Red-D-Arc LN-25 PRO EXTREME Operator's Manual
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Red-D-Arc LN-25 PRO EXTREME Operator's Manual

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IM939-A
March, 2008
LN-25 PRO EXTREME
11389, 11523
For use with machines having Code Numbers:
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 LN-25 PRO EXTREME

  • Page 1 For use with machines having Code Numbers: 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: California Proposition 65 Warnings

    1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source. turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or Mar ʻ95 magneto wire as appropriate. LN-25 PRO EXTREME...

  • Page 3: Electric Shock Can Kill

    (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b. AUG 06 LN-25 PRO EXTREME...
  • Page 4 6.I. Read and folllow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available Jan, 07 from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101. 6.j. Do not use a welding power source for pipe thawing. LN-25 PRO EXTREME...
  • Page 5 épaisse, pan- er à lʼinterrupteur à la boite de fusibles. talons sans revers, et chaussures montantes. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. Mar. ʻ93 LN-25 PRO EXTREME...
  • Page 6 Thank You for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment.

  • Page 7: Table Of Contents

    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 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...

  • Page 8: Installation

    WEIGHT 14.8 Inches 8.7 Inches 22.2 Inches 36 lbs (376 mm) ( 221 mm) (589 mm) (16 kg) Handle folded down TEMPERATURE RANGE OPERATION: -40°F to 104°F (-40°C to 40°C) STORAGE: -40°F to 185°F (-40°C to 85°C) LN-25 PRO EXTREME...

  • Page 9: Safety Precautions

    (61 to 76m) CYCLE 4 or 5 40 & 30 ** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables larger than recommended, or cables rated higher than 167°F(75°C). LN-25 PRO EXTREME...

  • Page 10: Cable Connections

    When the cylinder pressure gage stops moving, open the valve fully. 8. The flow regulator is adjustable. Adjust it to the flow rate recommended for the procedure and process being used before making a weld. LN-25 PRO EXTREME...

  • Page 11: Wire Drive Configuration

    8. Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews. CONNECTOR BLOCK 9. Close the idle arm and engage the idle roll pressure arm. Adjust the pressure appropriately. SOCKET HEAD CAP SCREW LOOSEN TIGHTEN LN-25 PRO EXTREME...

  • Page 12: Pressure Arm Adjustment

    Loading 10 to 15 lb. (4.5 – 6.8kg) Spools. THUMB SCREW A K468 spindle adapter is required for loading 2" (51mm) wide spools on 2" (51mm) spindles. Use a K468 spindle adapter for loading 2-1/2" (64mm) wide spools. LN-25 PRO EXTREME...

  • Page 13: Power Source To Ln25 Pro Extreme Cable Connection Diagrams

    Place the power source Remote/Local switch in the K2613-3 LN25 PRO EXTREME Local position. KP1695-XX KP1696-XX Drive Roll Kit Place CV/CC switch in the feeder in the "CV" position. KP1697-XX See magnum Literature Welding Gun CV power Source K1803-1 Welding Cables LN-25 PRO EXTREME...
  • Page 14 Remote/Local Switch. (See Figure A.8) FIGURE A.8 Description Place CV/CC switch in the feeder in the "CV" position. K2613-3 LN25 PRO EXTREME KP1695-XX KP1696-XX Drive Roll Kit KP1697-XX See Magnum Literature Welding Gun CC power Source K1841 Welding Cables LN-25 PRO EXTREME...
  • Page 15 FIGURE A.9 Place CV/CC switch in the feeder in the "CV" position. Description LN25 PRO EXTREME K2613-3 KP1695-XX KP1696-XX Drive Roll Kit KP1697-XX See Magnum Literature Welding Gun CV power Source K1841 Welding Cables K484 Jumper Plug kit LN-25 PRO EXTREME...

  • Page 16: Operation

    • Wear eye, ear and body protec- tion. INPUT VOLTAGE --------------------------------------------------------------------- SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS OUTPUT VOLTAGE AND IN THE FRONT OF THIS OPERATING MAN- UAL. ---------------------------------------------------------------------- INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION LN-25 PRO EXTREME...

  • Page 17: Definition Of Welding Terms

    General Functional Description The LN25 PRO EXTREME as designed is a simple, robust feeder. Standard features include a calibrated wire feed speed dial, CV-CC switch, Gas Purge and Cold Feed. LN-25 PRO EXTREME...

  • Page 18: Case Front Controls

    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. The voltmeter is polarity insensitive and the range is 0 – 40VDC. LN-25 PRO EXTREME...
  • Page 19 15 V 17 V CC WFS dial setting = desired WFS x 35 21 V Arc Volts 24 V (See Figure B.1a) 27 V FIGURE B.1a 100 150 200 250 300 350 400 450 500 550 650 700 LN-25 PRO EXTREME...
  • Page 20 Lincoln Electric. 6. POLARITY LED The Polarity LED lights when the wire + POLARITY feeder is connected POLARDAD for positive polarity. - POLARITÉ Use the polarity LED to verify the wire feeder is connected for the proper polarity. LN-25 PRO EXTREME...

  • Page 21: Internal Controls

    OPERATION INTERNAL CONTROLS FIGURE B.2 LN-25 PRO EXTREME...
  • Page 22 Adjust the speed of cold feed- ing by rotating the WFS knob. Cold feeding, or "cold inching" the electrode is useful for threading the electrode through the gun. LN-25 PRO EXTREME...

  • Page 23: Constant Current Wire Welding

    Lengthening the contact tip to work distance raises the voltage, short- ening the contact tip to work distance lowers the volt- age. FIGURE B-3 Current Wire Feeder CTWD Constant Current Power Source Current LN-25 PRO EXTREME...

  • Page 24: Rear Controls

    POWER-UP SEQUENCE For feeders with analog voltmeters, the thermal LED will briefly light during power-up. If the gun trigger is activated during power up, the feeder will not operate until the gun trigger is released. LN-25 PRO EXTREME...

  • Page 25: Accessories

    .068-.072" (1.7-1.8mm) KP1697-068 5/64" (2.0mm) KP1697-5/64 3/32” (2.4mm) KP1697-3/32 .035" (0.9 mm) KP1695-035A Includes: 2 polished Aluminum Wires: .040" (1.0mm) KP1695-040A U groove drive rolls, 3/64" (1.2mm) KP1695-3/64A outer wire guide and 1/16" (1.6mm) KP1695-1/16A inner wire guide. LN-25 PRO EXTREME...
  • Page 26 1/0 cable of length "xx". IIncludes: Lug to Lug, 3/0 Cable of length "xx" for lengths K1842-xx Weld Power Cable, Lug to Lug up to 60' (18.3m). Lug to Lug, 4/0 Cable of length "xx" for lengths greater than 60' (18.3m). LN-25 PRO EXTREME...
  • Page 27 #2-#4) Gun Receiver Bushing (for guns Includes: Gun receiver bush- K1500-3 with K613-7 Lincoln gun connec- ing with hose nipple, set screw tors; Magnum 550 guns and com- and hex key wrench. patible with Tweco® #5) LN-25 PRO EXTREME...
  • Page 28 (203mm) diameter spools on 2 in one for 2" wide spools and the (51 mm) spindles. other for 3" wide spools. Includes: Deluxe Gas Regulator K586-1 Deluxe Adjustable Gas Regulator for Mixed Gases, Adapter for CO2 and 10' (3.0m) Hose. LN-25 PRO EXTREME...

  • Page 29: Maintenance

    DC welding power source. The work lead of the LN25 PRO EXTREME must be connected to the work terminal of the power source. 3. Connect the reference voltmeter between the brass block of the LN25 PRO EXTREME and the work lead. LN-25 PRO EXTREME...
  • Page 30 6. Measure the motor rpm when the COLD FEED button is pressed. 9. Turn power OFF. 7. Verify the rpm is within the acceptable range. 10. Replace the cover and secure with the screws. FIGURE D.2 FIGURE D.1 COVER MOTOR SHAFT COVER P.C. BOARD LN-25 PRO EXTREME...

  • Page 31: Troubleshooting

    • Only qualified personnel should perform maintenance work. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. LN-25 PRO EXTREME...

  • Page 32: Digital Display Models Error Codes

    CAUTION 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. LN-25 PRO EXTREME...
  • Page 33 CAUTION 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. LN-25 PRO EXTREME...
  • Page 34 CAUTION 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. LN-25 PRO EXTREME...
  • Page 35 DIAGRAMS ENHANCED DIAGRAM 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 ● ● ● 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 41 ● ● ● 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 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...

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