Lincoln Electric IM-939A manual

LN-25 PRO EXTREME IM939-A March, 2008 Red-D-Arc Spec-Built W elding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operat[...]

LN-25 PRO EXTREME 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. ______________________________[...]

LN-25 PRO EXTREME ii SAFETY ii ARC RA YS 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 t[...]

FOR ELECTRICALL Y 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 manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical [...]

iv SAFETY iv LN-25 PRO EXTREME Mar. ʻ93 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 él[...]

v v Thank You for selecting a QUALITY product. We want you to take pride in operating this 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. Pay particular attention to the safety instructi[...]

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

A-1 INST ALLA TION A-1 TEMPERA TURE RANGE OPERATION: -40°F to 104°F (-40°C to 40°C) STORAGE: -40°F to 185°F (-40°C to 85°C) INPUT VOL T AGE and CURRENT TECHNICAL SPECIFICA TIONS – LN25 PRO (K2613-3) HEIGHT WIDTH DEPTH WEIGHT 14.8 Inches 8.7 Inches 22.2 Inches 36 lbs (376 mm) ( 221 mm) (589 mm) (16 kg) Handle folded down PHYSICAL DIMENSION[...]

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[...]

A-3 INST ALLA TION 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 other live electrical [...]

A-4 INST ALLA TION 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, electrode and drive mechan[...]

THUMB SCREW GUN A-5 INST ALLA TION 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" to work and g[...]

A-6 INST ALLA TION A-6 ACROSS THE ARC SET -UPS CC Power Sources with Output Terminals Always Hot (See Figure A.5) If the power source has a Remote/Local switch, place the switch in the Local position. Place the CV/CC switch in the feeder in the "CC" posi- tion. LN-25 PRO EXTREME CV Power Sources with Stud Connectors and Remote/Local Switc[...]

A-7 INST ALLA TION A-7 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. 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. FIGURE A.7 FIGURE A.8 LN-25 P[...]

A-8 INST ALLA TION A-8 LN-25 PRO EXTREME CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.9) Place CV/CC switch in the feeder in the "CV" position. FIGURE A.9 K# K2613-3 KP1695-XX KP1696-XX KP1697-XX See Magnum Literature K1841 K484 Description LN25 PRO EXTREME Drive Roll Kit Welding Gun CV power Source[...]

B-1 OPERA TION B-1 LN-25 PRO EXTREME • 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 cloth[...]

B-2 OPERA TION B-2 LN-25 PRO EXTREME 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 LN25 PRO EXTREME is specially engineered to be the most rugged[...]

B-3 OPERA TION B-3 1. ANALOG VOLTMETER The analog voltmeter shows the voltage between electrode and work. On across the arc models, the voltmeter shows open circuit voltage when the wire feeder is not welding. The voltmeter is polarity insensitive and the range is 0 – 40VDC. (See Customer Assistance Policy in the front of this Instruction Manual)[...]

B-4 OPERA TION B-4 2. WIRE FEED SPEED KNOB 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. Models with analog voltmeters have a calibrated scale printed ar[...]

B-5 OPERA TION B-5 3. 5-PIN GUN TRIGGER CONNECTOR 4. WORK SENSE LEAD 5. 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 trig[...]

B-6 OPERA TION B-6 INTERNAL CONTROLS LN-25 PRO EXTREME FIGURE B.2[...]

B-7 OPERA TION B-7 CV/CC SWITCH (See Figure B.2) The CV/CC switch sets the wire feed speed control method for the wire feeder. 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. In the CC position, the wire feed speed varies during welding. The[...]

B-8 OPERA TION B-8 CONST ANT CURRENT WIRE WELDING (See Figure B.3) 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 t[...]

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. POWER-UP SEQUENCE For feeders with analog voltmeters, the the[...]

C-1 ACCESSORIES C-1 LN-25 PRO EXTREME WIRE TYPE Steel Wires: Cored Wires: Aluminum Wires: ELECTRODE SIZE .023-.030 (0.6-0.8mm) .035 (0.9mm) .045 (1.2mm) .052 (1.4mm) 1/16 (1.6mm) .035,.045 (0.9, 1.2mm) .040 (1.0mm) .030-.035" (0.8-0.9mm) .040-.045" (1.0-1.2mm) .052" (1.4mm) 1/16" (1.6mm) .068-.072" (1.7-1.8mm) 5/64" (2[...]

C-2 ACCESSORIES C-2 LN-25 PRO EXTREME K1796-xx K2593-xx K1803-1 K1840-xx K1842-xx AWG 1/0 Co-Axial Power Cable AWG #1 Coaxial Power Cable Work and Feeder Cables Package Weld Power Cable, Twist-Mate to Lug Weld Power Cable, Lug to Lug Includes: 1/0 Coaxial weld cable of length "xx". Ends of the weld cable have lug con- nections. Use for Pu[...]

C-3 ACCESSORIES C-3 LN-25 PRO EXTREME 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 Bu[...]

C-4 ACCESSORIES C-4 LN-25 PRO EXTREME K1500-4 K1500-5 K489-7 K435 K468 K586-1 Gun Receiver Bushing (for gun with K466-3 Lincoln gun connec- tors; compatible with Miller® guns.) Gun Receiver Bushing (compatible with Oxo® guns.) Gun Receiver Bushing (for Lincoln Fast-Mate guns.) Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2 i[...]

D-1 MAINTENANCE D-1 LN-25 PRO EXTREME 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 i[...]

D-2 MAINTENANCE D-2 Wire Feed Speed Validation (See Figure D.1) Calibration of the LN25 PRO EXTREME 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. Tools required: • RPM meter • Constant voltage DC welding power so[...]

E-1 TROUBLESHOOTING E-1 LN-25 PRO EXTREME 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 repai[...]

E-2 TROUBLESHOOTING E-2 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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

E-3 TROUBLESHOOTING E-3 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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

E-4 TROUBLESHOOTING E-4 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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

F-1 DIAGRAMS F-1 LN-25 PRO EXTREME 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 n[...]

F-2 DIAGRAMS F-2 LN-25 PRO EXTREME 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 n[...]

F-3 DIMENSION PRINT F-3 LN-25 PRO EXTREME 23.17 14.81 16" CIRCLE 12" x 18" ELLIPSE 8.65 17.19[...]

NOTES LN-25 PRO EXTREME[...]

NOTES LN-25 PRO EXTREME[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

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