SVM179-B
April, 2011
™
LN-25 PRO WIRE FEEDER
For use with machines having Code Numbers: 11387, 11388
11507, 11508
11620, 11621
11716, 11717
11746, 11747
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 operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT
WITHOUT
READING THIS MANUAL
AND THE SAFETY PRE-
CAUTIONS
CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
SERVICE MANUAL
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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ii
ii
SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
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.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.
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.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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
fumes and gases.When welding, keep
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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 ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
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 specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally 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.
LN-25™ PRO
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iii
iii
SAFETY
WELDING and CUTTING
SPARKS can cause fire or
explosion.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
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. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
regulators designed for the gas and
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 circuits. 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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
LN-25™ PRO
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iv
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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
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
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.
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 levage,
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.
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.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique 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 defonc-
tionnement.
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.
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.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
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.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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.
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 rayon-
nement 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.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
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.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
LN-25™ PRO
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I
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-557
LN-25™ PRO
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A-1
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Wire Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Procedure To Install Drive Rolls and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Loading Spools of Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Gun Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Power Source to LN-25™ PRO Cable Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7/A-8
MACHINES COVERED IN THIS MANUAL
PRODUCT
NUMBER
CODE
NUMBERS
PRODUCT NAME
LN-25™PRO
(NORMAL SPEED)
11387, 11507
11620, 11716
K2613-1
K2613-2
K2613-5
K2613-7
LN-25™PRO
(EXTRA TORQUE)
11388, 11508
11621, 11717
LN-25™PRO
(NORMAL SPEED)
11746
11747
LN-25™PRO
(EXTRA TORQUE)
LN-25™ PRO
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS – LN-25™ PRO (K2613-1, -2, -5, and -7)
INPUT VOLTAGE and CURRENT
INPUT VOLTAGE ± 10%
INPUT AMPERES
4A
15-110 VDC
(24-42 VAC with remote voltage control kit installed)
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 & K2613-7
.023 – 1/16"
(0.6 – 1.6mm)
50 – 400 ipm
(0.8 – 10.1m/min)
30 – 400 ipm
(0.8 – 10.1m/min)
.030 - 3/32”
(10.3 – 2.4mm)
Normal Speed
K2613-1 & K2613-5
.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
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A-3
A-3
INSTALLATION
SAFETY PRECAUTIONS
The LN-25™ PRO is rated IP23 and is suitable for
outdoor use.
WARNING
The handle of the LN-25™ PRO is intended for
moving the wire feeder about the work place only.
ELECTRICꢀSHOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box
When suspending a wire feeder, insulate the
hanging device from the wire feeder enclosure.
before attempting to connect or
disconnect input power lines, out-
put cables or control cables.
• Only qualified personnel should
HIGH FREQUENCY PROTECTION
CAUTION
perform this installation.
• Do not touch metal portions of the LN-25™ PRO
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.
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.
--------------------------------------------------------------------------
• Only use on power sources with open circuit
voltages less than 110 VDC.
WELD CABLE SIzE
------------------------------------------------------------------------
Table A.1 Located below are copper cable sizes rec-
ommended for various 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 voltage drop in the cables.
LOCATION
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.
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
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A-4
A-4
INSTALLATION
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
CABLE CONNECTIONS
There is one circular connector for the gun trigger on
the front of the LN-25™ PRO.
Table A.2
.
Function
Wiring
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 outlet.
Pin
5-pin trigger
connector for
push-guns
only.
Trigger
Not used
Common
Not used
Not used
A
B
C
D
E
4. Attach the flow regulator to the cylinder valve and tight-
en 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.
C
D
B
E
6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.
A
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.
SHIELDING GAS CONNECTION
WARNING
8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making a weld.
CYLINDER may explode if
damaged.
WIRE DRIVE CONFIGURATION
(See Figure A.1)
• Keep cylinder upright and
chained to support.
CHANGING
BUSHING
THE
GUN
RECEIVER
• 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.
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.
• Do not touch electrically live parts.
• BUILD UP OF SHIELDING GAS MAY
HARM HEALTH OR KILL.
• Shut off shielding gas supply when not in
use.
• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• See American National Standard z-49.1, "Safety
in Welding and Cutting” Published by the
American Welding Society.
------------------------------------------------------------------------
Maximum inlet pressure is 100 psi. (6.9 bar.)
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
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A-5
A-5
INSTALLATION
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
Tools required:
• 1/4" hex key wrench.
WARNING
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.
• 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.
• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
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.
• Only qualified personnel should perform mainte-
nance work.
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.
7. Disconnect the shielding gas hose from the gun
bushing, if required.
3. Remove the outer wire guide by turning the knurled
thumbscrews counter-clockwise to unscrew them
from the feed plate. See Figure A.2.
8. Connect the shielding gas hose to the new gun
bushing, if required.
4. Rotate the triangular lock and remove the drive rolls.
5. Remove the inner wire guide
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
6. Insert the new inner wire guide, groove side out,
over the two locating pins in the feed plate.
and verify the thumb screw holes are aligned.
7. Install a drive roll on each hub assembly secure with
the triangular lock.
10. Tighten the socket head cap screw.
11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
8. Install the outer wire guide by aligning it with the pins
and tightening the knurled thumbscrews.
NOTE: Some gun bushings do not require the use of
the thumb screw.
9. Close the idle arm and engage the idle roll pressure
arm. Adjust the pressure appropriately.
FIGURE A.1
THUMB SCREW
FIGURE A.2
GUN RECEIVER BUSHING
OUTER WIRE GUIDE
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN
TIGHTEN
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A-6
A-6
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 spin-
dle shows the orientation of the brake tab. Be cer-
tain 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 seconds
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 between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6
• 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 seconds
after the gun trigger is released.
FIGURE A.3
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
The LN-25™ PRO 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.
FIGURE A.4
• Only qualified personnel should install,
use or service this equipment.
------------------------------------------------------------------------
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.
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A-7
A-7
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
LN-25 PRO
Electrode
Ranger10,000
(Across the Arc)
Ranger3 phase
SAE 400 with CV adapter
Work clip
Engine Driven welder with
Wire Feed Module
Work
K#
Description
If the power source has a Remote/Local switch, place
the switch in the Local position.
K2613-1
K2613-2
KP1695-XX
LN-25™ PRO Wire Feeder
LN-25™ PRO Extra Torque
Place the Power Source CC/CV switch (if present) or
Range Switch in the CV position if possible.
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CC power Source
Welding Cables
Set the CV/CC switch in the feeder to match the power
source.
K1803-1
CV Power Sources with Stud Connectors and
Remote/Local Switch (See Figure A.6)
FIGURE A.6
CV-655
CV-400
LN-25 PRO
(Across the Arc)
Electrode
DC-400
DC-600
DC-655
Work clip
V450-Pro
Work
K#
Description
K2613-1
K2613-2
KP1695-XX
LN-25™ PRO Wire Feeder
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
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A-8
A-8
INSTALLATION
CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.7)
FIGURE A.7
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 Wire Feeder
LN-25™ PRO Extra Torque
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CC power Source
Welding Cables
K1841
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.8)
Jumper
FIGURE A.8
CV-250
CV-300
CV-305
LN-25 PRO
(Across the Arc)
Electrode
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 Wire Feeder
LN-25™ PRO Extra Torque
KP1696-XX
KP1697-XX
See Magnum Literature
Drive Roll Kit
Welding Gun
CV power Source
Welding Cables
Jumper Plug kit
K1841-
K484
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions and Graphic Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4 / B-8
CV Wire Feed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
CC Wire Feed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
CV Wire Feed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Constant Current vs Constant Voltage Wire Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Description of Internal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10 / B-11
Gas Purge/Flow Meter/Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13
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B-2
B-2
OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
SAFETY PRECAUTIONS
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 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.
ON
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 MANU-
AL.
U
----------------------------------------------------------------------
I
1
I
OUTPUT CURRENT
2
PROTECTIVE
GROUND
WARNING OR
CAUTION
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B-3
B-3
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. Some newer codes
also have a Wire Speed range switch for more precise
setting at lower speeds.
WFS
• Wire Feed Speed
CC
• Constant Current
CV
• Constant Voltage
RECOMMENDED PROCESSES
• GMAW
• FCAW
GMAW
• Gas Metal Arc welding
SMAW
• Shielded 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.
FCAW
• Flux Core Arc Welding
GENERAL DESCRIPTION
EQUIPMENT LIMITATIONS
General Physical Description
• 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.
The LN-25™ PRO is specially engineered to be the
most rugged portable wire feeder available. The mod-
els covered by this manual are designed for “across
the arc” operation only.
• Maximum GMAW gun length is 25 ft.
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. The Standard
model features wire drive gearing for optimal perfor-
mance for both FCAW and GMAW wires of common
sizes. All of the models include a gas solenoid and
flow meter for the flexibility to run most wire processes.
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.
• Push-pull guns do not work with the wire feeder.
• K2330-1 Timer kits do not work with this feeder, use
K2330-2 kits
RECOMMENDED POWER SOURCES
• Ranger 3 Phase
• Ranger GXT
• Ranger 250
• Ranger 305
• SAE-400
• Pipeliner 200G
• Classic 300
• Vantage 300
• Vantage 400
• Vantage 500
• CV-305
• CV-400
• CV-655
• DC-400
• DC-600
• DC-655
• Invertec V-350 PRO
• Invertec V-450 PRO
• Multi-Weld 350
• Ranger 10,000
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 con-
trolled motor powers the patent pending drive rolls for
smooth, steady feeding without slippage.
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 that consists of mounting
the board in a plastic tray and potting it with epoxy.
With a 325 amp 100% duty cycle rating, these feeders
are ready for heavy duty welding.
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B-4
B-4
OPERATION
FIGURE B.1
5
1
1
5
6
6
2
2
7
3
3
4
4
K2613-1 & K2613-2
K2613-5 & K2613-7
CASE FRONT CONTROLS (See Figure B.1)
Models with analog voltmeters have a calibrated
scale printed around the wire feed speed knob using
"in/min" units. A separate decal with "m/min" units is
included with these models wire feeder. Units with a
range switch have two calibrated scales.
ITEM
1.
DESCRIPTION
Analog Voltmeter
2.
Wire Feed Speed Control
5-Pin Gun Trigger Receptacle
Work Sense Lead Connector
Thermal LED (Motor Overload)
Polarity LED
3.
4.
Wire Feed Speed, CV Operation
5
6.
When Across the Arc models are operated with CV
power sources, the wire feed speed will remain a con-
stant value, independent of arc voltage changes, as
long as the arc voltage does not drop below the mini-
mum values per the following table.
7.
Wire Feed Speed Range Switch
1. ANALOG VOLTMETER
The analog voltmeter shows the voltage between
electrode and work. The voltmeter shows open cir-
cuit voltage when the wire feeder is not welding. As
a result, it is not unusual to see the needle “pegged”
when not welding. The voltmeter is polarity insensi-
tive and the range is 0 - 40VDC.
TABLE B.1 - CV
OPERATION
Minimum
Arc Voltage
Maximum WFS Maximum WFS
(Standard)
(Extra Torque)
15 V
17V
21V
24V
27V
280”/min.
210”/min.
2. WIRE FEED SPEED KNOB
340”/min.
440”/min.
520”/min.
600”/min
235”/min.
400”/min.
400”/min.
400”/min.
The large, calibrated wire feed speed knob makes
for easy and accurate adjustment of the wire feed
speed. The knob rotates 3/4 turn. Turn the knob
clockwise to increase the wire feed speed, and
counter clockwise to reduce the wire feed speed.
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B-5
B-5
OPERATION
Wire Feed Speed, CC Operation (See Figure B.2 or
When Across the Arc models are operated with CC
power sources, the wire feed speed changes as the arc
voltage changes. When the arc voltage increases, the
wire feed speed will increase; and when the arc voltage
decreases, the wire feed speed will decrease.
4. Determine the vertical line representing the CC
representing the CC Wire Feed Speed setting
where the above two lines cross. (See Figure B.2
arrow line for 450.) Set the LN-25™ PRO wire feed
speed knob to this value.
To preset the wire feed speed on CC power sources:
CC WFS dial setting = desired WFS x 35
Arc Volts
1. Set the Wire Feed Mode switch inside the LN-25™
PRO to "CC".
Example:
375 in/min. (Horizontal Line) x 35
29 Arc Volts (Diagonal Line)
2. Refer to the Figure B.2 graph for the setting for the
wire feed speed knob setting. Select the horizon-
tal line representing the Desired Wire Feed Speed.
(See Figure B.2 arrow for 375 in/min.)
=
13125 = 452-5 (Vertical Line)
29
3. Select the diagonal line representing the Arc Volts.
(See Figure B.2 for 29 volts.)
Set the Wire Speed Control at 450”/min.,
and when welding at 29 volts the average
actual speed should be approximately
375“/min.
FIGURE B.2
35
700
650
600
550
500
450
400
350
300
250
200
150
100
50
33 V
31
29
27
25
23
21
19
17
15
50 100 150 200 250 300 350 400 450 500 550 600 650 700
CC
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B-6
B-6
OPERATION
TABLE B.2 - VV (CC) WIRE SPEED SETTING
Desired
In/Min
Arc Volts Used
22 24 26
80 73 67
131 117 105 95 88 81
153 136 123 111 102 94
16
18
20
88
28
63
75
88
30
58
70
82
32
55
66
77
88
34
51
62
72
82
93
50
60
70
80
109 97
175 156 140 127 117 108 100 93
197 175 158 143 131 121 113 105 98
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
380
400
420
440
460
480
500
219 194 175 159 146 135 125 117 109 103
241 214 193 175 160 148 138 128 120 113
263 233 210 191 175 162 150 140 131 124
284 253 228 207 190 175 163 152 142 134
306 272 245 223 204 188 175 163 153 144
328 292 263 239 219 202 188 175 164 154
350 311 280 255 233 215 200 187 175 165
372 331 298 270 248 229 213 198 186 175
394 350 315 286 263 242 225 210 197 185
416 369 333 302 277 256 238 222 208 196
438 389 350 318 292 269 250 233 219 206
459 408 368 334 306 283 263 245 230 216
481 428 385 350 321 296 275 257 241 226
503 447 403 366 335 310 288 268 252 237
525 457 420 382 350 323 300 280 263 247
547 486 438 398 365 337 313 292 273 257
569 506 455 414 379 350 325 303 284 268
591 525 473 430 394 365 338 315 295 278
613 544 490 445 408 377 350 327 306 288
634 564 508 461 423 390 363 338 317 299
656 583 525 477 438 404 375 350 328 309
678 603 543 493 452 417 388 362 339 319
700 622 560 509 467 431 400 373 350 329
642 578 525 481 444 413 385 361 340
661 595 541 496 458 425 397 372 350
681 613 557 510 471 438 408 383 360
700 630 572 526 484 450 420 394 370
666 604 554 512 472 444 416 392
700 636 584 538 500 466 438 412
668 612 566 526 490 460 432
700 642 592 550 514 482 452
670 620 576 536 504 472
700 646 600 560 526 494
674 626 584 546 514
520
540
560
580
600
620
640
660
680
700
700 650 606 568 536
676 630 590 556
700 654 612 576
676 634 598
700 656 618
678 638
700 658
680
700
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B-7
B-7
OPERATION
CONSTANT CURRENT VS CONSTANT
VOLTAGE WIRE WELDING
If the contact tip to work distance is properly main-
tained, a satisfactory operating voltage range may be
achieved, and a sound weld may result. However,
when a welder uses a longer contact tip to work dis-
tance, an arc-sensing wire feeder compensates by
increasing the wire feed speed to regulate the voltage.
Even if the voltage and current remain unchanged, the
increased wire feed speed may result in a deposition
rate well beyond the specified range of the electrode.
Under these conditions, the specified weld metal prop-
erties may not be achieved.
Most semiautomatic welding processes perform better
using constant voltage power sources.
Welding codes usually do not address the power
source selection or specifically, whether the welding
process is to be operated in the constant voltage or
constant current mode. Instead, codes typically spec-
ify limitations on the current, voltage, heat input and
preheat temperature based on the material to be weld-
ed. The intention is to assure that proper weld materi-
al properties will develop.
Constant voltage power sources deliver large current
surges to stabilize the arc when the electrode is short-
ed or the arc length is very short. However, a constant
current power source does not provide such a
response to stabilize the arc. It may be difficult to
achieve required weld metal properties, or to achieve
the required quality of welds needed to pass nonde-
structive tests, when such welds are made under con-
stant current operation.
Welding is sometimes performed using constant cur-
rent power sources. The operation can be more con-
venient because it may allow the use of an existing
stick (SMAW) power source and the power source can
be placed at a distant location without any provision for
adjusting the output settings.
For constant current operation, the power source is set
to deliver the specified current. The power source reg-
ulates this current regardless of changes in the weld-
ing circuit, including cable length, electrode diameter,
wire feed speed, contact tip to work distance, etc.
For these reasons, Lincoln Electric does NOT recom-
mend constant current semiautomatic welding for
applications which need to meet specified weld metal
chemical or mechanical property requirements or weld
quality requirements.
Changes in the wire feed speed (WFS) or contact tip to
work distance (CTWD) affect the arc voltage when
constant current power sources are used. Lowering
the wire feed speed raises the voltage, raising the wire
feed speed lowers the voltage. Lengthening the con-
tact tip to work distance raises the voltage, shortening
the contact tip to work distance lowers the voltage.
(See Figure B.3)
FIGURE B-3
Current
Wire
Feeder
+
-
CTWD
WFS
Constant Current
Power Source
Current
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B-8
B-8
OPERATION
3. 5-PIN GUN TRIGGER CONNECTOR
4. WORK SENSE LEAD
Must be connected for the drive motor to operate.
5. THERMAL LED, MOTOR OVERLOAD
The thermal light illuminates (yellow)
when the wire drive motor draws too
M
much current. If the thermal light illumi-
nates, the wire drive will automatically
shutdown for up to 30 seconds to allow
the motor to cool. To start welding
again, release the gun trigger, inspect the gun cable,
liner (and conduit). Clean and make repairs as nec-
essary. Start welding again when the problem has
been safely resolved.
For best results, keep the gun cable and conduit as
straight as possible. Perform regular maintenance
and cleaning on the gun liner, conduit and gun.
Always use quality electrode, such as L-50 or L-56
from Lincoln Electric.
6. POLARITY LED
The Polarity LED
lights (green) when
the wire feeder is
connected for posi-
tive polarity. and is
not lit in Negative
Polarity. Use the polarity LED to verify the wire
feeder is connected properly for the process being
used.
NOTE: Both LED’s will flash briefly when power is
applied to the feeder.
7. WIRE FEED SPEED RANGE SWITCH (K2613-5
and K2613-7 only.)
Used to select either HIGH or LOW range for the
Wire Feed Speed Control. LOW range allows for
more precise setting at lower feed rates. On the
Standard Torque models, selecting the LOW range
DOES NOT increase the torque of the wire drive
system.
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B-9
B-9
OPERATION
INTERNAL CONTROLS
FIGURE B.4
5
4
6
3
2
1
8
7
12
10
11
9
ITEM
DESCRIPTION
1
2
3
4
5
2 Step Trigger Interlock Switch
CV / CC Switch
Pressure Adjustment Arm
Optional Timer Kit (See Accessories Section)
Spool Retainer
6
Spindle Brake
7
Gun Bushing
Thumb Screw for securing the welding Gun
8
9
Socket Head Cap Screw for securing the Gun Bushing
10
11
12
Drive Hubs
Inlet Wire Guide
Cold Feed Pushbutton
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B-10
B-10
OPERATION
CV/CC SWITCH
INTERNAL CONTROLS DESCRIPTION
The CV/CC switch sets the wire
feed speed control method for the
wire feeder.
2 STEP - TRIGGER INTERLOCK
SWITCH
CC
CV
In the CV position, the wire feed
speed remains constant during
welding. A steady arc voltage is
regulated by the power source by
adjusting the arc current.
The 2 Step - Trigger Interlock
switch changes the function of the
gun trigger. 2 Step trigger opera-
tion turns welding on and off in
direct response to the trigger.
Trigger Interlock operation allows
welding to continue when the trig-
ger is released for comfort on long
welds.
In the CC position, the wire feed
speed varies during welding. The
arc length is maintained by chang-
ing the wire feed speed.
Place the toggle switch in the DOWN position for 2
Step operation or in the UP position for Trigger
Interlock operation.
COLD FEED PUSHBUTTON
2 Step Trigger
When cold feeding, the wire drive
will feed electrode but neither the
power source nor the gas solenoid
will be energized. Adjust the speed
of cold feeding by rotating the WFS
knob. Cold feeding, or “cold inching”
the electrode is useful for threading
the electrode through the gun.
2 Step trigger operation is the most common. When
the gun trigger is pulled, the welding power source
energizes the electrode output and the wire feeder
feeds wire for welding. The power source and wire
feeder continue welding until the trigger is released.
Trigger Interlock
Trigger Interlock operation provides for operator com-
fort when making long welds. When the gun trigger is
first pulled, the welding power source energizes the
output and the wire feeder feeds wire for welding. The
gun trigger is then released while the weld is made. To
stop welding, the gun trigger is pulled again, and when
it is released the welding power source output turns off
and the wire feeder stops feeding wire.
CAUTION
If the arc goes out while welding with
trigger interlock operation, the elec-
trode output from the welding power
source remains energized and the wire
feeder will continue to feed wire until
the gun trigger is again pulled and
then released.
------------------------------------------------------------------------
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B-11
B-11
OPERATION
OPTIONAL PREFLOW, BURNBACK AND
POSTFLOW TIMER KIT (K2330-2)
The preflow, Burnback and Postflow Timer Kit gives
you control over the shielding gas at the beginning and
end of the weld and prepares the end of the wire for
the next arc start. Additional shielding gas protection
is often required when welding aluminum, stainless
steel or exotic alloys.
NOTE: When stitch welding, set the postflow time to
maximum for best results.
Preflow Timer
The preflow timer range is OFF to 10 seconds.
Preflow time is the time delay from when the trigger is
pulled to when the wire starts to feed and is energized.
Preflow is used purge the welding gun with shielding
gads and helps to maximize porosity at the start of the
weld.
Burnback Timer
The Burnback timer range is OFF to 0.25 seconds.
The burnback timer controls the additional amount of
time the power source output remains ON after the
wire drive has stopped feeding wire. Burnback adjust-
ment prevents the wire from sticking to the weld at the
end of a weld and helps to condition the wire for the
next weld.
To set the burnback time, adjust the knob to approxi-
mately 0.03 seconds and then decrease or increase
the time as desired.
Postflow Timer
The postflow timer range is OFF to 10 seconds.
Postflow is the time from when the power source out-
put turns OFF until the postflow timer expires. Use
postflow to protect the weld while the weld cools.
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B-13
B-13
OPERATION
GAS PURGE PUSHBUTTON
POWER-UP SEQUENCE
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 and for purging the
lines.. Flow meters should always be adjusted while
the shielding gas is flowing.
For feeders with analog voltmeters, the thermal LED
and the Polarity LED will light breifly during power-up.
If the gun trigger is activated during power up, the feed-
er will not operate unless the gun trigger is released
and re-activated.
FLOW METER
The flowmeter shows the flow rate of shielding gas and
has a valve to adjust the flow. The flow meter is scaled
for CO , Ar, and Ar/CO blends. The middle of the ball
2
2
indicates the flow rate of shielding gas.
Adjust the flow rate while depressing the GAS PURGE
switch by turning the valve at the bottom of the meter.
Most weld procedures require 25-40 scfh (11.8 - 18.9
lpm) for sufficient shielding gas coverage. Gun angle,
nozzle diameter, joint configuration and wind condi-
tions may effect the amount of shielding gas required.
When using a wire feeder with
a flow meter, adjust the regula-
tor at the shield gas bottle or
supply to a flow rate that is
higher than the flow rate indi-
cated on the feeder flow meter.
Note that most regulators are
calibrated based upon having
low restrictions on the outlet.
The valve on the feeder flow
meter creates a high restric-
tion and may cause errors in
the readings at the supply reg-
ulator. Set the gas flow rate
using the feeder flow meter
reading and not the supply
regulator reading.
SCFH
10
20
Liter/Min.
4.7
9.4
30
40
50
60
70
80
14.2
18.9
23.6
28.3
33.1
37.8
LN-25™ PRO
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B-14
B-14
NOTES
LN-25™ PRO
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C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Factory Installed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Installation of the K590-6 Water Cooling Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
LN-25™ PRO
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C-2
C-2
ACCESSORIES
FACTORY INSTALLED EQUIPMENT
• K1500-2 Gun Receiver Bushing.
DRIVE ROLL KITS
KP KIT
WIRE TYPE
Steel Wires:
ELECTRODE SIzE
.023-.030 (0.6-0.8mm)
.035 (0.9mm)
KP1696-030S
KP1696-035S
KP1696-045S
KP1696-052S
Includes: 2 V groove
drive rolls and inner
.045 (1.2mm)
.052 (1.4mm)
1/16 (1.6mm)
.035,.045 (0.9, 1.2mm)
.040 (1.0mm)
KP1696-1/16S wire guide.
KP1696-1
KP1696-2
.030-.035" (0.8-0.9mm) KP1697-035C
.040-.045" (1.0-1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
.068-.072" (1.7-1.8mm)
5/64" (2.0mm)
3/32” (2.4mm)
KP1697-045C
KP1697-052C
KP1697-1/16C
KP1697-068
KP1697-5/64
KP1697-3/32
KP1695-035A
KP1695-040A
KP1695-3/64A
KP1695-1/16A
Cored Wires:
Includes: 2 Knurled
drive rolls and inner
wire guide.
.035" (0.9 mm)
.040" (1.0mm)
3/64" (1.2mm)
Includes: 2 polished
U groove drive rolls,
outer wire guide and
inner wire guide.
Aluminum Wires:
1/16" (1.6mm)
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C-3
C-3
ACCESSORIES
Includes: a complete alu-
K2596-1
K2596-2
Aluminum Case
minum case. Decals, skids,
insulation and latches are all
preassembled.
Includes: a complete engi-
neered plastic case. Decals
and latches are all preassem-
bled.
Plastic Case
Includes: 1/0 Coaxial weld
cable of length "xx". Ends of
the weld cable have lug con-
nections. Use for Pulse weld-
ing.
K1796-xx
K2593-xx
AWG 1/0 Co-Axial Power Cable
AWG #1 Coaxial Power Cable
Includes: AWG #1 Coaxial
weld cable of length "xx".
Ends of the weld cable have
lug connections. Use for
Pulse or STT™ welding.
Includes: Twist-Mate to Lug
2/0 cable 14' (1.2m) long with
Work and Feeder Cables Package Ground Clamp, and Twist-
K1803-1
Mate to Lug 2/0 Cable 9'
(2.7m) long.
K1840-xx
Weld Power Cable, Twist-Mate to Includes: Twist-Mate to Lug,
Lug
1/0 cable of length "xx".
Includes: Lug to Lug, 3/0
Cable of length "xx" for
lengths up to 60' (18.3m).
Lug to Lug, 4/0 Cable of
length "xx" for lengths greater
than 60' (18.3m).
K1842-xx
Weld Power Cable, Lug to Lug
Includes: 14 pin circular con-
nector with jumper for leads 2-
4. For use in power sources
for turning the weld terminals
"ON" at all times.
K484
Jumper Plug Kit
Timer Kit
Includes Panel and harness.
Provides adjustable Preflow,
post flow and Burnback.
K2330-2
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C-4
C-4
ACCESSORIES
K910-1
Ground Clamp
Includes: One 300 Amp
Ground Clamp.
K910-2
Ground Clamp
Includes: One 500 Amp
Ground Clamp.
K1500-1
Gun Receiver Bushing (for guns
with K466-1 Lincoln gun connec-
tors; Innershield and Subarc guns)
Includes: Gun receiver bush-
ing, set screw and hex key
wrench.
K1500-2
Gun Receiver Bushing (for guns Includes: Gun receiver bush-
with K466-2, K466-10 Lincoln gun ing with hose nipple, set
connectors; Magnum 200/300/400 screw and hex key wrench.
guns and compatible with Tweco®
#2-#4)
K1500-3
Gun Receiver Bushing (for guns Includes: Gun receiver bush-
with K613-7 Lincoln gun connec-
tors; Magnum 550 guns and com-
patible with Tweco® #5)
ing with hose nipple, set
screw and hex key wrench.
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C-5
C-5
ACCESSORIES
K1500-4
Gun Receiver Bushing (for gun
Includes: Gun receiver bush-
ing with hose nipple, set
screw and hex key wrench.
with K466-3 Lincoln gun connec-
tors; compatible with Miller®
guns.)
K1500-5
K489-7 *
K435
Gun Receiver Bushing (compatible Includes: Gun receiver bushing
with Oxo® guns.)
with hose nipple, 4 guide tubes,
set screw and hex key wrench.
Gun Receiver Bushing (for Lincoln Includes: Gun receiver bushing
Fast-Mate guns.) with trigger connector.
Spindle Adapter, for mounting 14 Includes: Spindle Adapter made
lb. (6.4 kg) Innershield Coils on 2 from 2 coil retainers. (Electrode
in (51 mm) spindles.
not included.)
K468
Spindle Adapter, for mounting 8in
(203mm) diameter spools on 2 in
(51 mm) spindles.
Includes: 2 Spindle Adapters,
one for 2" wide spools and the
other for 3" wide spools.
K590-6
Water Connection Kit (for
Includes: 2 hoses with female
European and Control cable mod- quick connectors at each end, 2
els only)
male connectors for 3/16" ID
hose, 2 male connectors for _" ID
hose, and mounting hardware.
K586-1
Deluxe Adjustable Gas Regulator Includes: Deluxe Gas Regulator
for Mixed Gases, Adapter for
CO2 and 10' (3.0m) Hose.
* Not compatible with K2613-5 & K2613-7 feeders (Codes 11746, & 11747)
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C-6
C-6
ACCESSORIES
4. Use a 5/16" nut driver to remove the screws holding
the water cooling cover on the case front of the inner
module and on the rear of the case.
INSTALLATION OF THE K590-6 WATER
COOLING KIT
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the dis-
connect switch before working on
this equipment.
• Do not touch electrically hot parts.
• Only qualified personnel should
install, use or service this equipment.
------------------------------------------------------------------------
The K590-6 components are rated up to 70 psi (5 bar)
and 158°F (70°C). Use a coolant fluid that is compati-
ble with the water cooler and the gun.
5. Install the fitting and hose assembly to the case
front. Route the hoses along the bottom of the inner
module and out through the cutout of the cover.
Slide the module back into the case.
Tools required:
• 3/8" wrench
• 5/16" nut driver
• medium flat bladed screw driver
• cutting tool
1. Turn power off at the welding power source.
2. Remove the screws securing the case to the inner
module using a 3/8" wrench.
6. Secure the module to the case with the screws.
(Shown in Step 2)
7. Install the fitting assembly to the rear of the case
3. Remove the module from the case by lifting the front
of the module approximately .25" (6 mm) and then
sliding forward.
ALUMINUM CASE
PLASTIC CASE
8. Slide the hose clamps on to the hoses. Trim the
hoses to length so that they lay flat on the case bot-
tom. Slide hose clamps on the hose. Slide the hoses
on to the fittings on the case rear and secure with
the hose clamps.
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D-1
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Wire Feed Speed Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
LN-25™ PRO
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D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
5. Energize the output circuit of the power source.
Adjust the power source output to 20±1 VDC as
measured on the reference meter.
WARNING
ELECTRIC SHOCK can kill.
6. Verify that LN-25™ PRO voltmeter reads between
19 and 21 volts.
• Do not operate with covers
removed.
• Turn off power source before
installing or servicing.
• Do not touch electrically hot
parts.
If the voltmeter reading is out of range, check for loose
connections or replace the voltmeter. There is no cal-
ibration adjustment for the LN-25™ PRO voltmeter.
• Turn the input power to the welding power
source off at the fuse box before working in the
terminal strip.
Flow Meter Validation
• Only qualified personnel should install, use or
service this equipment.
----------------------------------------------------------------------
Tools required:
• Flow meter reference standard.
• Constant voltage DC welding power source (DC-
400, V-350, CV-400 or equivalent).
ROUTINE MAINTENANCE
• Check weld cables and gas hoses for cuts.
• Clean and tighten all weld terminals.
To verify the flow meter accuracy:
1. Turn power OFF.
PERIODIC MAINTENANCE
2. Connect the LN-25™ PRO to the constant voltage
DC welding power source. The work lead of the
LN-25™ PRO must be connected to the work ter-
minal of the power source.
• Clean drive rolls and inner wire guide and replace if
worn.
• Blow out or vacuum the inside of the feeder.
CALIBRATION SPECIFICATION
3. Connect a supply of CO2 to the wire feeder. Do not
exceed the maximum inlet pressure of the wire
feeder.
The voltmeter and flow meter are not calibrated and
are for reference purposes only.
4. Disconnect the shielding gas hose that connects to
the gun bushing.
Voltmeter Validation, Across the Arc Analog Meter
Models
5. Connect the shielding gas hose to flow meter refer-
ence standard.
Tools required:
• DC voltmeter reference standard
6. Orient the LN-25™ PRO in a vertical position.
7. Turn power ON.
• Constant voltage DC welding power source with
adjustable no-load voltage (DC-400, V-350, CV-400
or equivalent).
8. Adjust the flow meter on the LN-25™ PRO to 40
scfh while pressing the GAS PURGE button.
To verify the analog voltmeter accuracy:
1. Turn power OFF.
9. Measure the gas flow with the calibrated flow meter
while pressing the GAS PURGE button.
2. Connect the LN-25™ PRO to the constant voltage
DC welding power source. The work lead of the
LN-25™ PRO must be connected to the work ter-
minal of the power source.
10. The measured flow rate should be between 35
and 45 scfh.
The LN-25™ PRO flow meter cannot be calibrated. If
the flow meter reads incorrectly, check for leaks or
kinks in the gas hose. Replace the flow meter if neces-
sary.
3. Connect the reference voltmeter between the brass
block of the LN-25™ PRO and the work lead.
4. Turn power ON.
LN-25™ PRO
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D-3
D-3
MAINTENANCE
Wire Feed Speed Validation
To change the wire feed speed calibration:
(See Figure D.1)
(See Figure D.2)
Tools required:
Calibration of the LN-25™ PRO may be required when
the p.c. board, wire feed speed potentiometer or motor is
replaced or serviced. Calibration matches the scale on
the name plate to the actual wire feed speed.
• 5/16" nut driver
• RPM meter
• Shorting plug. LE CO.part # S18250-982 - The short-
ing plug shorts pins 4 & 8 of connector J3 on the Control
P.C. Board. J3 is an 8 pin Molex connector.
Tools required:
• RPM meter
• Constant voltage DC welding power source (DC-400,
V-350, CV-400 or equivalent)
• 7/16" open end wrench
1. Turn power OFF.
2. Remove the 4 screws holding the rear cover inside the
feeder and remove the cover.
To verify if calibration is necessary:
1. Turn power OFF.
3. Open the idle arm.
4. Set the wire feed speed per the table.
2. Set the wire feed speed per the table.
Model gearing Wire Feed Speed Acceptable Range
Model gearing Wire Feed Speed
Normal Speed 400 in/min
Normal Speed 400 in/min
Extra Torque 150 in/min
69 - 77 rpm
25 - 31 rpm
Extra Torque
150 in/min
5. Connect the LN-25™ PRO to the constant voltage DC
welding power source. The work lead of the LN-25™
PRO must be connected to the work terminal of the
power source.
3. Remove the plastic cover from the lower portion of the
wire drive with a 7/16" wrench.
4. Connect the LN-25™ PRO to the constant voltage DC
welding power source. The work lead of the LN-25™
PRO must be connected to the work terminal of the
power source.
6. Turn power ON.
7. Insert the shorting plug into connector J3 on the Control
P.C. Board. The shorting plug shorts pins 4 & 8.
5. Turn power ON.
8. Remove the shorting plug.
9. Turn power OFF.
6. Measure the motor rpm when the COLD FEED button
is pressed.
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
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Digital Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
FIGURE E.1 — BLOCK LOGIC DIAGRAM.
ELECTRODE
INPUT
67
CURRENT TRANSDUCER
POLARITY
CONTACTOR
FEEDPLATE
INPUT
SOLENOID
TIMER OPTION
V M
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
TACH FEEDBACK
21
CONTROL BOARD
1
GUN TRIGGER
REMOTE
VOLTAGE
WIRE
SPEED
14 PIN AMPHENOL
CC
CV
TRIGGER
INTERLOCK
GAS
PURGE
COLD
FEED
21
DIGITAL
DISPLAY
BOARD
RUN IN
LN-25™ PRO
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 — GENERAL DESCRIPTION
ELECTRODE
INPUT
67
CURRENT TRANSDUCER
POLARITY
CONTACTOR
FEEDPLATE
INPUT
SOLENOID
TIMER OPTION
V M
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
TACH FEEDBACK
21
1
CONTROL BOARD
GUN TRIGGER
REMOTE
VOLTAGE
WIRE
SPEED
14 PIN AMPHENOL
CC
CV
TRIGGER
INTERLOCK
GAS
PURGE
COLD
FEED
21
DIGITAL
DISPLAY
BOARD
RUN IN
GENERAL DESCRIPTION
The heart of the LN-25™ PRO is a 2 roll MAXTRAC
wire drive system. The patented features on the wire
drive offer tool-less changing of the drive rolls and wire
guides for quick changeovers. A tachometer controlled
motor powers the patent pending drive rolls for smooth,
steady feeding without slippage.
Several models of the LN-25™ PRO are offered to best
meet the individual welders needs. The Extra Torque
model features additional torque for reliable feeding of
large diameter FCAW wire. The standard and control
cable models feature wire drive gearing for optimal per-
formance with both FCAW and GMAW wires of com-
mon sizes. All the models include a gas solenoid and
flow meter for the flexibility to run most wire processes.
Control Cable models also includes digital meters and
remote voltage control.
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 manufactured with Lincoln’s industry leading
environmental design protection which involces mount-
ing the board in a plastic tray and potting it with epoxy.
The plastic case is molded from high impact, flame
retardant plastic for durability and low weight. The
patent pending design keeps the internal components
protected and dry.
With a 325 amp, 100% duty cycle rating, these feeders
are ready for heavy duty welding.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
LN-25™ PRO
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 — INPUT POWER & TRIGGER CIRCUIT
ELECTRODE
INPUT
67
CURRENT TRANSDUCER
POLARITY
CONTACTOR
FEEDPLATE
INPUT
SOLENOID
TIMER OPTION
V M
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
TACH FEEDBACK
21
1
CONTROL BOARD
GUN TRIGGER
REMOTE
VOLTAGE
WIRE
SPEED
14 PIN AMPHENOL
CC
CV
TRIGGER
INTERLOCK
GAS
PURGE
COLD
FEED
21
DIGITAL
DISPLAY
BOARD
RUN IN
INPUT POWER
TRIGGERꢀCIRCUIT
The DC input voltage is applied from the power source
via the electrode cable and the work sensing lead on
the across the arc model. With the control cable model
24 to 42VDC is supplied from the power source via the
control cable and the work sense lead.
When the gun trigger is closed, the control board is sig-
naled to apply armature voltage to the drive motor and
to activate any auxiliary circuits that may be incorpo-
rated within the LN-25PRO.
Trigger interlock is used for long welds. When an arc
is established the trigger can be released. To stop
welding, the gun trigger is pulled again, and when it is
released the second time, the welding power source
output turns off and the wire speed stops.
This voltage is applied through a bridge rectifier and an
analog voltmeter (across the arc), or digital meter (con-
trol cable) and then is supplied to the control board.
The control board the regulates and disperses the var-
ious supply voltages needed for machine operation.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 — FEEDBACK & CONTROL CIRCUITS
ELECTRODE
INPUT
67
CURRENT TRANSDUCER
POLARITY
CONTACTOR
FEEDPLATE
INPUT
SOLENOID
TIMER OPTION
V M
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
TACH FEEDBACK
21
1
CONTROL BOARD
GUN TRIGGER
REMOTE
VOLTAGE
WIRE
SPEED
14 PIN AMPHENOL
CC
CV
TRIGGER
INTERLOCK
GAS
PURGE
COLD
FEED
21
DIGITAL
DISPLAY
BOARD
RUN IN
FEEDBACK AND CONTROL CIR-
CUITS
The wire speed pot provides command signal to the
control board indicating the desired wire speed. The
tachometer transforms the motor RPM to a digital fre-
quency that is fed back to the control board.
These three factors are monitored and compared, then
the appropriate armature voltage is applied to the wire
drive motor.
When the Run-in Switch is on, the wire speed is
reduced until an arc is struck. When it is off the run-in
wire speed is the same as the welding wire feed speed.
When operating in constant voltage (CV) mode, the
control board monitors the feedback signal, compares
it to the command signal and delivers the appropriate
voltage to the wire drive motor.
Pressing the cold feed button activates the drive rolls
but neither the power source nor the gas solenoid will
be activated.
When operating in constant current (CC) mode, a vari-
able wire speed is desirable to compensate for the
varying arc voltages associated with the constant cur-
rent process. To accomplish this, the control board
monitors the command voltage, the feedback signal
from the tach and the arc voltage.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 — OPTIONAL CIRCUITS & DIGITAL DISPLAY BOARD
ELECTRODE
INPUT
67
CURRENT TRANSDUCER
POLARITY
CONTACTOR
FEEDPLATE
INPUT
SOLENOID
TIMER OPTION
V M
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
TACH FEEDBACK
21
1
CONTROL BOARD
GUN TRIGGER
REMOTE
VOLTAGE
WIRE
SPEED
14 PIN AMPHENOL
CC
CV
TRIGGER
INTERLOCK
GAS
PURGE
COLD
FEED
21
DIGITAL
DISPLAY
BOARD
RUN IN
DIGITAL DISPLAY BOARD
(control cable models only)
OPTIONAL CIRCUITS
The preflow, burnback, and postflow timer kit gives
control over the shielded gas at the beginning and end
of the weld and prepares the end of the wire for the
next arc start.
When the wire feeder is not welding, the left display
shows the wire feed speed. The default units are
“in/min” and may be changed to “m/min” through the
setup menu. During welding the left display shows the
average welding current, and will continue to hold the
last value for 5 seconds after the trigger is released.
The preflow timer range is zero to 10 seconds. Preflow
is used to purge the welding gun with shielding gas and
helps to minimize porosity at the start of a weld.
When the wire feeder is in idle the right display shows
the preset voltage. This voltage will change with dif-
ferent power sources and can be changed through the
setup menu. During welding, the right display shows
the average welding voltage, and will hold the last
value for 5 seconds after the trigger is released.
The burnback timer range is zero to 0.25 seconds.
Burnback controls the additional amount of time the
power source output remains on after the wire drive
has stopped feeding wire.
The postflow timer range is zero to 10 seconds. Use
postflow to protect the weld while it cools.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-6
E-6
NOTES
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F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Gas Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11
Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Drive Motor and Tach Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Motor Overload Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17
Contactor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Front Panel Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Wire Drive Motor and Gear Box Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
PC Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Gas Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31
Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
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F-2
F-2
TROUBLESHOOTING & 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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
Course of Action” lists the most likely com-
procedure listed below.
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob-
lems, wire feeding problems, and welding
problems.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
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.
-----------------------------------------------------------------------------------------------------------------------------------
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- 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-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
- Remove your body’s static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
equipment frame.
grounded part of the
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Fault Code
Description
Possible Adjustment
Thermal LED Lit
1. The wire drive motor has over- 1. Remove any bends in the gun.
heated.
Motor overloaded, long term
(Err 81 on Digital Models)
2. Check to see if the wire moves
smoothly through the gun and
cable.
3. Check the tightness of the spin-
dle brake.
4. Wait for the motor to cool and
the error to reset.
Thermal LED Lit
1. The wire drive motor is in a 1. Verify that the motor can move
locked state causing the motor
to exceed it’s maximum amper-
age draw.
freely when the pressure arm is
released.
Motor overloaded, short term
(Err 82 on Digital Models)
2. Verify that the drive system is
free of dirt and debris.
OUTPUT PROBLEMS
The feeder does not power up - no
display (Digital Models) - no cold
feed.
1
The work sense lead has an 1. Connect the work sense lead to
open or poor connection
(across the arc model).
the work in a location free of dirt
or paint.
NOTE: Both LED’s should flash 2. The power source is off.
briefly when power is
applied.
2. Turn on the power source.
3. The circuit breaker for the feed- 3. Reset the circuit breaker.
er on the power source may
have tripped. (Control cable
model).
The wire feeder powers up but 1. The contactor coil connections 1. Verify the connections.
there is no welder output when the
gun trigger is pulled. The shielding
gas flows and the drive rolls turn.
are loose.
2. Check for opens in the leads.
2. The contactor has failed.
TEST, replace if necessary.
(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.
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Inconsistent wire feeding or wire not 1. The gun cable is kinked.
feeding but the drive rolls are turn-
ing.
1. Keep the gun as straight as
possible. Avoid sharp corners
or bends in the gun cable.
2. The wire is jammed in the gun
cable.
2. Remove the gun and clear the
jam.
3. The gun liner is dirty or worn.
4. The electrode is rusty or dirty.
3. Clear liner with pressurized air
(40 PSI) or less. Change liner if
worn.
5. The gun tip is worn or has splat-
ter.
6. Improper gun liner, tip, drive 4. Use only clean electrode. Use
rolls, or wire guides.
only quality electrode, like L-50
or L-56 from the Lincoln
Electric.
7. Incorrect pressure on the wire
drive rolls.
5. Replace the contact tip.
8. Spindle brake to tight.
9. Worn drive rolls.
6. Verify the proper parts are
installed.
7. Adjust the tension arm per the
manual. Most electrodes feed
well with the tension at around
“3”.
8. Verify the spool moves with
minimal effort.
9. Replace the drive rolls if need-
ed.
Wire feed speed consistently oper- 1. The jumper lead for normal 1. Properly connect the jumper.
ates at the wrong value. The speed
changes when the control knob is
adjusted.
speed / extra torque is connect-
ed improperly.
2. Install the proper pinion fear in
the wire drive unit.
2. The wrong gear is installed in
the wire drive unit.
3. Replace the motor/gearbox
assembly.
3. The motor brushes are worn.
This wire feeds but cannot be con- 1. The tachometer is connected 1. Verify that tachometer leads
trolled with the wire speed pot.
improperly.
are properly connected.
2. The tachometer has failed.
2. Perform the MOTOR AND
TACHOMETER TEST. Replace
the tachometer if necessary.
3. Possible control board problem.
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.
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Variable or “hunting” arc.
1. Wrong size, worn or melted tip. 1. Replace the tip.
2. Worn work cable or poor con- 2. Verify all the work and elec-
nection.
trode connections are tight and
in good condition Clean if nec-
essary and replace.
3. Wrong polarity’
4. The gas nozzle is extended
beyond the contact tip or the
wire stickout is too long.
3. Adjust polarity to recommended
procedure verify DIP switch 7
setting matches the electrode
polarity.
5. Poor gas shielding on process-
es requiring gas.
4. Adjust the gas nozzle and
shorten the stickout to 1/2 to
3/4 inches.
5. Check gas flow and mixture.
Remove or block sources of
necessary.
When the trigger is pulled, the wire The Run-in switch is “ON”
feeds slowly.
Turn the run-in switch to the “OFF”
position.
(Digital display models)
The preset voltage does not match The preset voltage calibration in the Use the setup menu to change the
feeder has been selected for a dif- preset voltage in the feeder to
ferent power source. match the power source.
the power source voltage.
(Digital display models)
Poor arc starts with sticking or “ Improper procedures or techniques. See “Gas metal arc welding guide”
Blast-offs”, weld porosity, narrow or
ropy looking beads.
(GS-100)
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.
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
GAS SHIELDING ISSUES
No shielding gas.
1. The gas supply is off or empty. 1. Verify the gas supply is ON and
flowing.
2. The gas hose is cut or crushed.
2. Reroute the gas hose to avoid
sharp corners and make sure
3. The flow meter is closed. Dirt
or debris is in the solenoid.
nothing is on it. Repair or
replace damaged hoses.
4. There is a loose connection at
the solenoid.
3. Open the flow meter valve.
5. The solenoid has failed.
4. Apply 80 psi of filtered air to the
solenoid to remove dirt and
debris.
5. Remove the cover and verify
that all the connections are in
good condition.
TEST, replace if necessary.
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.
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F-8
F-8
NOTES
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F-9
F-9
TROUBLESHOOTING & REPAIR
CASE REMOVAL PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the molded case
ssembly
MATERIALS NEEDED
Misc. Hand Tools
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F-10
F-10
TROUBLESHOOTING & REPAIR
CASE REMOVAL PROCEDURE (CONTINUED)
FIGURE F.1 – CASE REMOVAL
PROCEDURE
1. Remove the input power from the LN25 PRO
unit.
2. Using the 1/4-20 nut driver, remove the 8
screws holding the control box. Loosen the
cord grip connector, and slide the control box
assembly out of the case. See Figure F.1
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F-11
F-11
TROUBLESHOOTING & REPAIR
GAS SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the gas solenoid circuit is faulty.
MATERIALS NEEDED
1/4-20 Nut driver
#10-24 Nut driver
Digital meter
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F-12
F-12
TROUBLESHOOTING & REPAIR
GAS SOLENOID TEST (CONTINUED)
FIGURE F.2 – GAS SOLENOID
GAS SOLENOID
CONTROL BOX
CONTROL BOX COVER
PROCEDURE
6. If high voltage is seen (Approx. 35 volts) the
solenoid coil is open.
2. Remove the five #10-24 x .50 screws holding
the control box cover and access the solenoid
leads. See Figure F2.
7. Normal solenoid coil resistance is 22 ohms.
8. The solenoid can also be checked by discon-
necting the leads and applying 12VDC direct-
ly to the terminals. If the solenoid does not
activate the solenoid is faulty.
3. Apply the correct input voltage (15-110vdc) to
the unit.
4. While pressing the gas purge button or acti-
vating the gun trigger, check for approximate-
ly 4VDC is present at the solenoid leads. If
the 4VDC is present the solenoid should acti-
vate. If the 8VDC is present but the solenoid
does not activate the solenoid may be faulty.
9. If the solenoid fails any of the above tests
replace it.
10. Reassemble the feeder in reverse order.
5. If the 4VDC is missing or low, check the leads
and connections between the solenoid and
If the leads and connections are ok, the con-
trol board may be faulty.
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F-13
F-13
TROUBLESHOOTING & REPAIR
CONTACTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the contactor is faulty.
MATERIALS NEEDED
1/4-20 Nut driver
#10-24 Nut driver
Digital meter
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F-14
F-14
TROUBLESHOOTING & REPAIR
CONTACTOR TEST (CONTINUED)
FIGURE F.3 – CONTACTOR
CONTROL BOX
CONTACTOR
PROCEDURE
6. If high voltage is seen (Approx. 35 volts) the
Contactor coil is open.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
7. Normal solenoid coil resistance is 4 ohms.
8. The Contactor can also be checked by dis-
connecting the leads and applying 12VDC
directly to the terminals. If the solenoid does
not activate the solenoid is faulty.
3. Apply the correct input voltage (15-110vdc) to
the LN25 PRO unit.
4. Check for the correct voltage at leads 507 and
578 at the contactor. Look for 0VDC when the
trigger is open and about 3VDC when it is
closed. See wiring diagram.
9. If the contactor does not pass all the above
5. If the 3VDC is missing or low, check the leads
and connections between the Contactor and
If the leads and connections are ok, the con-
trol board may be faulty.
10. Reassemble the feeder in reverse order.
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F-15
F-15
TROUBLESHOOTING & REPAIR
DRIVE MOTOR AND TACH FEEDBACK TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the motor and tach circuit is faulty.
MATERIALS NEEDED
1/4-20 nut driver
#10-24 nut driver
Digital meter
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F-16
F-16
TROUBLESHOOTING & REPAIR
DRIVE MOTOR AND TACH FEEDBACK TEST (CONTINUED)
FIGURE F.4 – CONTROL BOX ASSEMBLY
CASE
CONTROL BOX ASSEMBLY
PROCEDURE
6. Check for 1.5 ohms of resistance between the
black and white leads. Also make sure there
is at least 550k ohms of resistance between
both leads and the motor shell.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
7. With the trigger activated and the motor run-
ning check for 15.6VDC input on the black
and red tach leads. Check for 6.2vdc at any
speed or ≈72hz (min.). to ≈1.2Khz (max). on
the black and blue return leads.
3. Remove the 5 #10-24 screws holding the con-
trol box cover, and locate the two motor leads
and the 3 tach leads See the Wiring
4. Apply the correct input voltage (15-110vdc) to
the unit.
8. For further testing on the drive motor you can
use an isolated source and apply between
2.6VDC and 32VDC to the motor leads.
5. With trigger activated and the motor running
check for 2.6VDC min. to 32VDC max.
between the black and white motor leads
(pins 7 and 8).
9. If all the above voltages are not there the
NOTE: If the tach feedback is missing the board
will limit the motor voltage to 10VDC no
matter where the w/s pot is set.
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F-17
F-17
TROUBLESHOOTING & REPAIR
MOTOR OVERLOAD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the motor overload circuit is faulty.
MATERIALS NEEDED
1/4-20 nut driver
#10-24 nut driver
Digital meter
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F-18
F-18
TROUBLESHOOTING & REPAIR
MOTOR OVERLOAD TEST (CONTINUED)
FIGURE F.5 – CONTROL BOX ASSEMBLY
CASE
CONTROL BOX ASSEMBLY
PROCEDURE
6. If the amperage exceeds 3.2 amps for more
than 8 seconds the motor will be disabled.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
7. If the motor armature current is normal and
the motor still shuts down the control board
may be faulty.
3. Remove the five #10-24 screws holding the
control box cover, and locate the two motor
leads and 3 tach leads. See the Wiring
8. If the current is high check for restrictions in
the feed system. They can be caused by a
clogged liner, spindle tightness, drive rolls to
tight, fault drive motor or a faulty gearbox.
4. Apply the correct input voltage (15-110vdc) to
the unit.
9. After testing replace faulty parts and reassem-
ble the feeder in reverse order of disassembly.
5. With the trigger activated and the motor run-
ning check the motor armature current.
Normal armature current is less then 3 amps.
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F-19
F-19
TROUBLESHOOTING & REPAIR
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the contactor.
MATERIALS NEEDED
1/4-20 nut driver
#10-24 nut driver
Adjustable wrench
Torque wrench
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F-20
F-20
TROUBLESHOOTING & REPAIR
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.6 – CONTROL BOX
CONTROL BOX
REMOVAL PROCEDURE
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
3. Disconnect both of the buss bar connectors.
DO NOT loosen the mounting block before
loosening the buss bar. See Figure F.6.
4. Remove the five #10-24 x .50 screws from the
wire drive panel, and separate the panel from
the control box.
5. Remove the two #10-24 x .50 screws at the
base of the control box that holds the contac-
tor and remove the contactor.
6. Disconnect the coil leads, and the buss bars
from the contactor.
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F-21
F-21
TROUBLESHOOTING & REPAIR
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.7 – BUSS BAR AND MOUNTING BLOCK
BUSS BAR
MOUNTING BLOCK
REPLACEMENT PROCEDURE
5. Slide the wire drive panel into place and reat-
tach using the five screws.
1. Loosely connect the buss bars to the new
contactor.
6. Reconnect the gas hose and tighten the other
two buss bar connections.
2. Reconnect the coil leads. Slide the buss bar
into the mounting block and start the 1/2-13
bolt.
7. Slide the control box into the case and
reassemble in reverse order.
3. Using the two #10-24 x .50 screws reattach
the contactor to the control box.
4. Tighten the buss bars to the contactor to 15fp.
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F-22
F-22
NOTES
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F-23
F-23
TROUBLESHOOTING & REPAIR
FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the front panel.
MATERIALS NEEDED
1/4-20 Nut driver
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F-24
F-24
TROUBLESHOOTING & REPAIR
FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.8 – FRONT PANEL
FRONT PANEL
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Connect the work lead that was previously
removed.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
2. Reconnect the molex plugs.
3. Slide the front panel into the control box and
attach it with two 1/4-20 screws.
3. Remove the two 1/4-20 screws that hold the
front panel and lift it out. See Figure F.8.
4. Slide the control box into the case and attach
it with the remaining 1/4-20 screws.
4. Disconnect the molex plugs from the control
harness. See wiring diagram.
5. Disconnect the work lead and set it aside to
use with the new panel.
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F-25
F-25
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND GEAR BOX
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the wire drive
motor and gear box.
MATERIALS NEEDED
1/4-20 Nut driver
#10-24 Nut driver
3/8 nut driver
Phillips head screwdriver
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F-26
F-26
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND GEAR BOX
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.9 – BUSS BAR AND GAS HOSE REMOVAL
Gas Hose
Gas Solenoid
Buss Bar
REMOVAL PROCEDURE
7. Remove the tach and motor leads by discon-
necting the P9 connector. see wiring diagram.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
8. Remove the three M6 x 1.00 phillips pan head
screws holding the motor to the motor panel
and lift out the motor.
3. Disconnect the gas hose and the buss bar
from the drive deck. See Figure F.9.
9. Remove the four 1/4-20 x .50 screws from the
back of the motor panel and remove the drive
deck. Note screw locations for reassembly.
4. Remove the four #10-24 x .50 screws holding
the control box cover.
5. Remove the five #10-24 x .50 screws from the
wire drive panel, and separate the panel from
6. Remove the plastic drive gear cover and with
a phillips head screwdriver remove the drive
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F-27
F-27
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND GEAR BOX
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.10 – WIRE DRIVE PANEL REMOVAL
CONTROL BOX
WIRE DRIVE PANEL
DRIVE GEAR COVER
REPLACEMENT PROCEDURE
7. Reconnect the gas hose and the buss bar
assembly.
1. Line up the gear box with the four holes on the
panel. Replace and tighten the four 1/4-20 x
.50 screws.
8. Replace the control box cover using the four
#10-24 x .50 screws.
2. Insert the drive motor through the panel and
gear box. Line up and tighten the three M6 x
1.00 in. phillips pan head screws.
9. Slide the control box into the case and secure
it in reverse order.
3. Replace the drive gear and secure in place
using the screw and lock washer previously
removed.
10. Reinstall the gun.
4. Replace the drive rolls and secure the locking
rings.
5. Reconnect the motor and tach leads to har-
ness.
6. Reassemble the wire drive panel and the con-
trol box using the five #10-24 x .50 screws.
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F-28
F-28
NOTES
LN-25™ PRO
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F-29
F-29
TROUBLESHOOTING & REPAIR
PC BOARD REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the Control PC
Board.
MATERIALS NEEDED
1/4-20 Nut driver
#10-24 Nut driver
3/8 Nut driver
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F-30
F-30
TROUBLESHOOTING & REPAIR
PCꢀBOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.11 – CONTROL PC BOARD LOCATION
CONTROL BOX
CONTROL BOARD
CONTROL BOX COVER
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove the new control board from the static
bag and place it on the 4 studs.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
2. Reassemble the 4 nuts and tighten hand tight.
3. Reassemble the harness plugs.
3. Disconnect the gas hose and the buss bar
from the drive deck.
4. Replace the wire drive panel and control box
assembly in reverse order.
4. Remove the five #10-24 x .50 screws from the
wire drive panel and separate the panel from
the box to access the control board.
5. Reconnect the buss bar and the gas hose.
6. Replace the control box cover.
5. Locate the control board and remove the har-
ness plugs on the control board. Observe sta-
tic electricity precautions. Label plugs for
reassembly. See Figure F.11.
7. Slide the control box into the case and secure
it in reverse order.
6. Remove the 4 nuts holding the board using
the 3/8 inch nut driver, and remove the board.
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F-31
F-31
TROUBLESHOOTING & REPAIR
GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the gas solenoid.
MATERIALS NEEDED
#10-24 nut driver
Adjustable pliers
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F-32
F-32
TROUBLESHOOTING & REPAIR
GAS SOLENOID
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.12 – SOLENOID NUT AND HOSE
GAS SOLENOID
GAS HOSE
CONTROL BOX
LOCK NUT
CONTROL BOX COVER
PROCEDURE
8. Reconnect the gas hose.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
9. Reconnect the wires to the solenoid coil.
10. Replace the control box cover.
3. Remove the 2 wires on the solenoid coil. See
wiring diagram.
4. Using the pliers remove the gas hose. Be
careful not to damage the hose. See Figure
F.12.
5. Remove the lock nut holding the solenoid.
See Figure F.12.
6. Remove the solenoid from the unit.
7. Install the new solenoid with the attached
hardware.
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F-33
F-33
TROUBLESHOOTING & REPAIR
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 charac-
teristics.
OR
• If you repair or replace any electrical components.
SET UP
1. Connect a supply of filtered compressed air at 80 psi to the gas inlet.
2. Supply 15 to 110 VAC to the machine.
3. Connect the gun to the connector block and connect the trigger.
OPERATION VERIFICATION
WIRE FEED SPEED (Standard) ...................50 through 700 IPM
WIRE FEED SPEED (Ext. Torque)...................50 through 400 IPM
VOLTMETER (Analog)..............Must read Inpit Voltage +/-2%
VOLTMETER (Digital)...............Must operate at 3 TO 12 VDC input volts
GAS SOLENOID.......................Must operate when Gun Trigger is activated.
CONTACTOR............................Must operate when Gun Trigger is activated
or after Pre-flow time if Timer Kit is installed.
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F-34
F-34
NOTES
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram - Code 11387, 11388 (G5681) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram - Code 11507, 11508 (G5681-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram - Code 11620, 11621,11716,11717 (G5681-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Wiring Diagram - Code 11746, 11747 (G5681-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Schematic - Complete Machine - Code 11387, 11388 (G5683) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6 / G-7
Schematic - Complete Machine - Code 11507, 11508 (G5683-1) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8 / G-9
Schematic - Complete Machine - Code 11620, 11621,11716, 11717 (G5683-2) . . . . . . . . . . . . . .G-10 / G-11
Schematic - Complete Machine - Code 11746, 11747 (G5683-3) . . . . . . . . . . . . . . . . . . . . . . . . .G-12 / G-13
Schematic - Control PC Board* - Code 11387/8, 11507/8 (G4745-1) . . . . . . . . . . . . . . . . . . . . . .G-14 / G-18
Schematic - Control PC Board* - Code 11620/1, 11716/7, 11746/7 (G4783-1) . . . . . . . . . . . . . . .G-19 / G-23
Schematic - Motor Filter PC Board* - Code 11746, 11747 (S27505-1) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-24
Schematic - K2330-2 Timer Kit PC Board* - All Codes (M21341-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-25
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered
and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.
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G-2
G-2
ElECTriCal DiaGrams
WiriNG DiaGram - lN-25 prO - CODEs 11387, 11388 (G5681)
WIRING DIAGRAM LN-25 PRO
ANALOG DISPLAY CASE FRONT
S1
S2
YELLOW
THERMAL
509D
509C
509D
509E
1W 1B
2B
2W
POLARITY
LED
TRIGGER
INTERLOCK
2 STEP
WIRE FEED SPEED
CONTROL RHEOSTAT
S4
/
LED
CC
/
CV
GAS PURGE
PUSHBUTTON
SWITCH
N.A.
N.A.
587A
523A
10K2W
R1
N.B.
,
N.F.
N.B.
SHOWN IN CV
SHOWN IN 2 STEP
CONNECTS TO
J7 ON HARNESS
FLEX
577A
575A
ARC
VOLTMETER
576A
CONNECTS TO J8
ON P ESET P.C. BD.
61
2
0
509A
N.O.
P16
R
61
53
2
0
58
52
7
3
70
0
7
62
2W
1W
509A
70 61
3B
50
2
0
VM
+
N.B.
509C
587A
523A
530A
50
9
50
9
1
2
3
4
72
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TRIGGER
CONNECTOR
S3
61
8
500A
587
523
530
509B
N.B.
COLD
FEED
509E
530A
721
667B
622A
A
B
C
D
E
622A
CONTROL P.C
.
BOARD
1 2
3
4
5
6
7
8 9 10
500A
N.O.
P14
1 2
3
4
5
6
7
8 9 10 11 12 13 14 15 16
575A
576A
577A
60
1
1
2
3
4
5
6
7
8
509B
21
A
BRIDGE
RECTIFIER
4B
J6
J1
FEED
P7
P60
60
60
60
60
5
6
8
7
PLATE
1
2
3
4
5
6
7
8
9
10
60
1
6
667A
667B
AC
-
60
TO WORK
CLIP
21B
TACH
608
GAS
SOLENOID
1B
1W
2B
R
U
B
AC
M
OT
O
R
/
D1
GEARBOX
60
60
5
7
CONNECTS
TO TIMER
KIT
J2
N.D.
67B
2W
CONNECTS TO J17
ON HARNESS
621A
69
0
1
EXTRA
TORQUE
W
B
67B
1
2
3
4
5
6
N.E.
P9
69
667A
21
P17
A
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
L4
L5
R
U
B
531
537
534
621A
CONNECTS TO
P7 ON ASE
RONT
J4
J5
C
J3
DIGITAL DISPLAY CASE FRONT
F
-
B
W
55
1
0
BLACK
RED
PRESET P.C BOARD
.
8
55
J12
J8
J10
1 2
3
4
5
6
7
9
10 11 12
1
2
3 4
5
6
7 8
FAN
721A
1
2
3
4
5
10
10 11 12 13 14 15 16
1 2
41
3
4
5
6
1 2
3
4
5
6
7
8 9
1 2
80
3
4
5
6
7
8 9
500
1
707A
702
75B
80
5
B
42B
55
0
55
69
1
0
69
50
1
7
57
53
7
7
57
53
8
1
53
575
66
7
2A 721A 67F
4A 21 62
62
70
2
7
80 80
2
4
67 21 70
1
708
76B
77B
4
576
D
1
6
7
8
9
10
11
12
13
14
15
16
57
57
57
70
5
FLEX
6
CONNECTS TO J1
ON CONTROL BD
7
8
J7
80
80
80
80
5
1
2
3
4
75C
76C
77C
4
1
2
WIRE FEED
SPEED
CONTROL
RHEOSTAT
REMOTE
P11
507
578
CONTROL
VOLTAGE
RHEOSTAT
CONTACTOR
COIL
21
D
S5
67F
1B
1W
2B
3B
4B
67C
CONNECTS TO J11
ON HARNESS
RUN-
IN
70
1
2
21
E
CURRENT
TRANSDUCER
1
2
3 4
21C
10K2W
R1
10K2W
N.C.
70
2W
67D
67E
INPUT ELECTRODE
CABLE CONNECTION
N.B. N.C.
,
R2
CONNECTS TO J7
ON HARNESS
SHOWN OFF
75
A
1
2
3
4
5
6
7
8
9
67
C
67
G
1
2
3
4
5
6
1
2
3
4
5
6
J11
577A
575A
77A
75
B
L7
500A
576A
76A
75
76
77
667D
66
7
76B
667C
21
J17
N
OT
N.A. PI
LEA
OGGL
ES:
N
CONTACTO
R
622A
707A
575A
576A
577A
21
C
G
NEAREST T
OF SOCKET.
SWITCHE SHOW
OL ABL
ACROS TH AR
" T "TORQUE
LL MODELS.
H
E
FL
A
T
EDG
E
OF
L
E
D
LEN
S
(ANODE)
A
LIGNS
WITH
WHITE
77
B
N.D.
76
C
C
77
4A 42
2A 41
21
C
E
D
LED
62
1
621C
1
2
3
4
N.C.
67E
75
N.B.
T
E
S
R
S
N
FR
O
M
REA
MODEL
MODEL
EXTR
R
S
S
CONNECTIO
ONLY.
ONLY.
TORQU
N
SIDE
OF
SWITCH.
42
41
N.C. PRESENT
N.D. PRESENT
N.E. CONNECT
O
O
N
N
CONT
C
E
J18
41
B
10
CONNECTS TO P17
ON ASE FRONT
1 2 3 4 5 6 7 8 9
J15
41
C
E
C
P7
CONNECTS TO P18
ON CASE FRONT
42
C
41
70
75
76
77
8
C
CONNECT TO J18
ON HARNESS
"
EXTRA
O
"
ON
A
E
MODEL
S
ONLY.
C
AC
BRIDGE
RECTIFIER
10
667B
N.F.
NOT
PRESENT
O
N
A
11
12
13
14
15
16
CONNECTS TO 14 PIN
CIRCULAR CONNECTO
TIMER KIT
(
OPTIONAL)
14 PIN CIRCULAR CONNECTOR
TO POWER SOURCE
J19
R
1 2 3 4
P18
AC
D2
-
A
B
POST-FLOW
BURNBACK
J60
E
42
42
B
C
D
C
A
B
C
D
67
2
4
OUTPUT
1
2
TRIGGER
J14
J12
621B
CONTRO
L
C
AVITY NUMBERING SEQUENCE
CONNECTOR
3
75
D
D
77
D
E
F
1 2 3 4
R
EMOTE
VOLTAGE
CONTRO
21
21
667B
667A
5 6 7 8
(VIEWED FROM COMPONENT
S
IDE OF
P.C. BOARD)
76
76
D
4
622A
G
ENER
ELEC RIC
LEAD CO
A
L
INFORMATION
A
B
A
P15
L
CONNECTS TO J17
ON HARNESS
G
5
77
D
75
D
1
1
3
4
1
2
500A
T
A
L
SYMBOLS PER E1537
608
H
I
AC
-
P14
6
21F
2
601
509B
605
21F
C
D
E
J
J3, J5, J9, J60
J12, J17
A
J11, J16, J18
I
67B
41
A
A
1
2
3
4
5
6
7
BRIDGE
LOR CODING
4B
606
607
K
5
8
4
6
3
4
42VA
C
B
L6
J
4
41
8
H
N
D1
AC
RECTIFIER
B
- B
L
AC
K
42
K
L
M
L
1
A
A
5
1
6
1
8
9
621B
C
G
667A
21
J1, J2, J8, J15
M
J4
J6, J7, J10
10
42
W
-
WHITE
P17
D
A
F
67B
TO WORK CLIP
10
E
6
12
16
7
9
21B
621A 67
TO P60 ON
HARNESS
N
67
621A
N.B
.
C
G5681
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-3
G-3
ElECTriCal DiaGrams
WiriNG DiaGram - lN-25 prO - CODEs 11507, 11508 (G5681-1)
WIRING DIAGRAM LN-25 PRO
S1
S2
509D
509C
509D
509E
TRIGGER
INTERLOCK
2 STEP
S4
/
CC
/
CV
GAS PURGE
PUSHBUTTON
SWITCH
587A
523A
N.B.
,
N.F.
N.B.
SHOWN IN CV
SHOWN IN 2 STEP
FLEX
CONNECTS TO J8
ON P ESET P.C. BD.
61
2
0
509A
N.O.
P16
R
61
53
2
0
58
52
7
3
70
0
7
62
2W
1W
509A
70 61
3B
50
2
0
N.B.
509C
587A
523A
530A
50
9
50
9
1
2
3
4
S3
61
8
587
523
530
509B
N.B.
COLD
FEED
509E
530A
CONTROL P.C
.
BOARD
1 2
3
4
5
6
7
8 9 10
N.O.
1 2
3
4
5
6
7
8 9 10 11 12 13 14 15 16
60
1
1
2
3
4
5
6
7
8
509B
4B
J6
J1
FEED
P60
60
60
60
60
5
6
8
7
PLATE
1
2
3
4
5
6
7
8
9
10
60
1
6
60
TACH
608
GAS
SOLENOID
R
U
B
M
OT
O
R
/
GEARBOX
60
60
5
7
CONNECTS
TO TIMER
KIT
J2
69
0
1
EXTRA
TORQUE
ANALOG DISPLAY CASE FRONT
W
B
N.E.
P9
YELLOW
THERMAL
69
1W 1B
2B
2W
POLARITY
LED
WIRE FEED SPEED
CONTROL RHEOSTAT
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
LED
L4
L5
R
U
B
53
53
53
1
7
4
N.A.
N.A.
10K2W
R1
CONNECTS TO
P7 ON ASE
RONT
J4
J5
C
J3
F
-
CONNECTS TO
J7 ON HARNESS
577A
575A
B
W
551
0
ARC
VOLTMETER
BLACK
RED
576A
8
55
1 2
3
4
5
6
7
9
10 11 12
1
2
3 4
5
6
7 8
FAN
VM
+
721A
72
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TRIGGER
CONNECTOR
500A
500
550
69
0
50
7
53
7
53
1
575
66
7
2A 721A 67F
4A 21 62
667B
721
622A
A
B
622A
62
70
2
7
55
1
69
1
577
578
534
576
D
1
500A
C
D
E
P14
575A
576A
577A
57
57
57
70
5
6
21
A
7
8
BRIDGE
RECTIFIER
J7
P7
75C
76C
77C
667A
667B
AC
-
TO WORK CLIP
21B
50
7
578
CONT
A
CT
O
R
C
OIL
21
D
67F
1B
1W
2B
3B
4B
1B
1W
2B
AC
D1
67C
21
E
CURRENT
TRANSDUCER
1
2
3 4
N.D.
67B
21
C
2W
CONNECTS TO J17
ON HARNESS
621A
2W
67
D
67E
INPUT ELECTRODE
CABLE CONNECTION
67C
67B
1
2
3
4
5
6
1
2
3
4
5
6
J11
66
7
667A
21
667C
21
J17
N
OT
N.A. PI
LEA
OGGL
ES:
N
P17
CONTACTOR
C
A
NEAREST T
OF SOCKET.
SWITCHE SHOW
OL ABL
ACROS TH AR
" T "TORQUE
LL MODELS.
HE
FL
A
T
EDG
E
OF
L
ED
LEN
S
(ANODE)
A
LIGN
S
W
IT
H
W
HITE
N.D.
76C
4A 42
2A 41
21
C
E
D
LED
621A
621
1
2
3
4
N.C.
67
E
75
C
77
N.B.
T
E
S
N
FR
E
O
M
REA
MODEL
MODEL
EXTR
R
S
S
CONNECTIO
ONLY.
ONLY.
TORQU
N
SIDE
OF
S
W
IT H.
C
42
41
667D
667E
N.C. PRESENT
N.D. PRESENT
N.E. CONNECT
O
O
"
N
N
CONT
R
S
O
C
E
J18
L7
10
CONNECTS TO P17
ON ASE FRONT
1 2 3 4 5 6 7 8 9
J15
C
CONNECTS TO P18
ON CASE FRONT
C
EXTR
A
N
"
O
N
A
E
MODEL
S
ONLY.
N.F.
NOT
P
RESENT
O
A
CONNECTS TO 14 PIN
CIRCULAR CONNECTO
TIMER KIT
(
OPTIONAL)
14 PIN CIRCULAR CONNECTOR
TO POWER SOURCE
J19
R
A
B
C
POST-FLOW
BURNBACK
J60
E
D
C
A
B
67
2
4
OUTPUT
1
2
J14
J12
CONTRO
L
D
C
AVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT
3
75
D
D
D
77
D
E
F
G
1 2 3 4
R
EMOTE
VOLTAGE
CONTRO
5 6 7 8
S
IDE OF
P.C. BOARD)
76
76
D
4
G
ENER
ELEC RIC
LEAD CO
A
L
INFORMATION
P15
L
5
77
75
D
1
1
3
4
1
2
T
A
L
SYMBOLS PER E1537
OR CODING
60
6
8
H
I
J
K
L
M
6
21F
2
601
509B
605
21F
J
J3, J5, J9, J60
J12, J17
A
J11, J16, J18
I
41
A
A
7
L
4B 60
607
K
5
8
4
6
3
4
42VA
C
B
L6
4
8
H
N
B
- B
L
AC
K
42
L
1
1
6
1
8
9
41
A
A
5
C
G
J1, J2, J8, J15
M
J4
J6, J7, J10
10
42
W
-
WHITE
D
F
10
E
6
12
16
7
9
TO P60 ON
HARNESS
N
67
B
G5681-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ElECTriCal DiaGrams
WiriNG DiaGram - lN-25 prO - CODEs 11620, 11621, 11716, 11717 (G5681-2)
WIRING DIAGRAM- LN-25 PRO ANALOG
J61
MOTOR FILTER P.C BOARD
.
S1
S2
1
2
3 4
509D
509E
TRIGGER
509D
509C
667D B1
INTERLOCK
2 STEP
/
CC CV
/
667E B2
587A
523A
N.B.
N.B.
(SHOWN IN CV)
(SHOWN
IN 2 STEP)
509A
P16/J16
53
2
0
58
52
7
3
70
0
7
62
2W
1W
509A
70 61
3B
50
0
N.B.
509C
587A
523A
530A
50
9
50
9
1
2
3
4
S3
61
8
2
587
523
530
509B
COLD
FEED
509E
530A
1
2
60
60
60
1
6
8
1 2
3
4
5
6
7
8 9 10
N.O.
1 2
3
4
5
6
7
8 9 10 11 12 13 14 15 16
60
1
1
3
2
3
4
5
6
7
8
509B
4
5
6
7
8
9
10
60
60
EXTR
5
7
4B
J6
J1
FEED
PLATE
J2
P60
N.D.
605
606
608
607
A
TORQUE
TACH
B2
R
U
B
555
M
OT
OR
/
CONNECTS
TO TIMER
KIT
GEARBOX
CONTROL P.C BOARD
.
GAS PURGE
PUSHBUTTON
SWITCH
ANALOG DISPLAY CASE FRONT
W
B
B1
P20/J20
YELLOW
THERMAL
61
2
0
1W 1B
2B
2W
POLARITY
LED
N.O.
WIRE FEED SPEED
CONTROL RHEOSTAT
61
1
2
LED
L4
S4
R
U
B
3
4
5
6
7
8
53
53
53
1
7
4
N.A.
N.A.
10K2W
R1
1
2
3
4
5
6
7
8
N.B.
J4
J5
L5
577A
575A
B
W
551
0
J3
ARC
VOLTMETER
576A
8
55
-
1 2
3
4
5
6
7
9
10 11 12
1
2
3 4
5
6
7 8
BLACK
RED
P7/J7
1
2
3
4
5
6
7
8
FAN
VM
+
721A
50
55
721
TRIGGER
CONNECTOR
500A
555A
622A
0
5
550
69
0
50
7
53
7
53
1
575
66
7
2A 721A 67F
4A 821B 62
667B
72
1
622A
500A
555A
A
B
C
D
E
62
2
55
1
69
1
577
578
534
576
1
707
69
0
1
P14
575A
576A
577A
57
57
57
70
5
GAS
SOLENOID
WORK
A
6
622B
7
8
BRIDGE
RECTIFIER
69
9
75C
76C
77C
10
11
12
13
14
15
16
667A
667B
AC
-
WORK
B
50
7
578
CONT
ACTO
R
COIL
67F
1B
1W
2B
3B
4B
1B
1W
2B
AC
D1
67C
TO WORK CLIP
67B
2W
621A
2W
67D
67E
67
C
67
B
1
2
3
4
5
6
667
667A
WOR
667C
821B
21
CONTACTO
R
K
A
INPUT ELECTRODE
ABLE CONNECTION
E
1
C
621A
62
1
76
C
77C
21
E
4A 42
2A 41
42
41
2
3
4
667D
67E
75C
667E
J18
P17/J17
TIMER KIT (OPTIONAL)
10
J15 1 2 3 4 5 6 7 8 9
C
AVITY NUMBERING SEQUENCE
E
(VIEWED FROM COMPONENT
S
IDE OF
P
.C. BOARD)
D
A
POST-FLOW
BURNBACK
J60
J14
1
3
1
2
N
OTES:
C
B
J11, J
16,
J12, J17
8
J18, J61
4
6
3
4
N.A. PI
LEA
N.B. SWITCHE
N.D. CONNECT
N
NEAREST T
OF SOCKET.
SHOW FR
EXTR " T
H
E
FL
A
T
EDG
E
OF
L
E
D
LEN
S
(ANODE)
A
LIGN
S
W
IT
H
WHITE
1 2 3 4
5 6 7 8
5
1
1
4
8
D
LED
J3, J5, J9,
J20, J60
J1
9
S
N
A
O
M
REA
R
CONNECTIO
"
N
SIDE
OF
E
SWIT
C
H.
ONLY.
60
6
8
60
601
509B
60
4B 60
5
5
4
"
O
"TORQUE
O
N
EXTR
A
TORQU
MODELS
G
ENER
ELEC RIC
LEAD CO
A
L
INFORMATION
SYMBOLS PER E1537
OR CODING
7
1
5
1
6
1
8
T
AL
J1, J2,
J15
J4
J6, J7
L
10
6
12
16
7
9
B
- B
L
AC
K
TO P60 ON
HARNESS
W
-
WHITE
A
G5681-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ElECTriCal DiaGrams
WiriNG DiaGram - lN-25 prO - CODEs 11746, 11747 (G5681-3)
WIRING DIAGRAM- LN-25 PRO ANALOG
J61
MOTOR FILTER P.C BOARD
.
S1
S2
1
2
3 4
509D
509E
TRIGGER
INTERLOCK
2 STEP
509D
509C
667D B1
/
CC CV
/
667E B2
587A
523A
N.B.
N.B.
(SHOWN IN CV)
(SHOWN
IN 2 STEP)
509A
P16/J16
53
2
0
58
52
7
3
70
0
7
62
2W
1W
509A
70 61
3B
50
0
N.B.
509C
587A
523A
530A
50
9
50
9
1
2
3
4
S3
61
8
2
587
523
530
509B
COLD
FEED
509E
530A
1
2
60
60
60
1
6
8
YELLOW
THERMAL
LED
1 2
3
4
5
6
7
8 9 10
POLARITY
LED
N.O.
1 2
3
4
5
6
7
8 9 10 11 12 13 14 15 16
60
1
1
3
2
3
4
5
6
7
8
509B
4
5
6
7
8
9
10
60
60
EXTR
5
7
4B
J6
J1
1W 1B
2B
FEED
PLATE
2W
J2
P60
N.D.
605
606
608
607
A
TORQUE
N.A.
N.A.
TACH
B2
R
U
B
555
M
OT
OR
/
CONNECTS
TO TIMER
KIT
GEARBOX
CONTROL P.C BOARD
.
GAS PURGE
PUSHBUTTON
SWITCH
W
B
B1
P20/J20
WIRE FEED SPEED
CONTROL
61
2
0
N.O.
61
WFS RANGE
SWITCH
1
2
POTENTIOMETER
L4
S4
S5
R
3
4
5
6
7
8
53
53
53
1
7
4
10K2W
R1
1
2
3
4
5
6
7
8
U
B
N.B.
N.B.
J4
J5
L5
577A
575A
B
W
551
0
J3
ARC
VOLTMETER
576A
8
55
-
1 2
3
4
5
6
7
9
10 11 12
1
2
3 4
5
6
7 8
BLACK
RED
P7/J7
555A
622B
FAN
VM
+
721A
50
55
72
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TRIGGER
500A
555A
622A
0
5
CONNECTOR
55
0
55
69
1
0
69
50
1
7
57
53
7
7
57
53
8
1
53
575
667
2A 721A 67F
4A 821B 62
667B
721
622A
500A
A
B
62
2
4
576
1
707
69
0
1
C
D
E
P14
575A
576A
577A
57
57
57
70
5
GAS
SOLENOID
WOR
K
A
6
7
8
BRIDGE
RECTIFIER
69
75C
76C
77C
667A
667B
AC
-
WOR
K
B
507
578
CONT
ACTOR
COIL
67F
1B
1W
2B
3B
4B
1B
1W
2B
AC
D1
67C
TO WORK CLIP
67B
2W
621A
2W
67D
67E
67
C
67
B
1
2
3
4
5
6
667
667A
WOR
667C
821B
21
CONTACTO
R
K
A
INPUT ELECTRODE
ABLE CONNECTION
E
1
C
621A
62
1
76
C
77C
21
E
4A 42
2A 41
42
41
2
3
4
667D
67E
75C
667E
J18
P17/J17
TIMER KIT (OPTIONAL)
10
J15 1 2 3 4 5 6 7 8 9
C
AVITY NUMBERING SEQUENCE
E
(VIEWED FROM COMPONENT
S
IDE OF
P
.C. BOARD)
D
A
POST-FLOW
BURNBACK
J60
J14
1
3
1
2
N
OTES:
C
B
J11, J
16,
J12, J17
8
J18, J61
4
6
3
4
N.A. PI
LEA
N.B. SWITCHE
N.D. CONNECT
N
NEAREST T
OF SOCKET.
SHOW FR
EXTR " T
H
E
FL
A
T
EDG
E
OF
L
E
D
LEN
S
(ANODE)
A
LIGN
S
W
IT
H
WHITE
1 2 3 4
5 6 7 8
5
1
1
4
8
D
LED
J3, J5, J9,
J20, J60
J1
9
S
N
A
O
M
REA
R
CONNECTIO
"
N
SIDE
OF
E
SWIT
C
H.
ONLY.
60
6
8
60
601
509B
60
4B 60
5
5
4
"
O
"TORQUE
O
N
EXTR
A
TORQU
MODELS
G
ENER
ELEC RIC
LEAD CO
A
L
INFORMATION
SYMBOLS PER E1537
OR CODING
7
1
5
1
6
1
8
T
AL
J1, J2,
J15
J4
J6, J7
L
10
6
12
16
7
9
B
- B
L
AC
K
TO P60 ON
HARNESS
W
-
WHITE
A.01
G5681-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11387, 11388 - (G5683) pG1
3 8 6 G 5
CHANGE
DETAIL:
REVISED LEADS GOING TO P17.
ENGINEERING CONTROLLED
MANUFACTURER: No
LN-25 PRO WIRE FEEDER
PRESE
T
P. C. BOARD CIRCUIT
SCHEMATIC
=
G4748
FRONT)
(LOCATED
O
N CASE
TIMER P. C. BOARD CIRCUIT
MOTOR
THERMAL
3 LEDs
WFS/AMPS DISPLA
Y
VOLTS DISPLA
VOLTS
Y
7 SEGMENT
DISPLAYS
(2 each)
Timer Board Summary
Has potentiometers for
701
702
J10-10
J10-11
B
urnback, Preflow and
P
ostflow.
WFS
set=WFS
actual = AMP
AMPS
0V = RUN
IN ENABLED
Preflow range from
Burnback range from 0 to 250 ms.
Postflow range from 0ms to 10 s.
Receives “Gas Flow Enable” signal.
Outputs 1 ms pulses to turn Gas Flow On
0ms to 10s.
S
T
O SWITCH S5 RUN
IN
SIGNALS TO
DISPLA & LED
{
{
Y
5
SERIAL SPI
OMMUNICATION
SPI (10 leads)
C
T
O J1
6
/
Off.
CONTROL
PC BOARD
77B
76B
75B
J10-16
J10-14
J10-15
MICROCONTROLLER
+
(LOCATED
REE COVER)
B
EHIND
WIRE
TO REMOTE VOLTS
POTENTIOMETER R2
AND POWER SOURCE
VOLTAGE
L
-
MEASUREMENT
OF REMOTE
VOLTS
(LOCATED
ON CASE FRONT)
POTENTIOMETER
ADJUST KNOB
-
+
ADJUST KNOB
ADJUST KNOB
SETUP
PUSHBUTTON
SETUP
LED
+5V
+5V
CW= +5
CCW= 0V
1
0K
1
0K
BURNBAC
POT.
K
ARC VOLTAGE
MEASUREMENT
FOR DISPLAY
ELECTRODE
67
21
J10-6
J10-8
PREFLOW
POT.
POSTFLO
POT.
W
ARC VOLTAGE
FEEDBACK
SETUP
{
WORK
PUSHBUTTON
(BOARDMOUNTED
COM
COM
COM
+15V
)
15V SIGNAL
-15V
1
5V
805
804
801
J10-9
J10-4
J10-1
15 ms PULSES
OUTPU
T
TOGGLE GAS FLOW
ON/OFF
ARC CURREN
T
MEASUREMENT
5V
FOR DISPLAY & ARC ESTABLISHED
ARC CURRENT
FEEDBACK
{
ARC ESTABLISHED OUTPUT
IF V> 10V RELATIVE TO COMMON
708
J10-12
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
802
J10-2
MICROCONTROLLER
0V= ARC NOT ESTABLISHED
COM
5V SIGNAL
GAS FLOW
ENABLE
+4V = +500A
-4V = -500A
TO CONTROL BOARD (VIA P7)
COM
J60-8
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2
J60-1
J12-1
J12-4
41
42
INPUT
POWER
CONTROL CABLE
NPU POWER
DETECTION
(<18 VAC O DETECT)
I
T
FROM CONTROL BOARD (VIA P7)
707
-15V
J6-8
{
T
NOT
USED
606A
509B
601
60
7
60
8
60
5
4B
TO CONTROL BD. (VIA P60 plug)
THIS DOCUMENT CONTAINS PROPRIETAR
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
INFORMATION OWNED B
T
Y
LINCOLN GLOBAL, INC. AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
M
ANUFACTURING TO
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( 0.5 mm)
ON PLACE CIMALS IS 002 in. 0.
ON ALL ANGL S IS ± .5 OF A D GREE
MATERI L TO ERANCE (" ) TO AGREE
WITH PU LISHED STANDARDS.
L
ERANC
E
P
ER
E2056
SCALE:
NONE
CONTROL: CLEVE
L
AND
EQUIPMENT TYPE:
2
2
LN-25 PRO
MACHI E SCHEMATIC
PAGE ___ OF ___
±
DRAWN BY:
ENGINEER:
APPROVED:
d
di
e
tz
3
D
E
E
L
±
.
(
±
0
5
mm)
IF PRIN
T
ED
DOCUMEN
NUMBER:
T
DOCUMENT
REVISION:
E
SUBJECT:
ATERIAL
@ A SIZ
2
E
N
A
"
ENYEDY
-
t
UNITS:
REFERENCE:
B
APPROVAL
M
PROJECT
NU BER:
G5683
UF
DISPOSITION:
11/16/2007
C
CRM39437
DATE
:
INCH
M
-
DO NO
T
SCALE
THIS DRAWING
Insight
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11387, 11388 - (G5683) pG2
3 8 6 G 5
CHANGE
DETAIL:
REVISED LEADS GOING TO P17.
ENGINEERING CONTROLLED
MANUFACTURER: No
LN-25 PRO WIRE FEEDER
PRESE
T
P. C. BOARD CIRCUIT
SCHEMATIC
=
G4748
FRONT)
(LOCATED
O
N CASE
TIMER P. C. BOARD CIRCUIT
MOTOR
THERMAL
3 LEDs
WFS/AMPS DISPLA
Y
VOLTS DISPLA
VOLTS
Y
7 SEGMENT
DISPLAYS
(2 each)
Timer Board Summary
Has potentiometers for
701
702
J10-10
J10-11
B
urnback, Preflow and
P
ostflow.
WFS
set=WFS
actual = AMP
AMPS
0V = RUN
IN ENABLED
Preflow range from
Burnback range from 0 to 250 ms.
Postflow range from 0ms to 10 s.
Receives “Gas Flow Enable” signal.
Outputs 1 ms pulses to turn Gas Flow On
0ms to 10s.
S
T
O SWITCH S5 RUN
IN
SIGNALS TO
DISPLA & LED
{
{
Y
5
SERIAL SPI
OMMUNICATION
SPI (10 leads)
C
T
O J1
6
/
Off.
CONTROL
PC BOARD
77B
76B
75B
J10-16
J10-14
J10-15
MICROCONTROLLER
+
(LOCATED
REE COVER)
B
EHIND
WIRE
TO REMOTE VOLTS
POTENTIOMETER R2
AND POWER SOURCE
VOLTAGE
L
-
MEASUREMENT
OF REMOTE
VOLTS
(LOCATED
ON CASE FRONT)
POTENTIOMETER
ADJUST KNOB
-
+
ADJUST KNOB
ADJUST KNOB
SETUP
PUSHBUTTON
SETUP
LED
+5V
+5V
CW= +5
CCW= 0V
1
0K
1
0K
BURNBAC
POT.
K
ARC VOLTAGE
MEASUREMENT
FOR DISPLAY
ELECTRODE
67
21
J10-6
J10-8
PREFLOW
POT.
POSTFLO
POT.
W
ARC VOLTAGE
FEEDBACK
SETUP
{
WORK
PUSHBUTTON
(BOARDMOUNTED
COM
COM
COM
+15V
)
15V SIGNAL
-15V
1
5V
805
804
801
J10-9
J10-4
J10-1
15 ms PULSES
OUTPU
T
TOGGLE GAS FLOW
ON/OFF
ARC CURREN
T
MEASUREMENT
5V
FOR DISPLAY & ARC ESTABLISHED
ARC CURRENT
FEEDBACK
{
ARC ESTABLISHED OUTPUT
IF V> 10V RELATIVE TO COMMON
V= ARC NOT ESTABLISHED
708
J10-12
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
802
J10-2
MICROCONTROLLER
0
COM
5V SIGNAL
GAS FLOW
ENABLE
+4V = +500A
-4V = -500A
TO CONTROL BOARD (VIA P7)
COM
J60-8
J60-4 J60-3
J60-7 J60-6 J60-5
J60-2
J60-1
J12-1
J12-4
41
42
INPUT
POWER
CONTROL CABLE
NPU POWER
DETECTION
(<18 VAC O DETECT)
I
T
FROM CONTROL BOARD (VIA P7)
707
-15V
J6-8
{
T
NOT
USED
606A
509B
601
60
7
608
60
5
4B
TO CONTROL BD. (VIA P60 plug)
THIS DOCUMENT CONTAINS PROPRIETAR
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
INFORMATION OWNED B
T
Y
LINCOLN GLOBAL, INC. AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
M
ANUFACTURING TO
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( 0.5 mm)
ON PLACE CIMALS IS 002 in. 0.
ON ALL ANGL S IS ± .5 OF A D GREE
MATERI L TO ERANCE (" ) TO AGREE
WITH PU LISHED STANDARDS.
L
ERANC
E
P
ER
E2056
SCALE:
NONE
CONTROL: CLEVE
L
AND
EQUIPMENT TYPE:
2
2
LN-25 PRO
MACHI E SCHEMATIC
PAGE ___ OF ___
±
DRAWN BY:
ENGINEER:
APPROVED:
d
di
e
tz
3
D
E
E
L
±
.
(
±
0
5
mm)
IF PRIN
T
ED
DOCUMEN
NUMBER:
T
DOCUMENT
REVISION:
E
SUBJECT:
ATERIAL
@ A SIZ
2
E
N
A
"
ENYEDY
-
t
UNITS:
REFERENCE:
B
APPROVAL
M
PROJECT
NU BER:
G5683
UF
DISPOSITION:
11/16/2007
C
CRM39437
DATE
:
INCH
M
-
DO NO
T
SCALE
THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11507, 11508 - (G5683-1) pG1
1 - 8 3 5 6 G
CHANGE
D
ETAIL: MISC. UP
D
ATES PER SE
R
VICE DEPARTMENT.
E
NGINEERING CONTROLLED
When tach feed back is lost,
the voltage to the motor is a
constant 10VDC.
Start-Up
On power-up, the LN-25 PRO wil
polarity LED 2-3 seconds.
MANUFACTURER: No
l
light the motor thermal LED and
P
7
=
=
16 PI
PIN (Both are located on lower front)
(contro
N
P17
6
LN-25 PRO WIRE FEEDER
l
led by software
)
If the feeder is powered-up with the trigger depressed, welding will
not start until the trigger is released and then depressed again.
G
earbox ratio is 23.5:1
72 HZ TO 1.2 KHZ
3
Motor resistanc
is 1.5 ohms
e
Motor case is at
electrode potential
R
B-
-B 15.0 VD
C
667C
62
667A
T
op of
motor
U
6.2 VDC ANY SPEED
667B
1 of 2
21A
P17
6
Leads Pass through
toroid 2 times.
Notes:
Motor overcu
(METE
R
DEPENDENT)
1
2
3
4
5
6
7
8
P
17
4
1
Motor is locate
behind
glastic pane
d
1
621A
R
U
rrent limit varies with WFS.
2 of 2
PLASTIC HO
CONNECTIO
U
N
SED BOLTE
(BASE CENTER)
D
L4
531
531
l
Before 2-20-2009
WOR
K
CLIP
21
C
D1
FEED
537
534
B
537
534
Current
Level
67C
67D
PLAT
E
MOT R /
O
21B
-
67B
GEARBOX
From Power Source
(Electrode onnection)
B
4.5
3.5
551
550
C
L
C
ocat
e
d
on
copper bar
case fron
t
weld cable
coppe bar
r
W
ase front
strain relief
case back
strain relief
67C
67B
TAKEN WITH 40 V INPUT
IN V MODE.
P9
L12081 2.6 V @ 50 IPM
27 V @ 700 IPM
gun connecto
r
C
67C & 67
D
Preset
WFS
Leads Pass
through
TRIGGE
R
CONNECTOR
J14
L13084 2.6 V @ 25 IPM
32 V @ 400 IPM
EXTRA TORQUE
TRIGGER
IN UT
Located on
toroid2times.
Located on Wir
A
622A
500A
P
e
B
C
D
14 PIN
LEA S ARE
PRESENT BUT
REMOTE
Drive
Panel
After 2-20-2009
Current
Level
TRIGGER INT
E
RLOCK
K2613-3)
D
Case
Front
0V.=TRIGGER
CLOSED
15VDC.=TRIGGER
OPEN
L5
(NOT PRESENT
ON
NOT
SE
E
S
1,
S
2
e
& S3 Located
NOT
THIS
U
U
SED I
NIT.
N
U
D
S1
15V=2 STEP
0V=TRIGGE
INTE LOCK
on Wir
Drive
Panel
R
4.5
3.5
J18
509E
587
R
T
rigger Interlock does not sto
elding hen the arc is broken.
ull and release to end the eld.
p
509B
IN HARNESS
CENTER BASE
AREA
w
w
9
10
Preset
WFS
2-STEP
P
w
509D
15V=CV
0V=CC
COLD FEED
370
530
700
77
76
75
C
C
C
5
4
3
1
6
2
7
8
S2
CC
*Extra Torque
180* 257* 400*
TIMER KIT P.C. BOARD
0V=CO
N.O.)
L
D FEE
D
509E
530A
509B
4
(
OPTIONAL
)
(
622
500
The WFS range of the LN-25 PRO
Normal Speed = 40- 700 IPM.
Extra Torque = 25- 400 IPM.
J15
SCHEMATIC
=
M21341
S3
N.O.
CV
SEE PAGE 2
2
21E
509C
WFS limited by arc voltage when operating across the arc
LINE FILTER FO
INVERTER INPUT POWER.
R
NOISE ON
1 of 4
P7
667B
523
509B 601
607 608 606A 605 4B
Maximum WFS
LO
CATED ABOVE CONTROL
4
0
3
O COIL
VDC OPEN
VDC CLOSED
Feeder Input Volts Standard Gear Extra Torque
ANALO
G
P16
on
top of motor
BOARD ON TOP CENTER OF
CONTROL BO
3
1
4
2
VOLTMETER
15
17
21
24
27
280
340
440
520
600
210
235
400
400
400
+
-
X
ASSEMBLY
L
ocated
8
7
6
4
3
5
2
1
12 VDC COIL
PWM CONTROLLED
P6
0
40V MAX.
721
Located under
Wire
Drive
Panel
CONTACTOR
10 75
11
12 77
C
P7-1
76C
Control Board Summary
3 of 4
C
Converts arc power to a usable control circuit voltage.
Receives switch signals from Trigger, Cold Feed, Gas Purge
Reads WFS potentiometer.
JUMPER TOGETHER FO
R
Connector
ocated
EXTRA TORQ E MACHINE
U
l
P7
4 of 4
behind cas
front
e
ISOLATED 2-4 TO
POWER SOURCE
575A
576A
577A
6
7
8
575A
576A
577A
Communicates with optional timer kit.
534
21D
550
4
622
531
EXTRA
606
Controls motor speed with PWM.
605
608
601
607
721
67F
530
537
551
2
578 507
Located on
Case Front
500
TORQUE
587
509A
523
Turns Gas Solenoid on, off, PWM
Reads the motor tachometer.
.
+35V
575A
J6-9
J6-3
J6-10
10K/2W
J4-12 J4-6
J5-7
J4-9
J4-2
J5-3
J2-1
J4-11
J4-10
J5-5
J6-4
J2-7
J5-6
J6-2
J5-4
J6-6
8
J4- J4-5
J2-5
J2-8
J4-7
J2-3
J2-6
O
perating V
oltage= 15-110 VDC.
J2-2
J4-1
+15V
MOTOR
SUPPL
+15
V
+5
V
100K
576A
577A
R1
+15
V
Shut down Voltage= 130 VDC
.
Y
20
ohm
o
hm
1
o
0K
hm
MOV
TRIGGER
Thermal light turns on when shutdown voltage exceeded.
Code and Serial numbers are below Wire Drive on plastic
housing Nameplate.
MACHINE
0 VDC MIN. WFS
5 VDC MA WFS
WI
R
E FEE
CONT
OT
D
R
SPEED
OL
+5V
J5-1
OUTPU
ENABLE
T
+15V
CC/VV
X.
COM
T
RIGGER INTERLOCK / 2 STEP
CONTACTOR DRIVE
+15V SPI
+5V SPI
-15V
P
E
NTIOMETER
COLD FEED
.05 uF
600 V
COM
POWER
SUPPL
Thermal “Yellow” Light
Y
+15V ISO
+5VDC
MICRO
CONTROLLER
100K
ohm
Motor Over Current
LED
COM
METER
Motor and trigger disabled for 30 seconds.
Must retrigger to start welding after 30 seconds pass.
Shutdown Voltage exceeded
3
5VDC
ISO
COMPENSATION
CIRCUIT
POLARITY
SENSE
4B
721 IS DRIVEN NEGATIVE TO COMPENSATE
FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE
GAS
ON - OF
F
667
+15
-15
MOTOR
May occur with some inverters.
May occur with some CC machines with high
inductance.
OVER
POWER
SUPPL
0V = OFF
0msec ---- 250msec
SUPPL
Y
VOLTAGE
Y
2
PROTECTION
BURNBACK
J5-8
62
1
DRIVE
COM
(LOCATED
OUTSI REAR
FEEDER)
AT
PW
M
Polarity “Green” Light
D
E
GAS PURGE
PUSHBUTTON
SWITCH (N.O.)
DRIVE
OF
+15V
On= Positive Polarity
M
D
OTO
RIVE
CIRCUI
R
BRAKE
GAS
FLOW
61
61
0
BRAKE
J6-7
J6-1
Off= Negative Polarity
MOTOR VOLTAGE
MOTOR CURRENT
YELLO
W
THERMAL LED
S4
T
2
COM
+5V SPI
J6-14
ENABLE
0.05K
oh
13.5 VDC WHEN
NOT EP ESSED
m
15
D
R
0-5V PULSE SIGNAL
FREQUENC
2B
1B
B
COM
(OUTSIDE BACK
OF CASE)
POLARITY LED
TACH
FEEDBACK
Y
=
SPEED
(LOCATED
FRONT
A
T
TOP
FEEDER)
13
OF
0V = MIN SPEED
5V = MAX SPEE
N
o
ot pres
ent
WIRE FEED
SPEED
+35V
D
n
K2613-3
J4-3
J4-4
GAS
690
COM
ARC ESTABLISHED
GAS PURGE
Y
ELLOW
MOTOR
TH RMAL
LE
SOLENOID
22 O COIL
14
16
GREEN
POLARITY
LED
GAS SOLENOID
J6-11
J6-12
J6-5
1W
2W
70
E
D
69
1
0
VDC OPEN
25 TO 35
NORMAL
PROGRAM
4 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
9
5
FLOW
RATE
8
-15V
(LOCATED
A
FEEDER)
T
REAR
FLE
X
IBLE POWER P.C. BOARD
+5
V
SPI
+5
V
+5V SPI
J1-2
+15V
OF
J6-8
707
SCHEMATIC G4745
=
COM
BALL FLOAT
SE MID LE OF
BALL TO SE
2 of 4
P7
U
D
T
J3-8
J3-7
J1-10
J3-6
J1-1
(LOCATEDINSIDE OF
CONTROL BOX)
RED
BLACK
ADJUST VALVE
FLOW METER
FAN BLOWS AIR ACROSS
CONTROL PC BOA
PROGRAMMING PCB
FACTORY USE ONLY
FAN
SPI DIGITAlL COMMUNICATION
GOOD FOR Ar, CO2,
CO2/Ar BLENDS
R
D
-
CONTINOUSLY AT 6200 RPMS.
Model
Ranger 8,9
Classic
Ranger 250, 305
V350
DC
-400, 600
Square Wave TIG 300/355
Miller Inverters
STT II
Note:
Commander 300,400,500
(Common Analog
Controls)
(Common Digital
Controls)
Most semiautomatic wire
welding processes perform
better using constant voltage
K
2613-1
Recommended
all CV
operation.
Recommended for
CV operation.
(Wire Feed
Recommended for CV
operation.
Recommended
for CV
operation.
May be used for
pulse welding if
the welding
procedure is
qualified by the
customer.
Recommended
for CV and CC
operation.
Not recommended for CC operation
because the customer may
experience short contactor life from
inductive nature of the power source.
Not recommended with high frequency
TIG starting.
Recommended
for CV voltage
sense operation.
Not
recommended for
use when pulse
welding.
Notrecommended power sources. Be sure the
for STT operation. proper power source is used
K2613-2
K2613-3
for your application. Contactor
life may be shortened in
applications using CC
THIS DOCUMENT CONTAINS PROPRIETAR INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
Y
PROPRIETARY & CONFIDENTIAL:
Module Required)
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU
T
THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
M
ANUFACTURING TO
L
ERANC
E
P
ER
E2056
CONTROL: CLEVE
L
AND
SCALE:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIPMENT TYPE:
1
2
machines with high OCV.
LN-25 PRO
E SCHEMATIC
PAGE ___ OF ___
T
ON
ON
ON
MATERI
WITH PU
2
3
A
PLAC
PLACE
LL ANGL
TO
LISHED STANDARDS.
E
D
D
E
E
L
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
±
S
±
.02 in.
(
0.
±
0.5 mm)
NONE
DRAWN BY:
ENGINEER:
APPROVED:
tpear
n
.
00
A
2
DE
TO
i
n.
GREE
GREE
(
±
0
5
mm)
DOCUMEN
REVISION:
T
DOCUMEN
NUMBER:
IF PRIN
T
ED
S
I
S
±
SUBJECT:
MA ERIAL
MACHI
2/12/2010
N
@
A
1
SIZ
E
A
L
E
"
)
A
ENYEDY
SCHOLTI
t
UNITS:
B
REFERENCE:
T
APPROVA
DA E:
L
PROJEC
T
G5683-
1
NA
C
CRM40936
DISPOSI ION:
T
T
NUMBER:
INCH
DO NO
T
SCAL HIS DR
E
T
A
WING
G5683
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11507, 11508 - (G5683-1) pG2
1 - 3 8 6 G 5
CHANGE
DETAIL: MISC. UP
DATES PER SE
RVICE DEPARTMENT.
ENGINEERING CONTROLLED
MANUFACTURER: No
LN-25 PRO WIRE FEEDER
TIMER P. C. BOARD CIRCUIT
Timer Board Summary
Has potentiometers for burnback, postflow and preflow.
Preflow range is 0 to 10 sec.
Burnback range is 0 to 0.25 sec.
Postflow range is 0.25 to 10 sec.
Receives “Gas Flow Enable” signal.
Outputs 100 msec pulses to turn Gas Flow On, Gas Flow Off.
(LOCATED
BEHIND
WIRE
REE COVER)
L
(LOCATED
ON CASE FRONT)
ADJUST KNOB
ADJUST KNOB
ADJUST KNOB
+5V
+5V
CW= +5
CCW= 0V
1
0K
1
0K
BURNBAC
K
POT.
PREFLOW
POT.
POSTFLO
POT.
W
COM
COM
COM
1
5V SIGNAL
1
5V
15 ms PULSES
OUTPU
T
TOGGLE GAS FLOW
ON/OFF
5V
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
MICROCONTROLLER
COM
5V SIGNAL
GAS FLOW
ENABLE
J60-8
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2
J60-1
NOT
USED
60
7
60
8
606A
509B
601
60
5
4B
TO CONTROL BD. (VIA P60 plug)
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
T
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
M
ANUFACTURING TO
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( 0.5 mm)
ON PLACE CIMALS IS 002 in. 0.
ON ALL ANGL S IS ± .5 OF A D GREE
MATERI L TO ERANCE (" ) TO AGREE
WITH PU LISHED STANDARDS.
L
ERANC
E
P
ER
E2056
SCALE:
NONE
CONTROL: CLEVE
L
AND
EQUIPMENT TYPE:
2
2
LN-25 PRO
E SCHEMATIC
PAGE ___ OF ___
±
DRAWN BY:
ENGINEER:
APPROVED:
tpear
n
3
D
E
E
L
±
.
(
±
0
5
mm)
IF PRIN
T
ED
DOCUMEN
NUMBER:
T
DOCUMEN
REVISION:
T
E
SUBJECT:
ATERIAL
@ A SIZ
2
E
MACHI
N
A
"
ENYEDY
SCHOLTI
t
UNITS:
REFERENCE:
B
APPROVAL
M
PROJECT
NU BER:
G5683-
1
NA
DISPOSITION:
2/12/2010
C
CRM40936
DATE
:
INCH
M
G5683
DO NO
T
SCALE
THIS DRAWING
Insight
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11620, 11621, 11716, 11717 - (G5683-2) pG1
2 - 3 8 6 G 5
CHANGE
D
ETAIL:
RELEASED A.03 FROM "X".
E
NGINEERING CONTROLLED
When tach feed back is lost,
the voltage to the motor is a
constant 10VDC.
Start-Up
On power-up, the LN-25 PRO wil
polarity LED 2-3 seconds.
MANUFACTURER: No
l
light the motor thermal LED and
P
7
=
=
16 PI
PIN (Both are located on lower front)
(contro
N
3
P17
6
LN-25 PRO WIRE FEEDER
667C
667A
l
led by software
)
WORK
LI
1 of 2
21A
P17
6
If the feeder is powered-up with the trigger depressed, welding will
not start until the trigger is released and then depressed again.
G
earbox ratio is 23.5:1
72 HZ TO 1.2 KHZ
P
17
4
1
667B
621A
C
P
Motor resistanc
is 1.5 ohms
e
Motor case is at
electrode potential
R
B-
-B 15.0 VD
C
2 of 2
T
op of
motor
21B
U
6.2 VDC ANY SPEED
Leads Pass through
toroid2times.
Notes:
Motor overcu
21
C
D1
(METE
R
DEPENDENT
)
1
2
3
4
5
6
7
8
Motor is locate
behind
glastic pane
d
R
U
rrent limit varies with WFS.
case fron
t
67B
-
PLASTIC HO
CONNECTIO
U
N
SED BOLTE
(BASE CENTER)
D
L4
531
531
L
C
ocat
ed
on
l
Before 2-20-2009
strain relief
FEED
667D
ase front
537
534
B
537
534
Current
Level
67C
67D
PLAT
E
MOT R /
O
GEARBOX
From Power Source
(Electrode onnection)
B
4.5
3.5
IN HARNESS
CENTER BASE
AREA
551
550
C
coppe bar
r
weld cable
coppe bar
r
W
case back
strain relief
67C
67B
MOTO
BOAR
S27592 BEFORE 6/15/200
S27505 AFTE 6/15/200
R
FILTE
R
P.C.
TAKEN WITH 40 V INPUT
IN V MODE.
P9
L12081 2.6 V @ 50 IPM
27 V @ 700 IPM
gun connector
C
D
SCHEM
ATIC=
67C & 67
D
Preset
WFS
667D
9
Leads Pass
through
TRIGGE
R
CONNECTOR
J14
R
9
1
L13084 2.6 V @ 25 IPM
32 V @ 400 IPM
U
SED FOR FILTERING
J61-
EXTRA TORQUE
TRIGGER
IN UT
Located on
as ront
INVERTE NOISE
R
toroid 2 times.
Located on Wir
A
622A
500A
P
e
B
C
D
14 PIN
LEA S ARE
PRESENT BUT
REMOTE
J61-2
Drive
Panel
TRIGGER INT
ERLOCK
After 2-20-2009
Current
Level
D
C
e
F
(NOT PRESENT
O
N
K2613-3)
555A
S1,
S2
& S3 Locate
d
L5
J61-3
NOT
SE
on Wir
e
D
riv anel
e
P
E
0V.=TRIGGER
CLOSED
15VDC.=TRIGGER
OPEN
NOT
THIS
USED I
N
667E
S1
U
D
622B
15V=2 STEP
0V=TRIGGE
INTE LOCK
UNIT.
J61-4
J18
R
4.5
3.5
509E
R
587
T
rigger Interlock does not sto
elding hen the arc is broken.
ull and release to end the
p
509B
B2
B1
w
w
9
10
Preset
WFS
2-STEP
P
w
eld.
509E
509D
15V=CV
0V=CC
S3
370
180* 257* 400*
530
700
77
76
75
C
C
C
5
4
3
1
6
S2
CC
J62-1
J62-
2
4
667B
*Extra Torque
TIMER KIT P.C. BOARD
0V=CO
L
D FEE
D
622
509B
ANALO
G
2
(
OPTIONAL
)
(
N.O.)
530A
VOLTMETER
500
555
The WFS range of the LN-25 PRO
Normal Speed = 40- 700 IPM.
Extra Torque = 25- 400 IPM.
SCHEMATIC
=
M21341
J15
+
-
COLD FEED
CV
U
SED TO DISCHARGE
POWER S PPLY CAP
AFTER A HIGH VOLTAGE
TRA SIENT. LATER
ELO ATED TO THE
SEE PAGE 2
3
21E
40V MAX.
4
0
3
O COIL
VDC OPEN
VDC CLOSED
U
509C
WFS limited by arc voltage when operating across the arc
2
7
8
721
1 of 4
P7
523
N
509B 601
607 608 606A 605 4B
R
C
12 VDC COIL
PWM CONTROLLED
Maximum WFS
CONTROL BOARD.
Feeder Input Volts Standard Gear Extra Torque
P7-1
621
P16
d
3
1
4
2
15
17
21
24
27
280
340
440
520
600
210
235
400
400
400
3 of 4
Located under
Locat
e
on
NOT P
ON S2750
RESENT
5
8
7
6
4
3
5
2
1
Wire
Drive
Panel
CONTACTOR
P6
0
top of motor
10 75
C
11
76C
12 77
C
Control Board Summary
P7
Connector
behind case front
l
ocated
4 of 4
Converts arc power to a usable control circuit voltage.
Receives switch signals from Trigger, Cold Feed, Gas Purge
Reads WFS potentiometer.
JUMPER TOGETHER FO
R
ISOLATED 2-4 TO
POWER SOURCE
EXTRA TORQUE MACHINE
575A
576A
577A
6
7
8
575A
576A
577A
Located on Case Front
575A
10K/2W
Communicates with optional timer kit.
534
21D
550
4
622
531
576A
577A
EXTRA
R1
606
Controls motor speed with PWM.
605
608
601
607
721
537
551
67F
530
2
578 507
555
500
TORQUE
587
509A
523
Turns Gas Solenoid on, off, PWM
Reads the motor tachometer.
.
WI
R
E FEE
CONT
OT NTIOMETER
D
R
SPEED
OL
0 VDC MIN. WFS
5 VDC MA WFS
MOTOR
SUPPL
X
.
+35V
J6-9
Y
J6-3
J6-10
J4-12 J4-6
J5-7
J4-9
J4-2
J5-3
J2-1
J4-11
J4-10
J5-5
J6-4
J2-7
P
E
J5-6
J6-2
J5-4
8
J4- J4-5
J2-8
J6-6
J2-5
J4-7
J2-3
J2-6
O
perating V
oltage= 15-110 VDC.
J2-2
J4-1
+15V
J2-10
+15
V
+5
V
100K
+15
V
Shut down Voltage= 130 VDC
.
20
ohm
o
hm
667
J5-1
1
o
0K
hm
MOV
TRIGGER
C
OM
Thermal light turns on when shutdown voltage exceeded.
Code and Serial numbers are below Wire Drive on plastic
housing Nameplate.
MACHINE
+5V
OUTPU
ENABLE
T
B1
B1
B2
+15V
CC/VV
T
RIGGER INTERLOCK / 2 STEP
CONTACTOR DRIVE
B2
COLD FEED
.05 uF
600 V
COM
Thermal “Yellow” Light
C1
MICRO
CONTROLLER
100K
ohm
+15V SPI
+5V SPI
-15V
Motor Over Current
C2
COM
METER
COMPENSATION
CIRCUIT
POWER
SUPPL
Motor and trigger disabled for 30 seconds.
Must retrigger to start welding after 30 seconds pass.
Shutdown Voltage exceeded
Y
+15V ISO
+5VDC
POLARITY
SENSE
62
1
4B
721 IS DRIVEN NEGATIVE TO COMPENSATE
FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE
LED
GAS
ON - OF
(LOCATED
A
T
OUTSIDE
3
5VDC
ISO
+15
-15
F
MOTOR
May occur with some inverters.
May occur with some CC machines with high
inductance.
REAR FEEDER)
O
F
C1
C2
SUPPL
Y
GAS PURGE
PUSHBUTTON
SWITCH (N.O.)
0V = OFF
0msec ---- 250msec
61
61
0
2
2
BURNBAC
K
S4
DRIVE
OVER
VOLTAGE
PROTECTION
POWER
SUPPL
Y
PW
M
Polarity “Green” Light
13.5 VDC WHEN
NOT EP ESSED
DRIVE
D
R
On= Positive Polarity
M
OTO
RIVE
CIRCUI
R
BRAKE
GAS
FLOW
BRAKE
D
Off= Negative Polarity
MOTOR VOLTAGE
MOTOR CURRENT
YELLO
W
THERMAL LED
(OUTSIDE
T
COM
BACK OF
CASE)
+5V SPI
J6-14
ENABLE
0.05K
oh
m
15
0-5V PULSE SIGNAL
FREQUENC
2B
1B
B
COM
POLARITY LED
TACH
FEEDBACK
25 TO 35
NORMAL
FLOW
Y
=
SPEED
(LOCATED
FRONT
A
T
TOP
FEEDER)
13
OF
0V = MIN SPEED
5V = MAX SPEE
WIRE FEED
SPEED
D
RATE
J5-8
+15V
COM
ARC ESTABLISHED
GAS PURGE
Y
ELLOW
MOTOR
TH RMAL
LE
14
16
+35V
GREEN
POLARITY
LED
COM
BALL FLOAT
SE MID LE
OF BALL TO
SET
GAS SOLENOID
J6-11
J6-12
J6-5
1W
2W
70
E
D
J6-7
J6-1
61
0
U
D
61
2
PROGRAM
9
5
8
ADJUST VALVE
-15V
J4-3
J4-4
FLOW METER
FLE
X
IBLE POWER P.C. BOARD
SCHEMATIC G4783
+5
V
SPI
+5
V
+5V SPI
J1-2
GAS
SOLENOID
+15V
J6-8
707
=
GOOD FOR Ar, CO2,
CO2/Ar BLENDS
COM
2 of 4
P7
690
J3-8
J3-7
J1-10
J3-6
J1-1
(LOCATED
CONTROL BOX)
INSIDE OF
22 O COIL
VDC OPEN
4 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
0
RED
69
(LOCATED
FEEDER)
Classic
1
FAN BLOWS AIR ACROSS
CONTROL PC BOA
CONTINO SLY AT 6200 RPMS.
PROGRAMMING PCB
FACTORY USE ONLY
FAN
SPI DIGITAlL COMMUNICATION
RD
-
A
T
REAR
BLACK
U
OF
Model
Ranger 8,9
Ranger 250, 305
V350
DC
-
400, 600
Square Wave TIG 300/355
Miller Inverters
STT II
Note:
Commander 300,400,500
(Common Analog
Controls)
(Common Digital
Controls)
Most semiautomatic wire
welding processes perform
better using constant voltage
K2613-1
K2613-2
Recommended
all CV
operation.
Recommended for
CV operation.
(Wire Feed
Module Required)
Recommended for CV
operation.
Recommended
for CV
operation.
May be used for
pulse welding if
the welding
procedure is
qualified by the
customer.
Recommended
for CV and CC
operation.
Not recommended for CC operation
because the customer may
experience short contactor life from
inductive nature of the power source.
Not recommended with high frequency
TIG starting.
Recommended
for CV voltage
sense operation.
Not
recommended for
use when pulse
welding.
Notrecommended power sources. Be sure the
for STT operation. proper power source is used
for your application. Contactor
life may be shortenedin
applications using CC
THIS DOCUMENT CONTAINS PROPRIETAR INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
Y
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU
T
THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
M
ANUFACTURING TO
L
ERANC
E
P
ER
E2056
CONTROL: CLEVE
L
AND
SCALE:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIPMENT TYPE:
1
2
machines with highOCV.
LN-25 P
MACHI
RO ANALOG
PAGE ___ OF ___
T
ON
ON
ON
MATERI
WITH PU
2
3
A
PLAC
PLACE
LL ANGL
TO
LISHED STANDARDS.
E
D
D
E
E
L
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
±
S
±
.02 in.
(
0.
±
0.5 mm)
NONE
DRAWN BY:
ENGINEER:
APPROVED:
tpear
n
.
00
A
2
DE
TO
i
n.
GREE
GREE
(
±
0
5
mm)
DOCUMEN
REVISION:
T
DOCUMEN
NUMBER:
IF PRIN
T
ED
S
I
S
±
SUBJECT:
MA ERIAL
N
E SCHEMATIC
T
@
A
1
SIZ
E
A
L
E
"
)
A
ENYEDY
BS
t
UNITS:
B
REFERENCE:
T
APPROVA
DATE:
L
PROJEC
G5683-
2
UF
11/6/2009
A
CRM40943
DISPOSI ION:
T
NUMBER:
INCH
DO NO
T
SCAL HIS DR
E
T
A
WING
G5683-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11620, 11621, 11716, 11717 - (G5683-2) pG2
2 - 3 8 6 G 5
CHANGE
DETAIL:
RELEASED A.03 FROM "X".
ENGINEERING CONTROLLED
MANUFACTURER: No
LN-25 PRO WIRE FEEDER
TIMER P. C. BOARD CIRCUIT
Timer Board Summary
Has potentiometers for burnback, postflow and preflow.
Preflow range is 0 to 10 sec.
Burnback range is 0 to 0.25 sec.
Postflow range is 0.25 to 10 sec.
Receives “Gas Flow Enable” signal.
Outputs 100 msec pulses to turn Gas Flow On, Gas Flow Off.
(LOCATED
BEHIND
WIRE
REE COVER)
L
(LOCATED
ON CASE FRONT)
ADJUST KNOB
ADJUST KNOB
ADJUST KNOB
+5V
+5V
CW= +5
CCW= 0V
1
0K
1
0K
BURNBAC
K
POT.
PREFLOW
POT.
POSTFLO
POT.
W
COM
COM
COM
1
5V SIGNAL
1
5V
15 ms PULSES
OUTPU
T
TOGGLE GAS FLOW
ON/OFF
5V
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
MICROCONTROLLER
COM
5V SIGNAL
GAS FLOW
ENABLE
J60-8
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2
J60-1
NOT
USED
60
7
60
8
606A
509B
601
60
5
4B
TO CONTROL BD. (VIA P60 plug)
THIS DOCUMENT CONTAINS PROPRIETAR
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
INFORMATION OWNED B
T
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
M
ANUFACTURING TO
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( 0.5 mm)
ON PLACE CIMALS IS 002 in. 0.
ON ALL ANGL S IS ± .5 OF A D GREE
MATERI L TO ERANCE (" ) TO AGREE
WITH PU LISHED STANDARDS.
L
ERANC
E
P
ER
E2056
SCALE:
NONE
CONTROL: CLEVE
L
AND
EQUIPMENT TYPE:
2
2
LN-25 P
RO ANALOG
PAGE ___ OF ___
±
DRAWN BY:
ENGINEER:
APPROVED:
tpear
n
3
D
E
E
L
±
.
(
±
0
5
mm)
IF PRIN
T
ED
DOCUMEN
NUMBER:
T
DOCUMEN
REVISION:
T
E
SUBJECT:
ATERIAL
@ A SIZ
2
E
MACHI E SCHEMATIC
N
A
"
ENYEDY
BS
t
UNITS:
REFERENCE:
B
APPROVAL
M
PROJECT
NU BER:
G5683-
2
UF
DISPOSITION:
1
1/6/2009
A
CRM40943
DATE
:
INCH
M
G5683-
1
DO NO
T
SCALE
THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-12
G-12
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11746, 11747 - (G5683-3) pG1
3 - 3 8 6 G 5
E
NGINEERING CONTROLLED
CHANGE DETAIL: A.02, COMPLETELY REVISED
When tach feed back is lost,
the voltage to the motor is a
constant 10VDC.
Start-Up
On power-up, the LN-25 PRO wil
polarity LED 2-3 seconds.
MANUFACTURER: No
l
light the motor thermal LED and
P
7
=
=
16 PI
PIN (Both are located on lower front)
(contro
N
3
P17
6
LN-25 PRO WIRE FEEDER
667C
667A
l
led by software
)
WORK
LI
1 of 2
21A
P17
6
If the feeder is powered-up with the trigger depressed, welding will
not start until the trigger is released and then depressed again.
G
earbox ratio is 23.5:1
72 HZ TO 1.2 KHZ
P
17
4
1
667B
621A
C
P
Motor resistanc
is 1.5 ohms
e
Motor case is at
electrode potential
R
B-
-B 15.0 VD
C
2 of 2
T
op of
motor
21B
U
6.2 VDC ANY SPEED
Leads Pass through
toroid2times.
Notes:
Motor overcu
21
C
D1
(METE
R
DEPENDENT
)
1
2
3
4
5
6
7
8
Motor is locate
behind
glastic pane
d
R
U
r
rent limit varies with WFS
.
case fron
t
67
B
-
PLASTIC HO
CONNECTIO
U
N
SED BOLTE
(BASE CENTER)
D
L4
531
531
Locat
ed
on
l
strain relief
FEED
667D
Case front
537
534
B
537
534
67C
67D
PLAT
E
MOT R /
O
GEARBOX
After 2-20-2009
Current
Level
From Power Source
(Electrode onnection)
B
551
550
C
coppe bar
r
IN HARNESS
CENTER BASE
AREA
weld cable
W
coppe bar
r
case back
strain relief
67C
67B
TAKEN WITH 40 V INPUT
IN V MODE.
P9
L12081-1 2.6 V @ 50 IPM
27 V @ 700 IPM
gun connector
MOTO
BOAR
R
FILTE
R
P.C.
ATIC=
4.5
3.5
C
67C & 67
D
D SCHEM
S27505
667D
TRIGGER
CONNECTOR
J14
Leads Pass
through
L13084-1 2.6 V @ 25 IPM
32 V @ 400 IPM
U
SED FOR FILTERING
J61-1
TRIGGER
INPUT
INVERTE NOISE
R
Located on
as ront
EXTRA TORQUE
toroid2times.
Located on Wir
A
B
C
D
622A
Preset
WFS
C
e
F
e
500A
555A
14 PIN
LEA S ARE
PRESENT BUT
REMOTE
J61-
2
4
0V.=TRIGGER
CLOSED
15VDC.=TRIGGER
OPEN
Drive
Panel
D
370 530 700
180* 257* 400*
TRIGGER INTERLOCK
S1,
S2
& S3 Locate
d
L5
J61-3
*Extra Torque
NOT
SE
on Wir
e
D
riv anel
e
P
E
NOT
THIS
U
U
SED I
NIT.
N
667E
S1
U
D
15V=2 STEP
0V=TRIGGE
INTE LOCK
Located on
as ront
J61-
J18
R
C
e
F
509E
R
622B
587
T
rigger Interlock does not sto
elding hen the arc is broken.
ull and release to end the
p
Low Range
High Range
(Red)
B2
B1
WFS limited by arc voltage when operating across the arc
w
w
9
(White)
50-200
50-200
2-STEP
P
w
eld.
509E
10
WF
S
S
RANGE
Normal Speed
Extra Torque
50-700
50-400
509D
Maximum WFS
Feeder Input Volts Standard Gear Extra Torque
WITCH
15V=CV
0V=CC
S3
77
76
75
C
C
C
5
4
3
1
6
S2
CC
509B
667B
0V=CO
L
D FEE
D
ANALO
G
15
17
21
24
27
400
450
570
650
700
220
250
300
350
400
(
N.O.)
530A
VOLTMETER
J15
+
-
509B
COLD FEED
4
CV
622
2
500
TIMER KIT P.C. BOARD
21E
40V MAX.
4
0
3
O COIL
VDC OPEN
VDC CLOSED
(
OPTIONAL
)
509C
2
7
8
721
SCHEMATIC
=
M21341
523
555
3
SEE PAGE 2
12 VDC COIL
PWM CONTROLLED
P7-1
621
P16
d
1 of 4
P7
3
1
4
2
509B
2
601
1
608 606A
4B
4
607
8
605
5
3 of 4
Located under
Locat
e
on
Wire
Drive
Panel
CONTACTOR
top of motor
10 75
C
7
6
3
P6
0
11
76C
12 77
C
Control Board Summary
P7
Connector located
behind case front
4 of 4
Converts arc power to a usable control circuit voltage.
Receives switch signals from Trigger, Cold Feed, Gas Purge
Reads WFS potentiometer.
ISOLATED 2-4 TO
POWER SOURCE
575A
576A
577A
6
7
8
575A
576A
577A
Located on Case Front
JUMPER TOGETHER FO
R
EXTRA TORQUE MACHINE
575A
10K/2W
Communicates with optional timer kit.
534
21D
550
4
622
531
576A
577A
EXTRA
R1
606
Controls motor speed with PWM.
605
608
601
607
721
537
551
67F
530
2
578 507
555
500
TORQUE
587
509A
523
Turns Gas Solenoid on, off, PWM
Reads the motor tachometer.
.
WI
R
E FEE
CONT
OT NTIOMETER
D
R
SPEED
OL
0 VDC MIN. WFS
5 VDC MA WFS
MOTOR
SUPPL
X
.
+35V
J6-9
Y
J6-3
J6-10
J4-12 J4-6
J5-7
J4-9
J4-2
J5-3
J2-1
J4-11
J4-10
J5-5
J6-4
J2-7
P
E
J5-6
J6-2
J5-4
J6-6
8
J4- J4-5
J2-5
J2-8
J4-7
J2-3
O
perating V
oltage= 15-110 VDC.
J2-2
J4-1
J2-6
+15V
J2-10
+15
V
+5
V
100K
+15
V
Shut down Voltage= 130 VDC
.
20
ohm
o
hm
667
J5-1
1
o
0K
hm
MOV
TRIGGER
C
OM
Thermal light turns on when shutdown voltage exceeded.
Code and Serial numbers are below Wire Drive on plastic
housing Nameplate.
MACHINE
+5V
OUTPU
ENABLE
T
B1
B1
B2
+15V
CC/VV
T
RIGGER INTERLOCK / 2 STEP
CONTACTOR DRIVE
B2
COLD FEED
.05 uF
600 V
COM
Thermal “Yellow” Light
MICRO
CONTROLLER
100K
ohm
+15V SPI
+5V SPI
-15V
Motor Over Current
COM
METER
COMPENSATION
CIRCUIT
POWER
SUPPL
Motor and trigger disabled for 30 seconds.
Must retrigger to start welding after 30 seconds pass.
Shutdown Voltage exceeded
Y
+15V ISO
+5VDC
POLARITY
SENSE
621
4B
721 IS DRIVEN NEGATIVE TO COMPENSATE
FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE
LED
GAS
ON - OF
(LOCATED
AT
OUTSIDE
3
5VDC
ISO
+15
-15
F
MOTOR
May occur with some inverters.
May occur with some CC machines with high
inductance.
REAR FEEDER)
O
F
SUPPL
Y
GAS PURGE
0V = OFF
0msec ---- 250msec
PUSHBUTTON
SWITCH (N.O.)
61
0
2
BURNBAC
K
S4
D
RIVE
61
2
OVER
VOLTAGE
PROTECTION
POWER
SUPPL
Y
PW
M
Polarity “Green” Light
13.5 VDC WHEN
NOT EP ESSED
DRIVE
D
R
On= Positive Polarity
M
D
OTO
RIVE
CIRCUI
R
BRAKE
GAS
FLOW
ENABLE
BRAKE
Off= Negative Polarity
MOTOR VOLTAGE
MOTOR CURRENT
Y
ELLO
W
THERMAL LED
(OUTSIDE
T
COM
BACK OF
CASE)
+5V SPI
J6-14
0.05K
oh
m
15
0-5V PULSE SIGNAL
2B
1B
B
COM
POLARITY LED
TACH
FEEDBACK
25 TO 35
NORMAL
FLOW
FREQUENC
Y
=
SPEED
(LOCATED
FRONT
A
T
TOP
FEEDER)
13
OF
0V = MIN SPEED
5V = MAX SPEE
WIRE FEED
SPEED
D
RATE
J5-8
+15V
COM
ARC ESTABLISHED
GAS PURGE
Y
ELLOW
MOTOR
TH RMAL
LE
14
16
+35V
GREEN
POLARITY
LED
COM
BALL FLOAT
SE MID LE
OF BALL TO
SET
GAS SOLENOID
J6-11
J6-12
J6-5
1W
2W
70
E
D
J6-7
J6-1
61
0
U
D
61
2
PROGRAM
9
5
8
ADJUST VALVE
-15V
J4-3
J4-4
FLOW METER
FLE
X
IBLE POWER P.C. BOARD
SCHEMATIC G4783
+5
V
SPI
+5
V
+5V SPI
J1-2
GAS
SOLENOID
+15V
J6-8
707
=
GOOD FOR Ar, CO2,
CO2/Ar BLENDS
COM
2 of 4
P7
690
J3-8
J3-7
J1-10
J3-6
J1-1
(LOCATED
CONTROL BOX)
INSIDE OF
22 O COIL
VDC OPEN
4 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
0
RED
69
(LOCATED
FEEDER)
1
FAN BLOWS AIR ACROSS
CONTROL PC BOA
CONTINO
PROGRAMMING PCB
FACTORY USE ONLY
FAN
SPI DIGITAlL COMMUNICATION
RD
-
A
T
REAR
BLACK
U
SLY AT 6200 RPMS.
OF
Model
Ranger 8,9
Classic
Multiweld, Rangers,
Vantages, Flextec
V350
DC-400, 600
Square Wave TIG 300/355
Miller Inverters
STT II
Note:
Most semiautomatic wire
welding processes perform
K2613-5
K2613-7
Recommended
all CV
operation.
Recommended for
CV operation.
(Wire Feed
Recommended for CV
and CC operation.
Recommended
for CV
operation.
Recommended
for CV and CC
operation.
Not recommended for CC operation
because the customer may
experience short contactor life from
Recommended
for CV voltage
sense operation.
Not recommended better using constant voltage
power sources. Be sure the
proper power source is used
for STT operation.
THIS DOCUMENT CONTAINS PROPRIETAR INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
Y
Module Required)
May be used for
pulse welding if
the welding
procedure is
qualified by the
customer.
inductive nature of the power source.
Not recommended with high frequency
TIG starting.
for your application. Contactor
life may be shortened in
applications using CC
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU
T
THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
M
ANUFACTURING TO
L
ERANC
E
P
ER
E2056
CONTROL: CLEVE
L
AND
SCA E:
L
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIPMENT TYPE:
1
2
LN-25 PRO ANALOG
PAGE ___ OF ___
T
ON
ON
ON
MATERI
WITH PU
2
3
A
PLAC
PLACE
LL ANGL
TO
LISHED STANDARDS.
E
D
D
E
E
L
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
±
S
±
.02 in.
(
0.
±
0.5 mm)
NONE
IF PRIN
DRAWN BY:
ENGINEER:
APPROVED:
T. PEARN
ENYEDY
-
machines with high OCV.
.
00
A
2
DE
TO
i
n.
GREE
GREE
(
±
0
5
mm)
DOCUMEN
REVISION:
T
DOCUMEN
NUMBER:
T
ED
E
S
I
S
±
SUBJECT:
MA ERIAL
MACHINE SCHEMATIC
REFERENCE:
@
A
1
SIZ
A
L
E
"
)
A
t
UNITS:
B
T
APPROVA
DATE:
L
PROJEC
NUMBER:
T
G5683-
3
NA
1/26/2011
A.02
XM6214-C
DISPOSI ION:
T
INCH
DO NO
T
SCAL HIS DR
E
T
A
WING
G5683-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-13
G-13
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11746, 11747 - (G5683-3) pG2
3 - 3 8 6 G 5
CHANGE DETAIL: A.02, COMPLETELY REVISED
ENGINEERING CONTROLLED
MANUFACTURER: No
LN-25 PRO WIRE FEEDER
TIMER P. C. BOARD CIRCUIT
Timer Board Summary
Has potentiometers for burnback, postflow and preflow.
Preflow range is 0 to 10 sec.
Burnback range is 0 to 0.25 sec.
Postflow range is 0.25 to 10 sec.
Receives “Gas Flow Enable” signal.
Outputs 100 msec pulses to turn Gas Flow On, Gas Flow Off.
(LOCATED
BEHIND
WIRE
REE COVER)
L
(LOCATED
ON CASE FRONT)
ADJUST KNOB
ADJUST KNOB
ADJUST KNOB
+5V
+5V
CW= +5
CCW= 0V
1
0K
1
0K
BURNBAC
K
POT.
PREFLOW
POT.
POSTFLO
POT.
W
COM
COM
COM
1
5V SIGNAL
1
5V
15 ms PULSES
OUTPU
T
TOGGLE GAS FLOW
ON/OFF
5V
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
MICROCONTROLLER
COM
5V SIGNAL
GAS FLOW
ENABLE
J60-8
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2
J60-1
NOT
USED
60
7
60
8
606A
509B
601
60
5
4B
TO CONTROL BD. (VIA P60 plug)
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
T
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
M
ANUFACTURING TO
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( 0.5 mm)
ON PLACE CIMALS IS 002 in. 0.
ON ALL ANGL S IS ± .5 OF A D GREE
MATERI L TO ERANCE (" ) TO AGREE
WITH PU LISHED STANDARDS.
L
ERANC
E
P
ER
E2056
SCALE:
NONE
CONTROL: CLEVE
LAND
EQUIPMENT TYPE:
2
2
LN-25 P
R
O A
NALOG
PAGE ___ OF ___
±
DRAWN BY:
ENGINEER:
APPROVED:
T. PEARN
ENYEDY
-
3
D
E
E
L
±
.
(
±
0
5
mm)
IF PRIN
T
ED
DOCUMEN
NUMBER:
T
DOCUMEN
REVISION:
T
E
SUBJECT:
ATERIAL
@ A SIZ
2
E
MACHI
NE SCHEMATIC
PROJECT
NU BER:
A
"
t
UNITS:
REFERENCE:
B
APPROVAL
M
G5683-
3
NA
DISPOSITION:
1/26/2011
A.02
X
M6214-C
DATE
:
INCH
M
G5683-
2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-14
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 1
G-14
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-15
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 2
G-15
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-16
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 3
G-16
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-17
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 4
G-17
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-18
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 5
G-18
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-19
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 1
G-19
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-20
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 2
G-20
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-21
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 3
G-21
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-22
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 4
G-22
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-23
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 5
G-23
ElECTriCal DiaGrams
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-24
G-24
ElECTriCal DiaGrams
sChEmaTiC - mOTOr FilTEr pC BOarD - CODE 11746, 11747 (s27505-1)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
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G-25
G-25
ElECTriCal DiaGrams
sChEmaTiC - K2330 TimEr KiT pC BOarD - all CODEs (m21341-1)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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|