Lincoln Electric IM359-G manual

LN-25 PORT ABLE C V/CC SEMIA UT OMA TIC WIRE FEEDER OPERA TING MANUAL IM359-G February, 1998 For use with machines having Code Number 10231 10232 10233 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful o[...]

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. ________________________________________________[...]

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 to protect your skin[...]

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 manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

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 L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

LN-25 Thank You 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. P[...]

LN-25 SAFETY ...............................................................................................................................................i-iv INSTALLATION ................................................................................................................... ....SECTION A Technical Specifications .....................[...]

TEMPERA TURE RANGE OPERA TION: - 40 o C to +40 o C (- 40 o F to +104 o F) STORAGE: - 40 o C to +85 o C (- 40 o F to +185 o F) LN-25 A-1 OPERA TING ARC VOL T AGE Constant Voltage (CV) or 15-40 VDC (110VDC Maximum OCV) Constant Current (CC) RA TED CURRENT Rated current without contactor 500 Amps 60% Duty Cycle Rated current with contactor 300 Amps 60[...]

LN-25 A-2 INST ALLA TION 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 o[...]

LN-25 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 electr[...]

LN-25 A-4 INST ALLA TION Install the barbed fitting and union nut to the 5 ⁄ 8 -18 female inert gas fitting on the front panel of the LN-25 case. Connect the 3 ⁄ 16 ” I.D. gas hose from the gun cable to the barbed fitting. When the gun is to be removed, this fitting can be easily detached by loosening the union nut. WELD CABLE CONNECTION The [...]

LN-25 B-1 ELECTRIC SHOCK can kill. • Do not touch electrically live part or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. ARC RAYS can burn. • Wear eye, ear and body pro- tection. FUMES AND GASSES can be dangerous. • Keep your head out of fumes. • Use ventilation or e[...]

LN-25 B-2 OPERA TION VOLTMETER (Factory installed on model Codes above 9218) The 40V DC analog voltmeter is mounted to the front control panel of the LN-25 and is connected to read the arc voltage between the LN-25 electrode cable connection and the work clip lead. NOTE: 1. The Voltmeter will read zero if the LN-25 work clip lead is not connected t[...]

LN-25 B-3 wire speed is set to 400 in/min., a welding procedure arc voltage of at least 17V would be required to obtain the 400 in/min. wire feed speed. WORK CLIP LEAD IMPORTANT SAFETY NOTE: To avoid possible electrical shock, do not touch the metal portions of the LN-25 work lead clip if the power source output is on. The clip will be electrically[...]

LN-25 B-4 OPERA TION g. To remove Readi-Reel from Adapter, depress re- taining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. It is not necessary to remove adapter from spindle. h. Load wire into wire drive per Loading Wire Drive Section. MOUNTING 10 TO 30 LB SPOOLS For 12” Diameter Spools: a. Rem[...]

LN-25 B-5 LOADING WIRE DRIVE a. Turn 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 properly straightened, it may not feed or may not go into the outgoing guide tube causing a “bi[...]

LN-25 B-6 OPERA TION 3. If the only result is drive roll slippage, shut off the power source, then loosen the gun cable clamping screw in the gearbox conductor block and pull the gun cable forward about six inches. There should be a slight waviness in the exposed wire. If there is no waviness, the pressure is too low. Increase the pressure setting [...]

LN-25 B-7 Arc Volts 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 93 100 219 194 175 159 146 135 125 117 109 103 110 241 214 193 175 160 148 138 128 120 113 120[...]

LN-25 B-8 ARC RAYS can burn. • Do not touch metal por- tions of the LN-25 lead Clip when welding power source is on. OPERA TION CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be dam- aged. • Never lift welder with cylin- der attached • Never allow welding elec-[...]

LN-25 B-9 OPERA TION 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 sou[...]

LN-25 C-1 LN-25 OPTION CHART O= CANNOT BE USED WITH X = REQUIRED ➀ = REQUIRES ONE OF THESE + = INCLUDED WITH Solenoid K430-1 Kit X ++ Remote Output K431-1 Control Module ➀➀ OX X O O O O O O Remote K432 Control Cable XX 115VAC K433 Power Source XX Remote Box Gas Flow K434-1 Timer Kit ➀➀ ➀ ➀ ➀ 50 Ft. K439 Ext. Cable X Contactor K443-1[...]

LN-25 C-2 OPTIONAL ACCESSORIES 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,[...]

LN-25 C-3 Installation instructions (M17590) are included with this kit. K460-1 PULSE POWER ADAPTER KIT (For use with K461 Pulse Power Control Cable.) This kit enables the LN-25 to pulse weld with a Pulse Power 500 power source above Code 9300 (or lower Codes updated with S18506 Kit). The kit includes a Remote PC board with output voltage control, [...]

LN-25 C-4 ACCESSORIES The Remote Box provides the proper welding power source control interface and isolated 24V AC input supply for the LN-25 equipped with the K431-1 Remote Output Control Kit. Remote Box requires 115V AC, 50/60 Hz input and a welding power source using a contact closure output pilot circuit, as available on appropriate Lincoln we[...]

LN-25 C-5 ACCESSORIES K444, K444-1 OR K444-2 REMOTE VOLTAGE CONTROL KIT (Not required if using K431-1 or K624-1 Remote Output Control Kit or K460-1 Pulse Power Adapter Kit.) The Remote Voltage Control Kit provides remote (10K ohm rheostat) control of power source output arc voltage level. K444 connects to power sources with control terminal strip c[...]

LN-25 C-6 ACCESSORIES “A Dia. Hole” To be Concentric to .749/.747 Wire Size Dia. Within .008 F.I.M. .068 thru 5 ⁄ 64 .125 ( 1 ⁄ 8 Drill) 1 ⁄ 16 (.062) .078 ( 5 ⁄ 64 Drill) .045 & .052 .062 ( 1 ⁄ 16 Drill) .023 thru .035 .055 (#54 Drill) Drive Roll & Guide Tube Wire Sizes Used Kit No. T-13355- 3 ⁄ 32 5 ⁄ 64 , .072 & .06[...]

LN-25 D-1 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 ser- vice thi[...]

LN-25 D-2 device is not screwed in far enough, the LN-25 motor speed could be unstable or run at full speed with no control. If screwed in too far, it will rub a moving part inside the gearbox. The module is properly mounted to the gearbox as shipped from the factory. If the device is ever removed or replaced, proper mounting technique is as follow[...]

LN-25 E-1 HOW T O USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe a[...]

LN-25 E-2 TROUBLESHOOTING PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled POSSIBLE AREAS OF MISADJUSTMENT(S) 1 . Power source must be on and open circuit voltage (OCV) present at weld terminals. 2. LN-25 work clip may not be connected. 3. LN-25 polarity switch must match electrode polarity. 4. Jumper plug on control or option board may [...]

LN-25 E-3 TROUBLESHOOTING Rough wire feeding or wire not feeding but drive rolls turning. 1 . Gun cable kinked and/or twisted. 2 . Wire jammed in gun and cable. 3. Incorrect size or installation of drive roll and guide tubes. 4. Drive roll loose. 5. Gun cable dirty. 6. Worn drive roll. 7. Electrode rusty and/or dirty. 8. Worn nozzle or cable liner.[...]

LN-25 E-4 TROUBLESHOOTING Solenoid does not close when trigger is pulled or purge button is pressed. Wire feeds properly. 1. Make certain that plugs J2 and J3 are connected to the control board securely. RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS WELD PROBLEMS POSSIBLE AREAS OF MISADJUSTMENT(S) PROBLEMS (SYMPTOMS) Contact your local Lincoln Autho[...]

LN-25 F-1 WIRING DIAGRAM                                       ?[...]

LN-25 F-2 LN-25 PHYSICAL DIMENSIONS 16.60 14.00 21.00 7.40 .25 DIMENSIONS 4/96[...]