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove the input power from the LN-25™ PRO 1. Connect the work lead that was previously DUAL POWER unit.
  • Page 85 CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 86 TROUBLESHOOTING AND REPAIR F-36 F-36 CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.14 – CONTROL BOX CONTROL BOX ASSEMBLY MOUNTING BLOCK BUS BAR CONNECTORS CONTACTOR PROCEDURE REPLACEMENT PROCEDURE 1. Remove the power from the LN-25™ PRO 1. Loosely connect the buss bars to the new con- DUAL POWER unit.
  • Page 87 PC BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 88 TROUBLESHOOTING AND REPAIR F-38 F-38 PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.15 – CONTROL PC BOARD LOCATION CONTROL BOX CONTROL BOARD CONTROL BOX COVER REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove the input power from the LN-25™ PRO 1. Remove the new control board from the static DUAL POWER unit.
  • Page 89 GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 90 TROUBLESHOOTING AND REPAIR F-40 F-40 GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – SOLENOID NUT AND HOSE GAS SOLENOID GAS HOSE CONTROL BOX ASSEMBLY LOCK NUT CONTROL BOX COVER CONTROL BOX COVER SCREWS PROCEDURE 1. Remove the input power from the LN-25™ PRO 7.
  • Page 91 TROUBLESHOOTING AND REPAIR F-41 F-41 RETEST AFTER REPAIR Retest a machine : • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components. SET UP 1.
  • Page 92 NOTES F-42 F-42 LN-25™ PRO DUAL POWER...
  • Page 93 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - Complete Machine - (G6334) .
  • Page 94 ElEcTrical DiaGramS WiriNG DiaGram - cOmplETE machiNE - (G6334) WIRING DIAGRAM- LN-25 PRO DUAL POWER MOTOR FILTER P.C. BOARD N.C. 1 2 3 4 TRIGGER 509D 509D INTERLOCK / 667D B1 PRESET P.C. BOARD 509E 509C 2 STEP CC / CV...
  • Page 95 ENGINEERING CONTROLLED CHANGE DETAIL: MISC. UPDATES PER SERVICE DEPARTMENT REQUEST AND ADDED BYPASS CAPACITOR ASSEMBLY Start-Up LN-25 PRO DUAL POWER MANUFACTURER: P7 = 16 PIN When tach feed back is lost, the voltage On power-up, the LN-25 PRO will light all LED's and displays to the motor is a constant 10VDC.
  • Page 96 MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: LN-25 PRO DUAL POWER UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) NONE ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm)
  • Page 97 ElEcTrical DiaGramS SchEmaTic - cONTrOl pc bOarD - (G4783) pG1 +15V_ISO +15V TACHOMETER 9 J4 1A/FR 4.75K 0.2A 400V 0.063W 0.063W 0.063W X7-8 Q5-G R110 600V TACH TACH_IN R230-R231 BLUE PSOC PWM_MOTR HC132 HC132 HC132 DZ14 100pF 100V 0.1uF 82uF 3.32K 0.5W 0.115A...
  • Page 98 ElEcTrical DiaGramS SchEmaTic - cONTrOl pc bOarD - (G4783) pG2 IM_PEAK CUR_SENSE IM_PEAK P0[0] P4[0] CUR_SENSE CC_SENSE GAS_PURGE CC_SENSE P0[1] P4[1] GAS_PURGE IM_AVE TRIG_INLK_2_STEP IM_AVE P0[2] P4[2] TRIG_INLK_2_STEP 35V_SENSE CV_CC 35V_SENSE P0[3] P4[3] CV_CC 13V_SENSE COLD_FEED 13V_SENSE P0[4] P4[4] COLD_FEED WFS_POT WFS_POT P0[5]...
  • Page 99 ElEcTrical DiaGramS SchEmaTic - cONTrOl pc bOarD - (G4783) pG3 RS232_RX RS232_RX MAX3221 0.1uF ROUT RS232_TX RS232_TX DOUT INVALID FORCEON 0.1uF FORCEOFF 3.32K 0.1W 0.1uF 0.1uF LAST NO. USED GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 SEE PAGE 1 .022/50V CAPACITORS = UNLESS OTHERWISE SPECIFIED) RESISTORS = Ohms ( 1/4W...
  • Page 100 ElEcTrical DiaGramS SchEmaTic - cONTrOl pc bOarD - (G4783) pG4 +15V 0.2A -15V 3 0.2A ELECTRODE R180 R175 R176 R177 221K 221K 221K 221K 0.2A POLARITY_SENSE R184 2.21K R182 221K 0.1uF 33074ADT 3.32K WORK R174 R173 R179 R178 221K 221K 221K 221K R170...
  • Page 101 ElEcTrical DiaGramS SchEmaTic - cONTrOl pc bOarD - (G4783) pG5 600V 15VDC_SUPPLY 15VDC_SUPPLY 78M15 82uF 220uF 600V 5VSPI_SUPPLY 5VSPI_SUPPLY 58P6091 10uH 1.02A T1-9 600V 220uF 0.0033uF 630V 600V 0.001F 33.2 400V R130 600V DZ16 600V 22.1K 0.063W 0.5W 600V 82uF 0.1uF R128 2.21K 0.063W...
  • Page 102 G-10 G-10 ElEcTrical DiaGramS SchEmaTic - mOTOr filTEr pc bOarD - (S27505-1) 1600V 1 J61 470uH 11.4A 470uF 470uF 350V 350V 2 J61 LAST NO. USED GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 .022/50V CAPACITORS = UNLESS OTHERWISE SPECIFIED) 1/4W LABELS RESISTORS = Ohms ( UNLESS OTHERWISE SPECIFIED) 1A,400V...
  • Page 103 G-11 G-11 ElEcTrical DiaGramS SchEmaTic - prESET pc bOarD - (G4748) pG1 CURRENT READING +15V ARC VOLTAGE FEEDBACK 0.1W 39.2K 0.1W 0.2A 150K Current 0.1W ELECTRODE Transducer ARC_I_POS 0.1uF 0.2A 39.2K ARC_V_POS -15V ARC_V_POS 0.1uF 0.1W 33074ADT AD620R 33074ADT 4.75K 2.21K 33074ADT 4.75K...
  • Page 104 G-12 G-12 ElEcTrical DiaGramS SchEmaTic - prESET pc bOarD - (G4748) pG2 BLOCK K DISPLAYS 33.2 DIGIT1 PG. 1 DATA0 DISP2 PG. 1 33.2 33.2 V_CC DIGIT1 DIGIT2 DETECT 42V SOURCE PG. 1 DATA1 DIGIT2 PG. 1 33.2 DIGIT3 33.2 DATA0 DIGIT1 DIGIT3...

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