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IM901-A
January, 2010
LN-25™ PRO
For use with machines having Code Number: 11387, 11388, 11507, 11508
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful opera-
tion 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.
IP23
IECꢀ60974-5
OPERATOR’SꢀMANUAL
Copyright © Lincoln Global Inc.
• 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 WEBꢀSITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
process used and properly operating
regulators designed for the gas and
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
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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 l’on pique le laitier.
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:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEbꢀSITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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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
Gun Connections..................................................................................................................A-5
Power Source to LN-25™ Pro Cable Connection Diagrams..................................A-6 thru A-8
________________________________________________________________________________
Operation.........................................................................................................................Section b
Safety Precautions ...............................................................................................................B-1
Graphic Symbols that appear on this Machine or in this Manual .........................................B-1
Definition of Welding Terms .................................................................................................B-2
General Description..............................................................................................................B-2
Recommended Processes, Equipment Limitations, Recommended Power Sources..........B-2
Case Front Controls ...............................................................................................B-3 thru B-5
Internal Controls...................................................................................................................B-6
Internal Controls Decription..................................................................................................B-7
Constant Current Wire Welding............................................................................................B-8
Rear Controls .......................................................................................................................B-9
Gas Purge Pushbutton.......................................................................................................B-10
Flow Meter..........................................................................................................................B-10
Power-Up Sequence ..........................................................................................................B-10
________________________________________________________________________________
Accessories ....................................................................................................................Section C
Factory Installed Equipment.................................................................................................C-1
Drive Roll Kits used..............................................................................................................C-1
Accessories Used ..................................................................................................C-2 thru C-5
Installation of Water Cooling Kit...........................................................................................C-6
________________________________________________________________________________
Maintenance....................................................................................................................Section D
Safety Precautions...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Calibration Specification................................................................................................D-1,D-2
________________________________________________________________________________
Troubleshooting .............................................................................................................Section E
How to Use Troubleshooting Guide .....................................................................................E-1
Digital Display Models Error Codes......................................................................................E-2
Troubleshooting Guide .................................................................................................E-3, E-4
________________________________________________________________________________
Wiring Diagram & Dimension Prints .............................................................................Section F
________________________________________________________________________________
Parts Pages ................................................................................................................P-557 Series
_______________________________________________________________________________
A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – LN-25™ PRO ACROSS THE ARC MODEL
(K2613-1, K2613-2)
INPUT VOLTAGE and CURRENT
INPUT VOLTAGE ± 10%
INPUT AMPERES
4A
15-110 VDC
RATED OUTPUT @ 104°F (40°C)
DUTY CYCLE
INPUT AMPERES
60% rating
450
325
100% rating
GEARING - WIRE FEED SPEED RANGE-WIRE SIzE
GMAW
FCAW
GEARING
WIRE SIzES
WFS RANGE
WFS RANGE
WIRE SIzES
Extra torque
K2613-2
.023 – 1/16"
(0.6 – 1.6mm)
30 – 400 ipm
(0.8 – 10.1m/min)
30 – 400 ipm
(0.8 – 10.1m/min)
.030 - 3/32”
(10.3 – 2.4mm)
Standard Speed
K2613-1
.023 – 1/16"
(0.6 – 1.6mm)
50 – 700 ipm
(1.3 – 17.7m/min)
50 – 700 ipm
(1.3 – 17.7m/min)
.030 - 5/64
(0.8 - 2.0mm)
PHYSICAL DIMENSIONS
WIDTH
HEIGHT
DEPTH
WEIGHT
14.8 Inches
(376 mm)
Handle folded down
8.7 Inches
( 221 mm)
22.2 Inches
(589 mm)
36 lbs
(16 kg)
TEMPERATURE RANGE
OPERATION:
STORAGE:
-40°F to 104°F (-40°C to 40°C)
-40°F to 185°F (-40°C to 85°C)
LN-25™ PRO ACROSS THE ARC MODEL
A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
The handle of the LN-25™ PRO is intended for
moving the wire feeder about the work place only.
WARNING
When suspending a wire feeder, insulate the
hanging device from the wire feeder enclosure.
ELECTRICꢀSHOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box
HIGH FREQUENCY PROTECTION
before attempting to connect or
disconnect input power lines, out-
put cables or control cables.
• Only qualified personnel should
perform this installation.
CAUTION
Locate the LN-25™ PRO away from radio controlled
machinery. The normal operation of the LN-25™
PRO may adversely affect the operation of RF con-
trolled equipment, which may result in bodily injury
or damage to the equipment.
• Do not touch metal portions of the work clip
when the welding power source is on.
• Do not attach the work clip to the wire feeder.
• Connect the work clip directly to the work, as
close as possible to the welding arc.
• Turn power off at the welding power source
before disconnecting the work clip from the
work.
----------------------------------------------------------------------------
• Only use on power sources with open circuit
voltages less than 110 VDC.
WELD CAbLE SIzE
------------------------------------------------------------------------
LOCATION
Table A.1 located below are copper cable sizes rec-
ommended for different currents and duty cycles.
Lengths stipulated are the distance from the welder to
work and back to the welder again. Cable sizes are
increased for greater lengths primarily for the purpose
of minimizing cable drop.
For best wire feeding performance, place the LN-
25™ PRO on a stable and dry surface. Keep the
wire feeder in a vertical position. Do not operate the
wire feeder on an angled surface of more than 15
degrees.
Do not submerge the LN-25™ PRO.
The LN-25™ PRO is rated IP23 and is suitable for
outdoor use.
TAbLE A.1
RECOMMENDED CAbLE SIzES (RUbbER COVERED COPPER - RATED 167°F or 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES PERCENT
DUTY
CYCLE
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
2
2
3
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
2
2
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
200
200
225
225
250
250
250
250
300
325
350
400
400
500
60
100
20
40 & 30
30
40
60
100
60
100
60
60
100
60
2
2
1
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
** 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 ACROSS THE ARC MODEL
A-3
A-3
INSTALLATION
SHIELDING GAS CONNECTION
CAbLE CONNECTIONS
WARNING
There is one circular connector for the gun trigger on
the front of the LN-25™ PRO.
CYLINDER may explode if
damaged.
• Keep cylinder upright and
chained to support.
Function
Wiring
Pin
• Keep cylinder away from areas where it may be
damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live
electrical circuits.
5-pin trigger
connector for
push-guns
only.
Trigger
Not used
Common
Not used
Not used
A
B
C
D
E
• bUILD UP OF SHIELDING GAS MAY
HARM HEALTH OR KILL.
• Shut off shielding gas supply when not
in use.
• See American National Standard z-49.1, "Safety
in Welding and Cutting” Published by the
American Welding Society.
C
B
----------------------------------------------------------------------------
Maximum inlet pressure is 100 psi. (6.9 bar.)
E
A
D
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
2. Remove the cylinder cap. Inspect the cylinder valves
and regulator for damaged threads, dirt, dust, oil or
grease. Remove dust and dirt with a clean cloth. DO
NOT ATTACH THE REGULATOR IF OIL, GREASE
OR DAMAGE IS PRESENT! Inform your gas supplier
of this condition. Oil or grease in the presence of high
pressure oxygen is explosive.
3. Stand to one side away from the outlet and open the
cylinder valve for an instant. This blows away any dust
or dirt which may have accumulated in the valve out-
let.
4. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench. Note:
if connecting to 100% CO cylinder, insert regulator
2
adapter between regulator and cylinder valve. If
adapter is equipped with a plastic washer, be sure it is
seated for connection to the CO cylinder.
2
5. Attach one end of the inlet hose to the outlet fitting of
the flow regulator. Attach the other end to the welding
system shielding gas inlet. Tighten the union nuts with
a wrench.
6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.
7. Standing to one side, open the cylinder valve slowly a
fraction of a turn. 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 ACROSS THE ARC MODEL
A-4
A-4
INSTALLATION
WIRE DRIVE CONFIGURATION
(See Figure A.2)
8. Connect the shielding gas hose to the new gun
bushing, if required.
9. Rotate the gun bushing until the thumb screw hole
aligns with the thumb screw hole in the feed plate.
Slide the gun receiver bushing into the wire drive
and verify the thumb screw holes are aligned.
10. Tighten the socket head cap screw.
CHANGING THE GUN RECEIVER
bUSHING
WARNING
11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
----------------------------------------------------------------------------
Tools required:
• 1/4" hex key wrench.
WARNING
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
Note: Some gun bushings do not require the use of
the thumb screw.
• Only qualified personnel should perform mainte-
nance work.
1. Turn power off at the welding power source.
2. Remove the welding wire from the wire drive.
3. Remove the thumb screw from the wire drive.
4. Remove the welding gun from the wire drive.
5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.
Important: Do not attempt to completely
remove the socket head cap screw.
6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the pre-
cision fit, light tapping may be required to remove
the gun bushing.
------------------------------------------------------------------------
1. Turn power off at the welding power source.
2. Release the idle roll pressure arm.
3. Remove the outer wire guide by turning the knurled
thumbscrews counter-clockwise to unscrew them
from the feed plate.
4. Rotate the triangular lock and remove the drive
rolls.
7. Disconnect the shielding gas hose from the gun
bushing, if required.
FIGURE A.2
THUMB SCREW
GUN RECEIVER BUSHING
5. Remove the inner wire guide.
OUTER WIRE GUIDE
6. Insert the new inner wire guide, groove side out,
over the two locating pins in the feed plate.
7. Install a drive roll on each hub assembly secure
with the triangular lock.
8. Install the outer wire guide by aligning it with the
pins and tightening the knurled thumbscrews.
9. Close the idle arm and engage the idle roll pressure
arm. Adjust the pressure appropriately.
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN
TIGHTEN
LN-25™ PRO ACROSS THE ARC MODEL
A-5
A-5
INSTALLATION
1. Squeeze the release bar on the retaining collar and
remove it from the spindle.
PRESSURE ARM ADJUSTMENT
WARNING
2. Place the spindle adapter on the spindle, aligning
the spindle brake pin with the hole in the adapter.
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the weld-
ing power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
3. Place the spool on the spindle and align the
adapter brake tab with one of the holes in the back
side of the spool. An indicator mark on the end of
the spindle shows the orientation of the brake tab.
Be certain the wire feeds off of the spool in the
proper direction.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
----------------------------------------------------------------------------
The pressure arm controls the amount of force the
drive rolls exert on the wire. Proper adjustment of the
pressure arm gives the best welding performance.
4. Re-install the retaining collar. Make sure that the
release bar snaps out and that the retaining collar
fully engages the groove on the spindle.
GUN CONNECTION
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the weld-
ing power source before installation or
changing drive rolls and/or guides.
Set the pressure arm as follows:
(See Figure A.3)
Aluminum wires
Cored wires
Steel, Stainless wires between 4 and 6
between 1 and 3
between 3 and 4
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
FIGURE A.3
• Only qualified personnel should perform mainte-
nance work.
----------------------------------------------------------------------------
The LN-25™ PRO ACROSS THE ARC MODEL
comes with a K1500-2 gun adapter installed. (See
Figure A.4)
ALUMINUM WIRES
Al
Fe, CrNi
CORED WIRES
Fe, CrNi
STEEL, STAINLESS WIRES
6
To install a gun,
1. Turn power OFF.
2. Remove the thumb screw.
3. Push the gun the completely into the gun bushing.
4. Secure the gun in place with the thumb screw.
5. Connect the trigger cable from the gun to the trigger
connector on the front of the feeder.
LOADING SPOOLS OF WIRE
WARNING
• Keep hands, hair, clothing and tools
away from rotating equipment.
• Do not wear gloves when threading wire
or changing wire spool.
Note: Not all gun bushings require the use of the
thumb screw.
• Only qualified personnel should install,
use or service this equipment.
FIGURE A.4
------------------------------------------------------------------------
Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.
THUMB
SCREW
GUN
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 ACROSS THE ARC MODEL
A-6
A-6
INSTALLATION
POWER SOURCE TO LN-25™ PRO
CAbLE CONNECTION DIAGRAMS
ACROSS THE ARC SET-UPS
CC Power Sources with Output Terminals Always
Hot (See Figure A.5)
CC Power Source
Ranger 250, 250 LPG
Ranger 305G, 305D
Commander 300
FIGURE A.5
Vantage 300, 400, 500
Air Vantage 500
O
PR
-25™
LN
Electrode
Ranger10,000
(Across the Arc)
Ranger3 phase
SAE 400 with CV adapter
Work clip
Engine Driven welder with
Work
Wire Feed Module
K#
Description
LN-25™ PRO
LN-25™ PRO Extra Torque
If the power source has a Remote/Local switch, place
the switch in the Local position.
K2613-1
K2613-2
KP1695-XX
Place the CV/CC switch in the feeder in the "CC" posi-
tion.
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CC power Source
Welding Cables
K1803-1
CV Power Sources with Stud Connectors and
Remote/Local Switch (See Figure A.6)
FIGURE A.6
CV-655
LN-25™ PRO
(Across the Arc)
Electrode
Work
DC-400
DC-600
DC-655
V450-Pro
Work clip
K#
Description
K2613-1
K2613-2
KP1695-XX
LN-25™ PRO
LN-25™ PRO Extra Torque
Place the power source Remote/Local switch in the
Local position.
KP1696-XX
KP1697-XX
See magnum Literature
Drive Roll Kit
Place CV/CC switch in the feeder in the "CV" position.
Welding Gun
CV power Source
Welding Cables
K1803-1
LN-25™ PRO ACROSS THE ARC MODEL
A-7
A-7
INSTALLATION
CV Power Sources with Stud Connectors and no
Remote/Local Switch. (See Figure A.7)
FIGURE A.7
Jumper
CV-400
CV-655
LN-25™ PR0
(Across The Arc)
Electrode
Work clip
Work
K#
Description
LN-25™ PRO
LN-25™ PRO Extra Torque
Jumper Plug Kit
Place CV/CC switch in the feeder in the "CV" position.
K2613-1
K2613-2
KP484
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CC power Source
Welding Cables
K1803-1
CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.8)
FIGURE A.8
LN-25™ PRO
(Across the Arc)
Electrode
V350-Pro
Work clip
Work
K#
Description
Place CV/CC switch in the feeder in the "CV" position.
K2613-1
K2613-2
KP1695-XX
LN-25™ PRO
LN-25™ PRO Extra Torque
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CC power Source
Welding Cables
K1841
LN-25™ PRO ACROSS THE ARC MODEL
A-8
A-8
INSTALLATION
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.9)
FIGURE A.9
Jumper
CV-250
CV-300
CV-305
LN-25™ PRO
Electrode
Work clip
Work
K#
Description
LN-25™ PRO
LN-25™ PRO Extra Torque
Place CV/CC switch in the feeder in the "CV" position.
K2613-1
K2613-2
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CV power Source
Welding Cables
Jumper Plug kit
K1841-
K484
LN-25™ PRO ACROSS THE ARC MODEL
b-1
b-1
OPERATION
GRAPHIC SYMbOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
bEFORE OPERATING MACHINE.
INPUT POWER
ON
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
remain energized several sec-
onds after the welding ceases..
• Do not touch electrically live part or electrode
with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards
removed or open.
-------------------------------------------------------------------------
• FUMES AND GASSES can be
dangerous.
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
INPUT POWER
-------------------------------------------------------------------------
• WELDING SPARKS can cause
fire or explosion.
DIRECT CURRENT
• Keep flammable material away.
OPEN CIRCUIT
VOLTAGE
U
0
-------------------------------------------------------------------------
ARCꢀRAYS can burn.
• Wear eye, ear and body protec-
tion.
U
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
1
2
-------------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MAN-
UAL.
U
-------------------------------------------------------------------------
I
1
I
OUTPUT CURRENT
2
PROTECTIVE
GROUND
WARNING OR
CAUTION
LN-25™ PRO ACROSS THE ARC MODEL
b-2
b-2
OPERATION
General Functional Description
DEFINITION OF WELDING TERMS
The LN-25™ PRO as designed is a simple, robust
feeder. Standard features include a calibrated wire
feed speed dial, 2 step/trigger interlock switch, CV-CC
switch, Gas Purge and Cold Feed.
WFS
• Wire Feed Speed
CC
• Constant Current
RECOMMENDED PROCESSES
• GMAW
• FCAW
CV
• Constant Voltage
GMAW
• Gas Metal Arc welding
PROCESS LIMITATIONS
• GMAW-P procedures must be qualified by the cus-
tomer.
• Across-the-Arc models are not recommended for
stitch or spot welding.
SMAW
• Shielded Metal Arc welding
FCAW
• Flux Core Arc Welding
EQUIPMENT LIMITATIONS
• The duty cycle of the wire feeder is 325A, 100% and
450A, 60%. Duty cycle is based upon the amount of
welding performed in a 10 minute period.
• The maximum spool size is 45 lb, 12" diameter.
• Maximum FCAW gun length is 15 ft.
• Maximum GMAW gun length is 25 ft.
GENERAL DESCRIPTION
General Physical Description
The LN-25™ PRO is specially engineered to be the
most rugged portable wire feeder available.
• Push-pull guns do not work with the wire feeder.
• When using the digital meter kit, preset voltage is
accurate only with the following power sources:
Several models of the LN-25™ PRO are offered to
best meet individual welder needs. The Extra Torque
model features additional torque gearing for reliable
feeding of large diameter FCAW wires. All of the mod-
els include a gas solenoid and flow meter for the flexi-
bility to run most wire processes.
Invertec V-350
Invertec V-450
DC-400
CV-305
CV-400
DC-600
DC-655
The plastic case is molded from a high impact, flame
retardant plastic for durability and low weight. The
patent pending design keeps the internal components
protected and dry.
RECOMMENDED POWER SOURCES
• CV-250
• CV-300
• CV-305
• CV-400
• CV-655
• DC-400
• Ranger 3 Phase
• Ranger GXT
• Ranger 250
• Ranger 305
• SAE-400
• Pipeliner 200G
• Classic 300
• Vantage 300
• Vantage 400
• Vantage 500
• Air Vantage 500
The heart of the LN-25™ PRO is the 2 roll MAX-
TRAC™ drive. The patented features on the wire
drive offer tool-less changing of the drive rolls and
wire guides for quick spool changes. A tachometer
controlled motor powers the patent pending drive rolls
for smooth, steady feeding without slippage.
• DC-600
• DC-655
• Invertec V-350 PRO
• Invertec V-450 PRO
• Multi-Weld 350
• Ranger 10,000
With only one p.c. board, the LN-25™ PRO is
designed to be simple, reliable and easy to service.
The p.c. board is mounted with Lincoln’s leading envi-
ronmental design protection by mounting the board in
a plastic tray and potting it with epoxy.
LN-25™ PRO ACROSS THE ARC MODEL
b-3
b-3
OPERATION
(See Customer Assistance Policy in the front of this
Instruction Manual)
CASE FRONT CONTROLS (See Figure b.1)
FIGURE b.1
1
5
6
2
3
4
ITEM
DESCRIPTION
1
2
3
4
5
6
Analog Voltmeter
Wire Feed Speed Knob
5-pin gun trigger connector
Work sense lead
Thermal LED, Motor Overload
Polarity LED
1. ANALOG VOLTMETER
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 ACROSS THE ARC MODEL
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