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Lincoln Electric IM10084 manual

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Table of contents for the manual

  • Page 1

    OPERA T ORʼS MANUAL • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • Copyright © Lincoln Global Inc. LN- 25 ™ IRONWORKER IM10084 October, 2010 For use wi[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC R A Y S can bur n. 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 clot hing made from durable flame-resistant material to protect your[...]

  • Page 4

    iii SAFETY iii FOR ELECTRIC ALL Y pow ered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. I ns t a ll 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. [...]

  • Page 5

    iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à[...]

  • Page 6

    v v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements[...]

  • Page 7

    vi vi Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supp[...]

  • Page 8

    vii vii Thank Y ou for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference[...]

  • Page 9

    viii viii T ABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation ..............................................................[...]

  • Page 10

    A-1 INST ALLA TION A-1 LN-25™ IRONWORKER TEMPERA TURE RANGE OPERATION: -40°F to 104°F (-40°C to 40°C) STORAGE: -40°F to 122°F (-40°C to 50°C) INPUT VOL T AGE and CURRENT TECHNICAL SPECIFICA TIONS – LN-25™ IRONWORKER (K2614-9) HEIGHT WIDTH DEPTH WEIGHT 14.8 Inches 8.7 Inches 23.2 Inches 38 lbs (376 mm) ( 221 mm) (589 mm) (17.2 kg) Hand[...]

  • Page 11

    WELD CABLE SIZE Table A.1 located below are copper cable sizes rec- ommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop. ** Tabled values are for operation at ambient[...]

  • Page 12

    A-3 INST ALLA TION LN-25™ IRONWORKER A-3 SHIELDING GAS CONNECTION CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • 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 ot[...]

  • Page 13

    A-4 INST ALLA TION LN-25™ IRONWORKER A-4 WIRE DRIVE CONFIGURA TION (See Figure A.2) CHANGING THE GUN RECEIVER BUSHING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before instal- lation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electr[...]

  • Page 14

    THUMB SCREW GUN A-5 INST ALLA TION LN-25™ IRONWORKER A-5 PRESSURE ARM ADJUSTMENT 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. • When inching with the gun trigger, electrode and drive mechanism are "hot[...]

  • Page 15

    CV Power Sources with Stud Connectors and no Remote/Local Switch. (See Figure A.7) Place CV/CC switch in the feeder in the "CV" position. Work c l ip Work E l ectrode J umper Ranger 250, 250 LPG Ranger 305G, 305D Ranger 10,000 Ranger 3 Phase Ranger 225GXT Ranger 225 Commander 300 V antage 300, 400, 500 Air V antage 500 LN-25™ IRONWORKER[...]

  • Page 16

    A-7 INST ALLA TION LN-25™ IRONWORKER A-7 CV Power Source with Twist-Mate Connectors and Remote/Local Switch. (See Figure A.8) Place CV/CC switch in the feeder in the "CV" position. Wor k c l ip Wor k E l ectrode CV -305 V350-Pro LN-25™ IRONWORKER FIGURE A.8 K# K2614-9 KP1695-XX KP1696-XX KP1697-XX See Magnum Literature K1841 Descripti[...]

  • Page 17

    B-1 OPERA TION LN-25™ IRONWORKER B-1 • 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 clo[...]

  • Page 18

    B-2 OPERA TION B-2 LN-25™ IRONWORKER DEFINITION OF WELDING TERMS WFS • Wire Feed Speed CC • Constant Current CV • Constant Voltage GMAW • Gas Metal Arc welding SMAW • Shielded Metal Arc welding FCAW • Flux Core Arc Welding GENERAL DESCRIPTION General Physical Description The LN-25™ IRONWORKER is specially engineered to be the most r[...]

  • Page 19

    Maximum WFS Standard Spin Gearing 280 340 440 520 600 Minimum Arc Volts 15 V 17 V 21 V 24 V 27 V WIRE FEED SPEED KNOB Wire Feed Speed, CV Operation 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 along as the arc voltage does not drop below the[...]

  • Page 20

    B-4 OPERA TION B-4 LN-25™ IRONWORKER THERMAL LED, MOTOR OVERLOAD The thermal light illuminates when the wire drive motor draws too much current. If the thermal light illuminates, 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[...]

  • Page 21

    B-5 OPERA TION B-5 LN-25™ IRONWORKER Wire Feed Speed Units To change the wire feed speed units: Rotate the WFS knob to the left to use “inches/minute” for the wire feed speed units. Rotate the WFS knob to the right to use “meters/minute” for the wire feed speed units. Then rotate the WFS knob to the 12 oʼclock position. Press the set-up [...]

  • Page 22

    B-6 OPERA TION B-6 LEFT DISPLAY SELECTION The left display can show either amperage or actual WFS during welding. Note that actual WFS is not the same as preset WFS. For example, the preset WFS may be set to 400 ipm, but the arc voltage is only 15V. The actual WFS will be approximately 280 ipm because there is not enough arc voltage to run at 400 i[...]

  • Page 23

    B-7 OPERA TION B-7 INTERNAL CONTROLS LN-25™ IRONWORKER 12 Step Trigger I nter l ock Switch 2 Pressure Adjustment Arm 3 Optiona l Timer Kit (See Accessories Section) 4 Spoo l Retainer 5 Spind l e Brake 6 Gun Bushing ITEM DESCRIPTION 1 9 8 7 6 3 2 7 Thumb Screw for securing the we l ding Gun 8 Socket Head Cap Screw for securing the Gun Bushing 4 5 [...]

  • Page 24

    B-8 OPERA TION B-8 INTERNAL CONTROLS DESCRIPTION (See Figure B.2) 2 Step - Trigger Interlock Switch 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 release[...]

  • Page 25

    GAS PURGE PUSHBUTTON 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. Flow meters should always be adjusted while the shielding gas is flowing. B-9 OPERA TION B-9 REAR CONTROLS: LN-25™ IRONWORKER 1 Gas P[...]

  • Page 26

    C-1 ACCESSORIES C-1 LN-25™ IRONWORKER F ACT OR Y INST ALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS (See Parts Pages) K1803-1 K1840-xx K1842-xx Work and Feeder Cables Package. Weld Power Cable, Twist-Mate to Lug. Weld Power Cable, Lug to Lug. Includes: Twist-Mate to Lug 2/0 cable 14' (1.2m) long with Ground Clamp, and Twi[...]

  • Page 27

    C-2 ACCESSORIES C-2 LN-25™ IRONWORKER K910-1 K910-2 K1500-1 K1500-2 K1500-3 Ground Clamp Ground Clamp Gun Receiver Bushing (for guns with K466-1 Lincoln gun connec- tors; Innershield and Subarc guns) Gun Receiver Bushing (for guns with K466-2, K466-10 Lincoln gun connectors; Magnum 200/300/400 guns and compatible with Tweco® #2-#4) Gun Receiver [...]

  • Page 28

    C-3 ACCESSORIES C-3 LN-25™ IRONWORKER K1500-4 K1500-5 K435 K468 K586-1 K283 Gun Receiver Bushing (for gun with K466-3 Lincoln gun connec- tors; compatible with Miller® guns.) Gun Receiver Bushing (compatible with Oxo® guns.) Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2 in (51 mm) spindles. Spindle Adapter, for mounting 8[...]

  • Page 29

    ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding 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 tr[...]

  • Page 30

    E-1 TROUBLESHOOTING E-1 LN-25™ IRONWORKER If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and rep[...]

  • Page 31

    E-2 TROUBLESHOOTING E-2 LN-25™ IRONWORKER Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 32

    E-3 TROUBLESHOOTING E-3 LN-25™ IRONWORKER Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 33

    E-4 TROUBLESHOOTING E-4 LN-25™ IRONWORKER Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 34

    F-1 DIAGRAMS F-1 LN-25™ IRONWORKER NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code[...]

  • Page 35

    F-2 DIMENSION PRINT F-2 LN-25™ IRONWORKER 16” C I RCLE 12” x 18” ELL I PSE 23.17 14.81 8.65 17.19 16” C I RCL E 12” x 18” EL L I PSE 23.17 14.81 8.65 17.19[...]

  • Page 36

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INS TRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S S AFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F ABRIC [...]

  • Page 37

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO S panish French G erman Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A AS INS TRUÇÕES DO F ABRICANTE P ARA ES TE EQUIP AMENTO E A S P ARTES DE USO , E SIGA A S PRÁTIC A S DE SEGUR ANÇA DO EMPREG ADOR. • Keep your head out of fumes. • Use ventilation or exhaust to r[...]

  • Page 38

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]