Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. I n s t a l l e q u i p m e n t i n a c c o r d a n c e w i t h t h e U . S . N a t i o n a l E l e c t r i c a l C o d e , a l l l o c a l c o d e s a n d t ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; QUALITY; Read this Operators Manual completely; Please Examine Carton and Equipment For Damage Immediately
LN-25 Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Companyproduct ••• as much pride as we have in bringing this productto you! Read this Operators Manual completely before attempting to use this equipment. Save this manua...
Page 7 - TABLE OF CONTENTS
LN-25 SAFETY ...............................................................................................................................................i-iv INSTALLATION .......................................................................................................................SECTION...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – LN-25
TEMPERATURE RANGE OPERATION: - 40 o C to +40 o C (- 40 o F to +104 o F) STORAGE: - 40 o C to +85 o C (- 40 o F to +185 o F) LN-25 A-1 OPERATING ARC VOLTAGE Constant Voltage (CV) or 15-40 VDC (110VDC Maximum OCV) Constant Current (CC) RATED CURRENT Rated current without contactor 500 Amps 60% Duty Cy...
Page 9 - SAFETY PRECAUTIONS
LN-25 A-2 INSTALLATION ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off at thefuse box before working in theterminal strip. • Only quali...
Page 10 - FOR GMA GUN AND CABLES:
LN-25 A-3 c. Set ELECTRODE POLARITY switch to constant voltage polarity required by electrode. d. Set toggle switch to “Constant Voltage” and set the Constant Voltage Control on welder and theportable field control on #5 for initial start. SA-200, —250 OR SAE-300, —400 (WITHCV ADAPTER) a . F o r e l...
Page 11 - WELD CABLE CONNECTION; ELECTRODE CABLE CONNECTION
LN-25 A-4 INSTALLATION Install the barbed fitting and union nut to the 5 ⁄ 8 -18 female inert gas fitting on the front panel of theLN-25 case. Connect the 3 ⁄ 16 ” I.D. gas hose from the gun cable to the barbed fitting. When the gun is to be removed, this fitting can beeasily detached by loosening t...
Page 12 - OPERATION
LN-25 B-1 ELECTRIC SHOCK can kill. • Do not touch electrically live part or electrode with skin orwet clothing. • I n s u l a t e y o u r s e l f f r o m w o r k and ground. • A l w a y s w e a r d r y i n s u l a t i n g gloves. ARC RAYS can burn. • Wear eye, ear and body pro- tection. FUMES AND GA...
Page 13 - VOLTMETER; “ELECTRODE POLARITY” SWITCH; FIGURE B.1 CONTROL LOCATIONS
LN-25 B-2 OPERATION VOLTMETER (Factory installed on model Codes above 9218) The 40V DC analog voltmeter is mounted to the frontcontrol panel of the LN-25 and is connected to readthe arc voltage between the LN-25 electrode cableconnection and the work clip lead. NOTE: 1. The Voltmeter will read zero ...
Page 14 - not; AWG
LN-25 B-3 wire speed is set to 400 in/min., a welding procedurearc voltage of at least 17V would be required toobtain the 400 in/min. wire feed speed. WORK CLIP LEAD IMPORTANT SAFETY NOTE: To avoid possible electrical shock, do not touch the metal portions of the LN-25 work lead clip if the power so...
Page 15 - MOUNTING 10 TO 30 LB SPOOLS; LOADING ELECTRODE; MOUNTING 22 TO 30 LB READI-REEL; SEQUENCE OF OPERATION
LN-25 B-4 OPERATION g. To remove Readi-Reel from Adapter, depress re- taining spring tab with thumb while pulling theReadi-Reel cage from the molded adapter withb o t h h a n d s . I t i s n o t n e c e s s a r y t o r e m o v eadapter from spindle. h. Load wire into wire drive per Loading Wire Driv...
Page 16 - LOADING WIRE DRIVE; just; IDLE ROLL PRESSURE SETTING
LN-25 B-5 LOADING WIRE DRIVE a. Turn the reel or spool until the free end of the electrode is accessible. b. While tightly holding the electrode, cut off the bent end and straighten the first six inches. Cutoff the first inch. (If the electrode is not properlystraightened, it may not feed or may not...
Page 17 - PRESETTING WIRE FEED SPEED; Maximum Speed
LN-25 B-6 OPERATION 3. If the only result is drive roll slippage, shut off t h e p o w e r s o u r c e , t h e n l o o s e n t h e g u n c a b l eclamping screw in the gearbox conductor blockand pull the gun cable forward about six inches.T h e r e s h o u l d b e a s l i g h t w a v i n e s s i n t...
Page 18 - MAKING A WELD; without
LN-25 B-7 Arc Volts Used Desired In/Min 16 18 20 22 24 26 28 30 32 34 50 109 97 88 80 73 67 63 58 55 51 60 131 117 105 95 88 81 75 70 66 62 70 153 136 123 111 102 94 88 82 77 72 80 175 156 140 127 117 108 100 93 88 82 90 197 175 158 143 131 121 113 105 98 93 100 219 194 175 159 146 135 125 117 109 1...
Page 19 - Cut; WELDING
LN-25 B-8 ARC RAYS can burn. • D o n o t t o u c h m e t a l p o r - t i o n s o f t h e L N - 2 5 l e a dClip when welding powersource is on. OPERATION C Y L I N D E R m a y e x p l o d e i fdamaged. • K e e p c y l i n d e r u p r i g h t a n d chained to support. • K e e p c y l i n d e r a w a y...
Page 20 - However; CAUTION; OVERVOLTAGE SHUTDOWN
LN-25 B-9 OPERATION Do not use LN-25 models below Code 9200 withany TIG or Square Wave welding power sources.Do not use LN-25 models equipped with internalcontactors with non-Lincoln TIG or Square Wavewelding power sources. Damage to the LN-25 circuitcan occur as a result of the high output inductan...
Page 21 - ACCESSORIES
LN-25 C-1 LN-25 OPTION CHART O = CANNOT BE USED WITH X = REQUIRED ➀ = REQUIRES ONE OF THESE + = INCLUDED WITH Solenoid K430-1 Kit X + + Remote Output K431-1 Control Module ➀ ➀ O X X O O O O O O Remote K432 Control Cable X X 115VAC K433 Power Source X X Remote Box Gas Flow K434-1 Timer Kit ➀ ➀ ➀ ➀ ➀ ...
Page 22 - OPTIONAL ACCESSORIES; With
LN-25 C-2 OPTIONAL ACCESSORIES ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off atthe fuse box before workingin the terminal strip. • O ...
Page 23 - K460-1 PULSE POWER ADAPTER KIT; K431-1 REMOTE OUTPUT CONTROL KIT
LN-25 C-3 Installation instructions (M17590) are included withthis kit. K460-1 PULSE POWER ADAPTER KIT (For use with K461 Pulse Power Control Cable.) This kit enables the LN-25 to pulse weld with a PulsePower 500 power source above Code 9300 (or lowerCodes updated with S18506 Kit). The kit includes ...
Page 26 - FIGURE C.2 SWITCH REQUIREMENTS
LN-25 C-6 ACCESSORIES “A Dia. Hole” To be Concentric to .749/.747 Wire Size Dia. Within .008 F.I.M. .068 thru 5 ⁄ 64 .125 ( 1 ⁄ 8 Drill) 1 ⁄ 16 (.062) .078 ( 5 ⁄ 64 Drill) .045 & .052 .062 ( 1 ⁄ 16 Drill) .023 thru .035 .055 (#54 Drill) Drive Roll & Guide Tube Wire Sizes Used Kit No. T-13355...
Page 27 - Do not; MAINTENANCE
LN-25 D-1 ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off atthe fuse box before workingin the terminal strip. • O n l y q u a l i f i e...
Page 29 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING; LOCAL AUTHORIZED LINCOLN E L E C T R I C F I E L D S E R V I C E F A C I L I T Y
LN-25 E-1 HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician and machine operator and will invalidate yourfactory warranty. For your safety ...
Page 30 - FEEDING PROBLEMS
LN-25 E-2 TROUBLESHOOTING PROBLEMS(SYMPTOMS) No wire feed when gun trigger ispulled POSSIBLE AREAS OFMISADJUSTMENT(S) 1. P o w e r s o u r c e m u s t b e o na n d o p e n c i r c u i t v o l t a g e( O C V ) p r e s e n t a t w e l dterminals. 2. LN-25 work clip may not beconnected. 3. LN-25 polari...
Page 32 - OUTPUT PROBLEMS
LN-25 E-4 TROUBLESHOOTING Solenoid does not close whentrigger is pulled or purge buttonis pressed. Wire feeds properly. 1. Make certain that plugs J2and J3 are connected to thecontrol board securely. RECOMMENDEDCOURSE OF ACTION OUTPUT PROBLEMS WELD PROBLEMS POSSIBLE AREAS OFMISADJUSTMENT(S) PROBLEMS...
Page 33 - WIRING DIAGRAM
LN-25 F-1 WIRING DIAGRAM !" " "" # $ $ ! $ $ ! %% "! % " & % % ' " !! & $ # $ $ # $ !" " ' " % # # $ (($ $ # # $ % ' % " % !"()" * !&++' %!! '! ""!! " !!"!!! ! !!"! !"! %% %',! ! ! !! " !" # # # " % &...
Page 34 - LN-25 PHYSICAL DIMENSIONS; DIMENSIONS
LN-25 F-2 LN-25 PHYSICAL DIMENSIONS 16.60 14.00 21.00 7.40 .25 DIMENSIONS 4/96
