Lincoln Electric LN-25 Manual de usuario

LN-25 WIRE FEEDER

Operator’s Manual

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM620-B | Issue Date 5-Sep

For use with machines having Code Numbers:

10556, 11144, 10557, 11145, 10558,

11282, 11283

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

THANK YOU FOR SELECTING

A QUALITY PRODUCT BY

LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR

DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser

upon receipt by the carrier. Consequently, claims for material

damaged in shipment must be made by the purchaser against the

transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

incoln 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

PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

This statement appears where the information must be followed

exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed

to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.

Use corrective lenses if necessary

to stay a reasonable distance

away from the arc.

READ and obey the Safety Data

Sheet (SDS) and the warning label

that appears on all containers of

welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to

keep the fumes and gases from

your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away

from your face.

If you de velop unusual symptoms, see your supervisor.

Perhaps the welding atmosphere and ventilation system

should be checked.

EAR CORRECT EYE, EAR &

BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate

(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen

clothing, flame-proof apron and gloves, leather

leggings, and high boots.

PROTECT others from splatter, flash, and glare

with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously

had been in contact with hazardous substances unless they are

properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release

highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,

mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an

electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 06/15/2016

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel En ines

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and other

reproductive harm.

Gasoline En ines

The engine exhaust from this product contains chemicals known

to the State of California to cause cancer, birth defects, or other

reproductive harm.

ARC ELDING CAN BE HAZARDOUS. PROTECT

YOURSELF AND OTHERS FROM POSSIBLE SERIOUS

INJURY OR DEATH. KEEP CHILDREN A AY.

PACEMAKER EARERS SHOULD CONSULT ITH

THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For

additional safety information, it is strongly recommended

that you purchase a copy of “Safety in Welding & Cutting -

ANSI Standard Z49.1” from the American Welding Society,

P.O. Box 351040, Miami, Florida 33135 or CSA Standard

W117.2-1974. A Free copy of “Arc Welding Safety” booklet

E205 is available from the incoln Electric Company,

22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,

MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED

EQUIPMENT.

1.a. Turn the engine off before troubleshooting

and maintenance work unless the

maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.

Stop the engine and allow it to cool before

refueling to prevent spilled fuel from

vaporizing on contact with hot engine parts

and igniting. Do not spill fuel when filling

tank. If fuel is spilled, wipe it up and do not start engine until

fumes have been eliminated.

1.d. Keep all equipment safety guards, covers

and devices in position and in good repair.

Keep hands, hair, clothing and tools away

from V-belts, gears, fans and all other

moving parts when starting, operating or

repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to

perform required maintenance. Remove guards only when

necessary and replace them when the maintenance requiring

their removal is complete. Always use the greatest care when

working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to

override the governor or idler by pushing on the throttle control

rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning

the engine or welding generator during maintenance work,

disconnect the spark plug wires, distributor cap or magneto wire

as appropriate.

1.h. To avoid scalding, do not remove the radiator

pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS MAY

BE DANGEROUS

2.a. Electric current flowing through any conductor

causes localized Electric and Magnetic Fields (EMF).

Welding current creates EMF fields around welding cables

and welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health effects

which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work

cables. If the electrode cable is on your right side, the

work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-

sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 06/15/2016

ELECTRIC SHOCK

CAN KILL.

3.a. The electrode and work (or ground) circuits are

electrically “hot” when the welder is on. Do

not touch these “hot” parts with your bare skin or wet clothing.

Wear dry, hole-free gloves to insulate hands.

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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic welding

gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection should

be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)

ground.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

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.

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 It ems 6.c. and 8.

ARC RAYS CAN BURN.

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.

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.

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 your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep fumes and gases

away from the breathing zone. hen welding hardfacing

(see instructions on container or SDS) or on lead

or cadmium plated steel and other metals or

coatings which produce highly toxic fumes, keep

exposure as low as possible and within applicable

OSHA PEL and ACGIH TLV limits using local

exhaust or mechanical ventilation unless exposure

assessments indicate otherwise. In confined

spaces or in some circumstances, outdoors, a

respirator may also be required. Additional

precautions are also required when welding

on galvanized steel.

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 exposure

level should be checked upon installation and periodically

thereafter to be certain it is within applicable OSHA PE and

ACGIH T V limits.

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 products.

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

Safety Data Sheet (SDS) and follow your employer’s safety

practices. SDS forms are available from your welding

distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 06/15/2016

WELDING AND CUTTING

SPARKS CAN CAUSE

FIRE OR EXPLOSION.

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 adjacent areas. Avoid welding near hydraulic lines.

Have a fire extinguisher readily available.

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.

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.

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).

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.

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.

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.

CYLINDER MAY EXPLODE IF

DAMAGED.

7.a. Use only compressed gas cylinders containing

the correct shielding gas for the process used

and properly operating 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.

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.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

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, 14501 George Carter Way

Chantilly, VA 20151.

FOR ELECTRICALLY

POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

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.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 06/15/2016

SAFETY

Mar. ‘93

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et

les précautions de sûreté specifiques qui parraissent dans ce manuel

aussi bien que les précautions de sûreté générales suivantes:

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 l e s

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.

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.

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.

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.

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.

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, pantalons sans

revers, et chaussures montantes.

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.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la

masse. Un court-circuit accidental peut provoquer un échauffe-

ment 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.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci

est particuliérement important pour le soudage de tôles gal-

vanisées 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 pro-

duits irritants.

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.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

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.

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 debrancher à

l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

SAFETY ..............................................................................................................................................................i-iv

INSTALLATION ....................................................................................................................................SECTION A

Technical Specifications .................................................................................................................................A-1

Safety Precautions ..........................................................................................................................................A-2

Power Source Connections............................................................................................................................A-2

Gun Cable Connection to Feeder .................................................................................................................A-3

Weld Cable Connection ..................................................................................................................................A-4

Electrode Cable Connection......................................................................................................................A-4

Work Cable Connection .............................................................................................................................A-4

Wire Feed Drive Roll and Guide Tube Kits .................................................................................................A-4

OPERATION..........................................................................................................................................SECTION B

Safety Precautions ..........................................................................................................................................B-1

General Description.........................................................................................................................................B-1

Recommended Processes and Equipment..................................................................................................B-1

Welding Capability...........................................................................................................................................B-1

Controls and Settings......................................................................................................................................B-2

Sequence of Operation...................................................................................................................................B-4

Loading Electrode .......................................................................................................................................B-4

Loading Wire Drive .....................................................................................................................................B-5

Idle Roll Pressure Setting ..........................................................................................................................B-5

Presetting Wire Feed Speed .....................................................................................................................B-6

Making a Weld.............................................................................................................................................B-7

Procedure at End of Coil ................................................................................................................................B-8

Automatic Protection Shutdown.....................................................................................................................B-8

ACCESSORIES ....................................................................................................................................SECTION C

LN-25 Option Chart .........................................................................................................................................C-1

Options and Accessories................................................................................................................................C-2

K430-2 Gas Solenoid Kit ...........................................................................................................................C-2

K434-1 Gas Flow Timer Kit .......................................................................................................................C-2

K460-1 Pulse Power Adapter Kit..............................................................................................................C-3

K461 Pulse Power Control Cable Assembly...........................................................................................C-3

K443-2, K443-3 LN-25 Contactor Kits....................................................................................................C-3

Remote Output Control Options and Control Cable Assemblies..............................................................C-3

K431-1 Remote Output Control Kit ..........................................................................................................C-3

K433 Power Source Remote Box.............................................................................................................C-4

K432 Remote Control Cable Assembly ...................................................................................................C-4

K439 Remote Extension Cable Assembly...............................................................................................C-4

K624-1 42V Remote Output Control Module ..........................................................................................C-4

K625, K626, K626 Remote Control Cable Assembly ............................................................................C-4

K444, K444-1 or K444-2 Remote Voltage Control Kit...........................................................................C-5

K557-1 Rear Handle Kit.............................................................................................................................C-5

MAINTENANCE....................................................................................................................................SECTION D

Safety Precautions ..........................................................................................................................................D-1

Routine Maintenance ......................................................................................................................................D-1

Circuit Protection and Automatic Shutdown ................................................................................................D-1

Adjusting Speed Sensor Module...................................................................................................................D-1

Calibration of the LN-25 Wire Speed Dial ...................................................................................................D-2

TROUBLESHOOTING GUIDE............................................................................................................SECTION E

How to Use the Troubleshooting Guide .......................................................................................................E-1

Troubleshooting Guide....................................................................................................................................E-2

WIRING DIAGRAM...............................................................................................................................SECTION F

PHYSICAL DIMENSIONS....................................................................................................................SECTION F

PARTS MANUAL ..............................................................................................................................P333 SERIES

TABLE OF CONTENTS

LN-25

A-1

TEMPERATURE RANGE

OPERATION: - 40oC to +40oC (- 40oF to +104oF)

STORAGE: - 40oC to +85oC (- 40oF to +185oF)

A-1

OPERATING ARC VOLTAGE

Constant Voltage (CV)

or 15-40 VDC (110VDC Maximum OCV)

Constant Current (CC)

RATED CURRENT

Rated current without contactor 500 Amps 60% Duty Cycle

Rated current with contactor 300 Amps 60% Duty Cycle

WIRE SPEED RANGE

50 – 700 Inches Per Minute (IPM)

RECOMMENDED ELECTRODE WIRE SIZES

.023” to 1⁄16”SOLID STEEL WIRE

.045” to 5⁄64”CORED WIRE

.035” to 1⁄16”ALUMINUM WIRE

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

(Handle Down) w/o Options

14 Inches 7.4 Inches 21 Inches 28 lbs

(354 mm) (187 mm) (531 mm) (13 kg)

RATED

CURRENT

WIRE

FEED

SPEED

PHYSICAL

DIMENSIONS

ENVIRONMENTAL

RATING

WIRE

DIAMETERS

VOLTAGE

INSTALLATION

TECHNICAL SPECIFICATIONS – LN-25

IP23

LN-25

A-2

A-2 INSTALLATION

ELECTRIC SHOCK can kill.

• Do not operate with covers

removed.

• Turn off power source before

installing or servicing.

• Do not touch electrically

hot parts.

• Turn the input power to the

welding power source off at the

fuse box before working in the

terminal strip.

• Only qualified personnel should

install, use or service this

equipment.

DC-250

a. Connect a jumper from 2 to 4 on the power source

terminal strip so the output will be energized when

the DC-250 is turned on.

b. Connect electrode cable to the “Innershield/

GMAW” output terminal of polarity required by

electrode. Connect work lead to other

“Innershield/GMAW” output terminal.

c. Place “Set to CV Electrode Cable Polarity” switch

at appropriate position.

d. Place power source toggle switch in “Output

Control at DC-250” position, unless a Remote

Control is connected to 75, 76 and 77 on the DC-

250 terminal strip.

e. Place mode switch in “Innershield GMAW (CV)”

position. Set CV arc control to “2” (or “NORMAL”

on some machines). Initially set the output

control on “7”.

DC-400 AND CV-400

a. Connect a jumper from 2 to 4 on the power

source terminal strip so the output will be

energized when the power source is turned on.

NOTE: DC-400 machines above Code 9200 have

an output toggle switch to perform this function.

b. Connect the electrode cable to the output

terminal of polarity required by electrode.

Connect work lead to other output terminal.

SAFETY PRECAUTIONS

Unless an optional output control or contactor is used

with the LN-25, the electrode circuit (including welding

wire, wire drive and welding gun) is electrically hot

when the welding power source is on. The gun trigger

controls wire feed only.

Disconnect or shut off welding power source before

making connections or installations to the LN-25.

Welding gun should be stored in the insulated

gun holder, located near the rear on the top of the

LN-25 case, to avoid accidental arcing.

The LN-25 should be positioned upright on a

horizontal surface.

ELECTRIC SHOCK can kill.

• Do not touch metal portions

of the LN-25 lead clip when

welding power source is on.

POWER SOURCE CONNECTION

The LN-25 can be used with most DC welding power

source. A constant voltage power source is

recommended; however, the LN-25 can also be used

with a constant current power source as long as the

open circuit voltage is less than 110V DC.

Do not use LN-25 models below Code 9200 with any

TIG or Square Wave welding power sources. Do not

use LN-25 models equipped with internal contactors

with non- Lincoln TIG or Square Wave welding power

sources. Damage to the LN-25 circuit can occur as a

result of the high output inductance typically

associated with these power sources. TIG high

frequency power should never be applied to the LN-25.

If not using an LN-25 Remote Output Control option

(See Remote Output Control Options and Cable

Assemblies Section), the power source output must

be electrically “hot” at all times when the power

source is turned on.

See the power source instruction manual for proper

power source connections and setting required.

WARNING

CAUTION

LN-25

A-3 A-3

c. Set ELECTRODE POLARITY switch to constant

voltage polarity required by electrode.

d. Set toggle switch to “Constant Voltage” and set

the Constant Voltage Control on welder and the

portable field control on #5 for initial start.

SA-200, —250 OR SAE-300, —400 (WITH

CV ADAPTER)

a. For electrode negative welding, connect the

electrode lead from the LN-25 to the output

terminal on the CV Adapter, and the work lead to

the power source output terminal labeled

“POSITIVE”. For electrode positive welding,

interchange the above lead connections so the

LN-25 electrode lead is then connected to the

positive power source terminal.

b. Place both switches on the CV Adapter to the CV

INNERSHIELD position and make appropriate

power source settings per the CV Adapter instruc-

tions provided for the power source being used.

c. The output voltage is set with the voltage control

on the CV Adapter.

NOTE: Refer to the Instruction Manual provided with

the machine for details on connection and operation

of the LN-25 with the power source.

INVERTEC, CV300 AND OTHER NEWER

LINCOLN POWER SOURCES

Refer to the instruction manual provided with the

power source for details on connection and operation

of the LN-25 with these newer machines.

GUN CABLE CONNECTION

TO FEEDER

Lay the cable out straight. Insert the connector on the

welding conductor cable into the brass conductor

block on the front of the wire drive unit. Make sure it is

all the way in and tighten the hand wheel clamp. Keep

this connection clean and bright. Connect the control

cable polarized amphenol plug into the mating 5-cavity

receptacle on the front panel of the wire feeder case.

FOR GMA GUN AND CABLES:

Requires installation of K430-1 Gas Solenoid Kit

(factory installed on K446 and K449 models).

See K430-1 Gas Solenoid Kit Section (in Accessories

Section) for gas solenoid operation and gas supply

connection.

c. Place “Set to Same Polarity As Electrode Cable

Connection” switch at appropriate position.

d. Place power source toggle switch in “Output

Control at DC(CV) -400” position, unless a

remote control is connected to 75, 76 and 77 on

the power source terminal strip.

e. If power source has a mode switch, set switch to

Constant Voltage Innershield. Initially set the

output control on “6”.

DC-600

a. Connect a jumper from 2 to 4 on the power

source terminal strip so the output will be

energized when the DC-600 is turned on. (For

DC-600 below Code 8200, also jumper N to S.)

b. Connect the electrode cable to the output

terminal of polarity required by electrode.

Connect work lead to other output terminal.

c. Place “Set to Same Polarity As Electrode Cable

Connection” switch at appropriate position.

d. Place power source toggle switch in “Output

Control at DC-600” position, unless a remote

control is connected to 75, 76 and 77 on the DC-

600 terminal strip.

e. Set mode switch to Constant Voltage Innershield.

Initially set output control on “4”.

R3S-325

a. Connect a jumper from 4 to 32 on the power

source terminal strip so that the output will be

energized when the R3S-325 is turned on.

b. Connect the electrode cable to the output

terminal of polarity required by electrode.

Connect work lead to other output terminal.

c. Set power source per its instruction manual.

NOTE: Use of the optional Line Voltage

Compensator available for the R3S-325 is

recommended if input line voltage variation

exceeds ±3%.

SAM-400, —650

a. Connect a jumper from 2 to C4 on the power

source terminal strip so the output will be

energized when the SAM power source is on.

b. Connect work lead to WORK stud. Connect

electrode to AUTO EQUIPMENT stud. Connect

SAM-650 “Tap” lead to the Innershield stud

desired.

INSTALLATION

Otros manuales para LN-25

Este manual sirve para los siguientes modelos

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