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Lincoln Electric LN-25 SVM114-C manual

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Table of contents for the manual

  • Page 1

    LN-25 ™ POR T ABLE C V/CC SEMIA UTOMA TIC WIRE FEEDER Safety Depends on Y ou Lincoln arc welding and cutting equip- ment is designed and built with saf ety in mind. Howe v er , your ov erall saf ety can be increased by proper installation ... and thoughtful operation on y our par t. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT REA[...]

  • Page 2

    SAFETY i i i i Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FOR ENGINE powered equipment. 1.a. T ur n the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well[...]

  • Page 3

    SAFETY i i i i i i i i Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Av oid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to k e[...]

  • Page 4

    S S A A F F E E T T Y Y i i i i i i i i i i i i Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Jan ‘07 FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U .S . Nati[...]

  • Page 5

    S S A A F F E E T T Y Y i i v v i i v v Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Mar ‘93 PRÉCAUTIONS DE SÛRETÉ P our votre propre protection lire et obser ver toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de s?[...]

  • Page 6

    v v LN-25™ MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . [...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION - LN-25™ Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Saf ety Precautions . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 8

    INST ALLA TION A-2 LN-25™ A-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEMPERA TURE RANGE OPERA TION: - 40 o C to +40 o C (- 40 o F to +104 o F) ST ORA GE: - 40 o C to +70 o C (- 40 o F to +158 o F) OPERA TING ARC V O[...]

  • Page 9

    INST ALLA TION A-3 LN-25™ A-3 ELECTRIC SHOCK can kill. • Do not operate with cov ers remov ed. • T ur n off po wer source bef ore installing or ser vicing. • Do not touch electr ically hot par ts. • T ur n the input po wer to the welding pow er source off at the fuse bo x bef ore working in the terminal strip. • Only qualified personnel[...]

  • Page 10

    INST ALLA TION A-4 LN-25™ A-4 c. Place “Set to Same P olarity As Electrode Cable Connection” s witch 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 pow er source terminal str ip or to the MS type c on n ec t or. e. I[...]

  • Page 11

    INST ALLA TION A-5 LN-25™ A-5 Install the barbed fitting and union nut to the 5 ⁄ 8 -18 f emale inert gas fitting on the front panel of the L N- 25™ case. Connect the 3 ⁄ 16 " I.D . gas hose from the gun cable to the barbed fitting. When the gun is to be remov ed, this fitting can be easily detached by loosening the union nut. WELD CAB[...]

  • Page 12

    NO TES A-6 A-6 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 13

    T ABLE OF CONTENTS - OPERA TION SECTION - LN-25™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Saf ety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 General Descr iption . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 14

    OPERA TION B-2 B-2 LN-25™ ELECTRIC SHOCK can kill. • Do not touch electrically live par t or electrode with skin or wet clothing. • Insulate yourself from w ork and ground. • Alwa ys wear dr y insulating glov es. ARC RA YS can burn. • W ear ey e, ear and body pro- tection. FUMES AND GASSES can be dangerous. • K eep your head out of fume[...]

  • Page 15

    OPERA TION B-3 B-3 LN-25™ V OL TMETER (F actory installed on model Codes above 9218) The 40V DC analog v oltmeter is mounted to the front control panel of the LN-25™ and is connected to read the arc v oltage betw een the LN-25™ electrode cab le connection and the work clip lead. N OTE : 1. The V oltmeter will read zero if the LN-25™ work cl[...]

  • Page 16

    OPERA TION B-4 B-4 LN-25™ WORK CLIP LEAD I M P O R TA N T S A F E T Y N O T E : T o av oid possible electrical shock, do not touch the metal por tions of the LN-25™ work lead clip if the po wer source output is on. The clip will be electrically “HOT” to work if the input electrode cable to the LN-25™ is electrically “HO T” ev en if th[...]

  • Page 17

    OPERA TION B-5 B-5 LN-25™ g. T o remov e Readi-Reel ® from Adapter , depress re - taining spring tab with thumb while pulling the Readi-Reel ® c ag e f r om th e m o ld e d a da p te r w i t h both hands. It is not necessary to remov e adapter f ro m s p in d le . h. Load wire into wire drive per Loading Wire Drive Section. MOUNTING 10 T O 30 L[...]

  • Page 18

    OPERA TION B-6 B-6 LN-25™ LO ADING WIRE DRIVE a. T urn the reel or spool until the free end of the electrode is accessible . b . While tightly holding the electrode, cut off the bent end and straighten the first six inches. Cut off the first inch. (If the electrode is not proper ly s tr ai g ht e n ed , i t m ay n ot fe e d o r m ay no t g o i n [...]

  • Page 19

    OPERA TION B-7 B-7 LN-25™ screw in the gearbox conductor b lock and pull the gun cable f orward about six i nches. There should be a slight wa viness in the exposed wire. If there is no w aviness , the pressure is too low . Increase the pressure setting 1 ⁄ 4 tur n, lock the gun cable in place and repeat the abov e steps . DESIRED IN/MIN ARC VO[...]

  • Page 20

    OPERA TION B-8 B-8 LN-25™ Arc V olts Used Desired In/Min 16 18 20 22 24 26 28 30 32 34 50 109 97 88 80 73 67 63 58 55 51 60 131 117 105 95 88 81 75 70 66 62 70 153 136 123 111 102 94 88 82 77 72 80 175 156 140 127 117 108 100 93 88 82 90 197 175 158 143 131 121 113 105 98 93 100 219 194 175 159 146 135 125 117 109 103 110 241 214 193 175 160 148 [...]

  • Page 21

    OPERA TION B-9 B-9 LN-25™ ARC RA YS can b urn. • Do not touch metal portions of the LN-25™ lead Clip when w elding po wer source is on. CYLINDER may explode if damaged. • K eep cylinder upright and chained to suppor t. • K eep cylinder awa y from areas where it ma y be dam- aged. • Ne ver lift welder with cylinder attached • Ne ver al[...]

  • Page 22

    OPERA TION B-10 B-10 LN-25™ Do not use LN-25™ models below Code 9200 with any TI G or S qua re W av e we ldi ng p ower s ou rce s. D o not use LN-25™ models equipped with inter nal contactors with non-Lincoln TIG or Square W a v e welding power sources. Damage to the LN-25™ circuit can occur as a result of the high output inductance typical[...]

  • Page 23

    T ABLE OF CONTENTS - ACCESSORIES SECTION - LN-25™ Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C LN-25™ Option Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 24

    A CCESSORIES C-2 C-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-25™ LN-25™ OPTION CHART O= CANNO T BE USED WITH X = REQUIRED ➀ ➀ = REQUIRES ONE OF THESE + = INCLUDED WITH Solenoid K430-1,2 Kit X ++ Remote Outpu[...]

  • Page 25

    A CCESSORIES C-3 C-3 LN-25™ OPTIONAL A CCESSORIES ELECTRIC SHOCK can kill. • Do not operate with cov ers remov ed. • T u rn of f po we r s o ur ce be f or e i ns ta l l in g o r s e rv ic i n g . • Do not touch electrically hot par ts. • T ur n the input pow er to the welding pow er source off at the fuse bo x bef ore working in the termi[...]

  • Page 26

    LN-25™ CONT A CTOR KIT (K443-1 FOR CODES BELO W 10500, K443-2 FOR CODES 10500 TO 10558 OR K433-3 FOR CODES ABO VE 11144) (F act ory ins ta ll ed i n K 44 9 Mod el .) The internal contactor provides “cold” electrode until the gun tr igger is pressed, and a fixed bur nbac k time dela y to pre v ent electrode from sticking in the weld crater whe[...]

  • Page 27

    A CCESSORIES C-5 C-5 LN-25™ K439 REMO TE EXTENSION CABLE ASSEMBL Y The 50 ft. Extension cab le assemb lies are used to e x - tend the K432 Remote Control Cab le Assembly when longer cable lengths are required. Multiple K439 Extensions ma y be used, how e v er , to pre vent excessiv e weld cable voltage drops, the 500 amp max. rating of the K432 s[...]

  • Page 28

    A CCESSORIES C-6 C-6 LN-25™ TO GUN SWITCH CONNECT LEADS TO PINS "A" AND "C" S12024-1 (L.E. PART NO.) AMPHENOL AN3057-10 (OR EQUIV.) S12020-6 (L.E. PART NO.) AMPHENOL MS-3106A-18-11P (OR EQUIV.) “A Dia. Hole” T o be Concentric to .749/.747 Wire Siz e Dia. Within .008 F .I.M. .068 thr u 5 ⁄ 64 .125 ( 1 ⁄ 8 Drill) 1 ⁄ 1[...]

  • Page 29

    T ABLE OF CONTENTS - MAINTENANCE SECTION - LN-25™ Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Saf ety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 30

    MAINTENANCE D-2 D-2 LN-25™ ELECTRIC SHOCK can kill. • Do not operate with cov ers remov ed. • T urn of f p o w e r so u r ce be f or e installing or ser vicing. • Do not touch electrically hot par ts. • T ur n the input po wer to the welding power source off at the fuse bo x before w orking in the terminal strip. • Only qualified person[...]

  • Page 31

    MAINTENANCE D-3 D-3 LN-25™ Proper positioning of this module is critical to proper operation of the LN-25™ wire feed speed control. If the de vice is not screw ed in f ar enough, the LN-25™ motor speed could be unstable or r un at full speed with no control. If screwed in too far , it will rub a moving par t inside the gearbo x. The module is[...]

  • Page 32

    NO TES D-4 D-4 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 33

    T ABLE OF CONTENTS - THEOR Y OF OPERA TION SECTION - LN-25™ Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E General Descr iption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 Control Circuit Operation . . . . . . . . . . . . . . . . . . . .[...]

  • Page 34

    THEOR Y OF OPERA TION E-2 E-2 LN-25™ GENERAL DESCRIPTION The LN-25™ is a portable semiautomatic wire f e e d e r d e s i g n e d t o o p e r a t e f r o m a D C a r c voltage . It is designed f or maximum versatility in a v ariety of field applications . It can be used with most constant voltage or constant current DC power sources without the [...]

  • Page 35

    THEOR Y OF OPERA TION E-3 E-3 LN-25™ FEEDB A CK AND CONTROL CIRCUITS The combination of the range s witch and wire speed control provides a command voltage for the control board. The hall eff ect module transf orms the motor RPM to a digital voltage frequency that is “fed back” to the control board. When op erating in the constant v oltage (C[...]

  • Page 36

    THEOR Y OF OPERA TION E-4 E-4 LN-25™ OPTIONAL CIRCUITS CONT A CT OR The contactor , contactor PC board, and cold inch s witch are commonly incorporated in the LN-25™. This f eature enab les the user to ha v e an electrically “COLD” gun ev en though the power sources output ter minals are electr ically “HOT”. Upon receiving a command fro[...]

  • Page 37

    THEOR Y OF OPERA TION E-5 E-5 LN-25™ PR O TECTIVE DEVICES AND CIRCUITS O VER V OL T A GE SHUTDO WN If the power source open circuit voltage e xceeds ab ou t 110 - 12 0 vo l ts , th e LN- 25 ™ wi ll n ot op er a te un t il th e po w er sou rc e v ol t ag e dro p s bel o w ab ou t 10 2- 11 2 v o lt s . MO T OR O VERLO AD SHUTDO WN If e xce ss iv [...]

  • Page 38

    NO TES E-6 E-6 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 39

    T ABLE OF CONTENTS - TR OUBLESHOO TING AND REP AIR SECTION - LN-25™ T r o u b l e s h o o t i n g a n d R e p a i r .................................... S e c t i o n F How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2 PC Board T roub leshooting Procedures . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-25™ TROUBLESHOOTING AND REP AIR F-2 F-2 This T roubleshooting Guide is pro vided to help you locate and repair possib le machine malfunctions. Simply follo w the three-step [...]

  • Page 41

    LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REP AIR F-3 F-3 Sometimes machine f ailures appear to be due to PC board f ailures. These problems can sometimes be traced to poor electrical connect[...]

  • Page 42

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 . With the gun tr igger circuit activ ated and the mode s witch in the CV position, check f or the presence of 2 to 23 VDC at leads 539 to 541. This is the nor mal r ange for a[...]

  • Page 43

    The wire stops or stubs while welding. NO TE: On codes abov e 10100, the motor leads (541 & 539) are in Control Board Connector J4, pins 13 & 14. FEEDING PROBLEMS (Contin ued) TR OUBLESHOO TING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roub leshooting Guide – See Wiring Diagrams f or location of spe[...]

  • Page 44

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 . Per for m t he C o nt a ct o r Tes t . N OTE : T est is code specific. Codes abov e 10100 ma y o r m a y n o t h a v e a Contactor PC Board. 2 . Th e C on t ac t or P C b o a[...]

  • Page 45

    TR OUBLESHOO TING AND REP AIR F-7 F-7 LN-25™ TEST DESCRIPTION This test will deter mine if the gas solenoid v alv e or the solenoid PC board are functional. MA TERIALS NEEDED Phillips Head Screwdriv er 12 VDC Supply V olt/Ohmmeter DC V oltage Source (25 to 100 VDC) GAS SOLENOID V AL VE AND SOLENOID PC BO ARD TEST (FOR CODES BELO W 10500 ONL Y) Se[...]

  • Page 46

    TR OUBLESHOO TING AND REP AIR F-8 F-8 LN-25™ TEST PROCEDURE GAS SOLENOID V AL VE 1 . O pe n t he c a se d o o r . R e mo ve th e w i re r e el by removing the retaining collar . See Figure F .1. 2 . Remov e the screws holding the control bo x cov er in place and remov e the control bo x c ove r . S ee F i gu r e F . 1 . Return to Section TOC Retu[...]

  • Page 47

    TR OUBLESHOO TING AND REP AIR F-9 F-9 LN-25™ 3. Locate and remove the tw o solenoid leads from the solenoid v alve (F or codes 9812 and belo w , remov e the two leads from the Solenoid PC Board). See Figure F .2. 4. Make sure the gas supply f or the solenoid is hooked up , and then apply 12 VDC to the gas solenoid. 5. If the solenoid activates an[...]

  • Page 48

    TR OUBLESHOO TING AND REP AIR F-10 F-10 LN-25™ SOLENOID PC BO ARD 1. Apply at least 25 VDC but no more than 100 VDC to the LN-25™ from the electrode cable to the work sensing lead. Mak e sure the polarity s witch is set to match the polarity of the e le c t r od e c a bl e. F or ex a m pl e , if t h e e l ec t r od e cable is positiv e and the [...]

  • Page 49

    TR OUBLESHOO TING AND REP AIR F-11 F-11 LN-25™ 2 . Check f or the presence of the DC v oltage applied from lead 624A(+) to lead 621(-). See F ig u re F . 4 3. Check f or the presence of 12 VDC from lead 512(+) to lead 621(-). 4. Check f or the presence of 10 VDC from lead 606(+) to lead 621(-). When the LN-25™ tr igger circuit is activ ated, th[...]

  • Page 50

    NO TES F-12 F-12 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 51

    TR OUBLESHOO TING AND REP AIR F-13 F-13 LN-25™ GAS SOLENOID V AL VE AND CONTROL PC BO ARD TEST (FOR CODES ABO VE 10500 ONL Y) W ARNING Ser vice and repair should be perf ormed by only Lincoln Electric factory trained personnel. Unauthorized repairs perf ormed on this equipment may result in danger to the technician or machine operator and will in[...]

  • Page 52

    TR OUBLESHOO TING AND REP AIR F-14 F-14 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GAS SOLENOID V AL VE AND CONTROL PC BO ARD TEST (FOR CODES ABO VE 10500 ONL Y) (continued) FIGURE F .5 – CONTROL BO X CO VER RE[...]

  • Page 53

    TR OUBLESHOO TING AND REP AIR F-15 F-15 LN-25™ 3. Locate and remov e the two solenoid leads #690 and #691 from the solenoid v alve . See Figure F . 6 . 4. Make sure the gas supply f or the solenoid is hooked up , and then apply 12 VDC to the gas solenoid. 5. If the solenoid activates and allows gas flo w , then the solenoid v alve is good. N OT E[...]

  • Page 54

    TR OUBLESHOO TING AND REP AIR F-16 F-16 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GAS SOLENOID V AL VE AND CONTROL PC BO ARD TEST (FOR CODES ABO VE 10500 ONL Y) (continued) FIGURE F .7. – APPLIED V OL T A GE P[...]

  • Page 55

    TR OUBLESHOO TING AND REP AIR F-17 F-17 LN-25™ 690 691 512 500 555 667 621 J1 J3 J4 J2 2 . Check f or the presence of the DC v oltage a pp l ie d f ro m p lu g J 1 pi n 1 ( 6 67 + ) to p l ug J 1 p in 3 621(-). See Figure F .8.or F .8.a. 3. Check f or the presence of 5 to 6 VDC from lead 690(+) to lead 691(-) at solenoid valv e . The LN-25™ tri[...]

  • Page 56

    NO TES F-18 F-18 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 57

    TR OUBLESHOO TING AND REP AIR F-19 F-19 LN-25™ HALL EFFECT MODULE TEST TEST DESCRIPTION This test will determine if the hall effect module is functioning correctly . MA TERIALS NEEDED Phillips Head Screwdriv er V olt/Ohmmeter DC V oltage Source (25 to 100 VDC) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC[...]

  • Page 58

    TR OUBLESHOO TING AND REP AIR F-20 F-20 LN-25™ TEST PROCEDURE 1. Open the case door . Remo ve the wire reel b y removing the retaining collar . See Figure F .5. 2 . Remov e the screws holding the control bo x cov er in place and remov e the control bo x c ove r . See Figure F .5. 3. Locate the three hall effect leads 500, 512 an d 555 incor porat[...]

  • Page 59

    TR OUBLESHOO TING AND REP AIR F-21 F-21 LN-25™ 4. Apply at least 25 VDC but no more than 100 VDC to the LN-25™ from the electrode cable to the work sensing lead. Obser v e polarity and set p ol a r it y sw it c h. 5. Check f or the presence of 12 VDC from lead 5 1 2 ( + ) t o l e a d 5 0 0 ( - ) . I f t h e 1 2 V D C i s n o t present or low , [...]

  • Page 60

    NO TES F-22 F-22 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 61

    TR OUBLESHOO TING AND REP AIR F-23 F-23 LN-25™ WIRE DRIVE MO T OR TEST TEST DESCRIPTION The f ollowing procedure will determine if the wire dr iv e motor is functional. MA TERIALS NEEDED Phillips Head Screwdriv er V oltage Source (v ariable 2 to 23 VDC) V olt/Ohmmeter Ser vice and repair should be perf ormed by only Lincoln Electric factory train[...]

  • Page 62

    TROUBLESHOOTING AND REP AIR F-24 F-24 LN-25™ TEST PROCEDURE 1. Open the case door . Remove the wire reel by removing the retaining collar . See Figure F .5. 2 . Remove the screws holding the control box cover in place and remove the control box c ov e r . See Figure F .5. 3. For codes 10148 and above, separate the in- line connector (containing t[...]

  • Page 63

    TR OUBLESHOO TING AND REP AIR F-25 F-25 LN-25™ CONT A CT OR & CONT A CT OR PC BO ARD TEST TEST DESCRIPTION The f ollowing test will determine if the contactor is functional. MA TERIALS NEEDED Phillips Head Screwdriv er 12 VDC Supply V olt/Ohmmeter NOTE: LN-25™ units with the L12253-[ ] Control Board do not use a Contactor PC Board. Codes ab[...]

  • Page 64

    TR OUBLESHOO TING AND REP AIR F-26 F-26 LN-25™ CONT A CT OR TEST PROCEDURE 1. Open the case door . Remo ve the wire reel b y removing the retaining collar . See Figure F .5. 2 . Remov e the screws holding the control bo x cov er in place and remov e the control bo x c ove r . See Figure F .5. 3.Separate the two in-line connectors located behind t[...]

  • Page 65

    TR OUBLESHOO TING AND REP AIR F-27 F-27 LN-25™ 4. Apply 12 VDC to the contactor coil leads. Do not leave the 12 VDC applied to the contactor coil for a pr olonged period of time (15 seconds maximum). Damage to contactor may result. 5. If the contactor does not activate when the 12 VDC is applied, the contactor is f aulty . Replace. 6. If the cont[...]

  • Page 66

    TROUBLESHOOTING AND REP AIR F-28 F-28 LN-25™ CONT ACTOR PC BOARD TEST 1. Check to be sure plug J9, on contactor board and plug J3, on the control board are present and secure. See Figures F .14 an d F . 15 . 2 . If optional gas timer pc board is in stalled, remove plug J6 from contactor board and install jumper plug. See Wiring Diagram. 3 . Apply[...]

  • Page 67

    TR OUBLESHOO TING AND REP AIR F-29 F-29 LN-25™ TP1 R65 D49 R81 R43 R49 C40 DZ10 Q7 R60 D32 C5 R110 D37 R115 X4 R37 R2 C22 R14 C31 R117 R16 X5 R52 R113 T1 R4 R88 D8 Q10 DZ15 D18 D16 C26 R71 R35 C4 R95 X7 R97 C42 R118 Q3 R101 C35 R58 R74 R98 D22 R27 X2 D25 D44 R103 R9 C17 C9 R114 R75 C43 R59 R53 R77 DZ2 D41 R76 D7 DZ11 R18 R29 D14 D11 R24 D43 R44 D[...]

  • Page 68

    NO TES F-30 F-30 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 69

    TR OUBLESHOO TING AND REP AIR F-31 F-31 LN-25™ CONT A CT OR PC BO ARD REPLA CEMENT T OOLS REQ UIRED Phillips Head Screwdriv er Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Ser vice and repair should be perf ormed by only [...]

  • Page 70

    TR OUBLESHOO TING AND REP AIR F-32 F-32 LN-25™ REP AIR PROCEDURE 1 . Obser ve the static electricity precautions detailed in PC Board T roubleshooting Procedures at the beginning of this section. 2. Open the case door . Remo ve the wire reel b y removing the retaining collar . See Figure F .5. 3 . Remov e the screws holding the control bo x cov e[...]

  • Page 71

    TROUBLESHOOTING AND REP AIR F-33 F-33 LN-25™ 5 . For codes 9812 and below, remove the contactor coil leads and plug J7 from the contactor PC board. See Figure F .17. A l so f o r codes 9812 and below , remove plug J3 from the c on t ro l P C bo a rd . S ee F i g ur e F . 1 8 . Return to Section TOC Return to Section TOC Return to Section TOC Retu[...]

  • Page 72

    6. Remov e the four scre ws from the front panel holding the contactor PC board assembly in place. Carefully remo ve the contactor PC board assembly . See Figure F .19. 7. Place the new contactor PC board assemb ly in position behind the front panel. Secure the contactor PC board assembl y by installing the f our screws into the front panel. 8. For[...]

  • Page 73

    TR OUBLESHOO TING AND REP AIR F-35 F-35 LN-25™ CONTR OL PC BO ARD REPLA CEMENT T OOLS REQ UIRED Phillips Head Screwdriv er Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Ser vice and repair should be perf ormed by only Linc[...]

  • Page 74

    TR OUBLESHOO TING AND REP AIR F-36 F-36 LN-25™ REP AIR PROCEDURE 1 . Obser ve the static electricity precautions detailed in PC Board T roubleshooting Procedures at the beginning of this section. 2 . O pe n t he c a se d o o r . R e mo ve th e w i re r e el by removing the retaining collar . See Figure F .5. 3 . Remov e the screws holding the con[...]

  • Page 75

    TR OUBLESHOO TING AND REP AIR F-37 F-37 LN-25™ TP1 R65 D49 R81 R43 R49 C40 DZ10 Q7 R60 D32 C5 R110 D37 R115 X4 R37 R2 C22 R14 C31 R117 R16 X5 R52 R113 T1 R4 R88 D8 Q10 DZ15 D18 D16 C26 R71 R35 C4 R95 X7 R97 C42 R118 Q3 R101 C35 R58 R74 R98 D22 R27 X2 D25 D44 R103 R9 C17 C9 R114 R75 C43 R59 R53 R77 DZ2 D41 R76 D7 DZ11 R18 R29 D14 D11 R24 D43 R44 D[...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 7 . R e m o v e t h e s c r e w s h o l d i n g t h e c o n t r o l P C board to the inside of the case. Carefully remov e the control board. See Figure F .24. 8 . Place the new [...]

  • Page 77

    TR OUBLESHOO TING AND REP AIR F-39 F-39 LN-25™ T OOLS REQ UIRED Phillips Head Screwdriv er 5/16" Nut Driver 11/16" Wrench Ser vice and repair should be perf ormed by only Lincoln Electric factory trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in [...]

  • Page 78

    TROUBLESHOOTING AND REP AIR F-40 F-40 LN-25™ REP AIR PROCEDURE 1. Open the case door . Remove the wire reel by removing the retaining collar . See Figure F .5. 2 . Remove the screws holding the control box cover in place and remove the control box c ov e r . See Figure F .5. 3. Remove the baffle from in front of the contactor . S ee F i gu r e F [...]

  • Page 79

    Ser vice and repair should be perf ormed by only Lincoln Electric factory trained personnel. Unauthorized repairs perf ormed on this equipment may result in danger to the technician or machine operator and will in validate y our f actory warranty . For y our saf ety and to a void electrical shock, please observe all saf ety notes and precautions de[...]

  • Page 80

    F-42 TROUBLESHOOTING AND REP AIR F-42 LN-25™ CONT ACTOR REPLACEMENT (continued) WORK SENSING LEAD POLARITY SWITCH ELECTRODE CABLE V OLTAGE SENSING LEAD #67 WELDING CABLES CONTACTOR IN-LINE CONNECTORS 11/16" BRASS NUTS ELECTRODE LEAD FIGURE F .26. REP AIR PROCEDURE 1. Open the case door . Remove the wire reel by removing the retaining collar [...]

  • Page 81

    TR OUBLESHOO TING AND REP AIR F-43 F-43 LN-25™ GAS SOLENOID V AL VE AND/OR SOLENOID PC BO ARD (IF PRESENT) REPLA CEMENT T OOLS REQ UIRED Phillips Head Screwdriv er 3/4" Wrench Pliers Ser vice and repair should be perf ormed by only Lincoln Electric factory trained personnel. Unauthorized repairs perf or med on this equipment ma y result in d[...]

  • Page 82

    TR OUBLESHOO TING AND REP AIR F-44 F-44 LN-25™ REP AIR PROCEDURE 1 . O pe n t he c a se d o o r . R e mo ve th e w i re r e el by removing the retaining collar . See Figure F .5. 2 . Remov e the screws holding the control bo x cov er in place and remov e the control bo x c ove r . See Figure F .5. NOTE : If only the gas solenoid valv e needs repl[...]

  • Page 83

    TR OUBLESHOO TING AND REP AIR F-45 F-45 LN-25™ 4c. Remove the gas hose from the solenoid nipple . 4 d. Using the 3/8” nut driver , remov e the purge button n ut from the assembly . Remo ve the purge button. 4e. Remove an y necessary brass fittings required. S ee F i gu r e F . 3 0. 4 f . Reassemble in re v erse order and reconnect leads as nece[...]

  • Page 84

    5 . F o r c o d e s 9 8 1 2 a n d b e l o w, r e m o v e t h e t w o solenoid leads from the solenoid PC board and disconnect the purge s witch leads. See Figure F .31. Also , remov e plug J2 from the control b oa r d. 6 . R e m o ve t h e g a s h o s e f r o m t h e g a s s o l e n o i d nipple. Remov e the br ass fitting connected to the gas sole[...]

  • Page 85

    TR OUBLESHOO TING AND REP AIR F-47 F-47 LN-25™ DRIVE MO T OR AND GEARBO X REPLA CEMENT AND A CCESS T O HALL EFFECT MODULE T OOLS REQ UIRED Phillips Head Screwdriv er 3/4" Wrench 5/8" Wrench 7/16" Wrench Slot Head Screwdriv er Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TO[...]

  • Page 86

    TROUBLESHOOTING AND REP AIR F-48 F-48 LN-25™ REP AIR PROCEDURE 1 . Observe the static electricity precautio ns detailed in PC Board Troubleshooting Procedures at the beginning of this section. 2. Open the case door . Remove the wire reel by removing the retaining collar . See Figure F .5. 3 . Remove the screws holding the control box cover in pla[...]

  • Page 87

    TR OUBLESHOO TING AND REP AIR F-49 F-49 LN-25™ 7 . R e m o v e t h e t w o s c r e w s a n d l o c k w a s h e r s holding the rear end plate to the gearbo x and remov e the rear end plate. Remo ve the three drive motor mounting scre ws, flat w ashers and lock w ashers (one is inside the gearbo x h ou s in g ). See Figure F .34. 8 . C a r e f u l[...]

  • Page 88

    TR OUBLESHOO TING AND REP AIR F-50 F-50 LN-25™ DRIVE MO T OR AND GEARBO X REPLA CEMENT AND A CCESS T O HALL EFFECT MODULE (continued) FIGURE F .34. – DRIVE MOT OR REPLA CEMENT . DRIVE MOTOR GEARBOX REAR END PLATE LOCKWASHER END PLATE MOUNTING SCREW FLAT WASHER LOCKWASHER DRIVE MOTOR MOUNTING SCREW HALL EFFECT MODULE Return to Section TOC Return[...]

  • Page 89

    TR OUBLESHOO TING AND REP AIR F-51 F-51 LN-25™ RETEST AFTER REP AIR If a f ailed test indicates that any mechanical part that could aff ect the machine’ s electr ical characteristics must be replaced or if an y electrical components are re pa ir ed o r rep la ce d, t he m ach in e mu st be r et es te d and meet the f ollowing standards . W i r [...]

  • Page 90

    NO TES F-52 F-52 LN-25™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 91

    LN-25™ G-1 ELECTRICAL DIA GRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIA GRAMS SECTION- E L E C T R I C A L D I A G R A M S ..........................................................S E C T I O N G WIRING DIA GRAM - ABO VE CODE 11140 (G4679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 WIRING DIA GRAM - CODE 10556 THR U 105[...]

  • Page 92

    ELECTRICAL DIA GRAMS G-2 ¤ ¤ WIRING DIA GRAM - ABO VE CODE 11140 (G4679) 530A 512 606 607 530 500 HI LO 523B 522 VM AR C VOL T ME TE R + 667 621 632 633 631 10K R1 WI RE SPEE D CONTR OL R HE OS TA T W N.B. S2 S3 S1 TO BLACK POS 667 621 67 N.B. NE G A B C D E 622A 500A J5 T RI G GE R CON NE CTOR 7 J3 3 2 1 4 1 4 5 2 621 621 500A 667 622A 608 J2 J1[...]

  • Page 93

    ELECTRICAL DIA GRAMS G-3 ¤ ¤ WIRING DIA GRAM - CODE 10556 THRU 10500 (L10925) G-3 NOTE: This diag ram is for ref erence only . It may not be accur ate for all machines cov ered by this manual. The wir ing diagram specific to y our code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Retur n to Section TOC Retur[...]

  • Page 94

    ELECTRICAL DIA GRAMS G-4 ¤ ¤ WIRING DIA GRAM - CODE 10100 THRU 10500 (L9644) G-4 NOTE: This diag ram is for ref erence only . It may not be accur ate for all machines cov ered by this manual. The wir ing diagram specific to y our code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Retur n to Section TOC Return[...]

  • Page 95

    ELECTRICAL DIA GRAMS G-5 ¤ ¤ WIRING DIA GRAM - BELO W CODE 9900 (L7545) G-5 NOTE: This diag ram is for ref erence only . It may not be accur ate for all machines cov ered by this manual. The wir ing diagram specific to y our code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Retur n to Section TOC Return to S[...]

  • Page 96

    ELECTRICAL DIA GRAMS G-6 ¤ ¤ SCHEMA TIC - COMPLETE MACHINE - CODES ABO VE 11140 (G5366) EN-170 G5366 LN -25 (A CR OSS T H E AR C) MAC HI N E SC HEM ATIC NONE G4198- 1 M . D IDI ON M . D IDI ON DO NO T SC AL E T HIS DR A WING D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : REFER ENCE: EQ UIP M ENT TYPE: SUBJECT: SCA L E: M ATER IAL DI S[...]

  • Page 97

    ELECTRICAL DIA GRAMS G-7 ¤ ¤ SCHEMA TIC - COMPLETE MACHINE - BELO W CODE 9900 ONL Y (G1833) G-7 NOTE: This diagr am is for ref erence only . It may not be accurate f or all machines cov ered by this manual. Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to[...]

  • Page 98

    ELECTRICAL DIA GRAMS G-8 ¤ ¤ SCHEMA TIC - CONTROL PC BD - ABOVE CODE 11140 (G4616-5) G-8 NOTE: This diagr am is for ref erence only . It may not be accurate f or all machines cov ered by this manual. Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master[...]

  • Page 99

    ELECTRICAL DIA GRAMS G-9 ¤ ¤ SCHEMA TIC - CONTROL PC BD - CODE 10556 THRU 10558 (G3424-3) G-9 NOTE: This diagr am is for ref erence only . It may not be accurate f or all machines cov ered by this manual. Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to M[...]

  • Page 100

    ELECTRICAL DIA GRAMS G-10 ¤ ¤ SCHEMA TIC - CONTROL PC BD - CODE 10100 THRU 10500 (G2194) G-10 NOTE: This diagr am is for ref erence only . It may not be accurate f or all machines cov ered by this manual. Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to M[...]

  • Page 101

    NOTE: Lincoln Electric assumes no responsibility for liab lilities resulting from board level troub leshooting. PC Board repairs will in validate your f actory warranty . Individual Printed Cir cuit Board Components are not available fr om Lincoln Electric. This inf ormation is pro- vided for reference only . Lincoln Electric discourages board lev [...]

  • Page 102

    NOTE: Lincoln Electric assumes no responsibility for liab lilities resulting from board level troub leshooting. PC Board repairs will in validate your f actory warranty . Individual Printed Cir cuit Board Components are not available fr om Lincoln Electric. This inf ormation is pro- vided for reference only . Lincoln Electric discourages board lev [...]

  • Page 103

    NOTE: Lincoln Electric assumes no responsibility for liab lilities resulting from board level troub leshooting. PC Board repairs will in validate your f actory warranty . Individual Printed Cir cuit Board Components are not available fr om Lincoln Electric. This inf ormation is pro- vided for reference only . Lincoln Electric discourages board lev [...]

  • Page 104

    NOTE: Lincoln Electric assumes no responsibility for liab lilities resulting from board level troub leshooting. PC Board repairs will in validate your f actory warranty . Individual Printed Cir cuit Board Components are not available fr om Lincoln Electric. This inf ormation is pro- vided for reference only . Lincoln Electric discourages board lev [...]

  • Page 105

    ELECTRICAL DIA GRAMS G-15 ¤ ¤ SCHEMA TIC - CONT ACT OR PC BD - ABO VE CODE 10500 (M10965) POWER SUPPLY SOURCE POINT CONTACTOR SUP’S’D’G. DIODES = CAPACITORS = GENERAL INFORMATION LAST NO. USED LABELS PULL-IN TIMER CURRENT LIMIT 11 RESISTORS = Ohms ( MFD 1A, 400V ( C- R- VOLTAGE NET 14 37 D- UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPEC[...]

  • Page 106

    ELECTRICAL DIA GRAMS G-16 ¤ ¤ SCHEMA TIC - CONT ACT OR PC BD - CODE 10100 THRU 10500 (M17621) y ( y y ) g R i i D S STANDARD This print is Current G-16 NOTE: This diagr am is for ref erence only . It may not be accurate f or all machines cov ered by this manual. Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section[...]

  • Page 107

    ELECTRICAL DIA GRAMS G-17 ¤ ¤ SCHEMA TIC - CONT ACT OR PC BD - BELO W CODE 9900 (L7535-[ ] CONT ACT OR - M15428) G-17 NOTE: This diagr am is for ref erence only . It may not be accurate f or all machines cov ered by this manual. Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return t[...]

  • Page 108

    ELECTRICAL DIA GRAMS G-18 ¤ ¤ SCHEMA TIC - CONT ACT OR PC BD - BELO W CODE 9900 (L9185-[ ] CONT ACT OR - M17139) y ( y y ) g G-18 NOTE: This diagr am is for ref erence only . It may not be accurate f or all machines cov ered by this manual. Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master [...]

  • Page 109

    NOTE: Lincoln Electric assumes no responsibility for liab lilities resulting from board level troub leshooting. PC Board repairs will in validate your f actory warranty . Individual Printed Cir cuit Board Components are not available fr om Lincoln Electric. This inf ormation is pro- vided for reference only . Lincoln Electric discourages board lev [...]

  • Page 110

    NOTE: Lincoln Electric assumes no responsibility for liab lilities resulting from board level troub leshooting. PC Board repairs will in validate your f actory warranty . Individual Printed Cir cuit Board Components are not available fr om Lincoln Electric. This inf ormation is pro- vided for reference only . Lincoln Electric discourages board lev [...]

  • Page 111

    NOTE: Lincoln Electric assumes no responsibility for liab lilities resulting from board level troub leshooting. PC Board repairs will in validate your f actory warranty . Individual Printed Cir cuit Board Components are not available fr om Lincoln Electric. This inf ormation is pro- vided for reference only . Lincoln Electric discourages board lev [...]