Lincoln Electric Ln 25 Svm179 B Users Manual
SVM179-B to the manual d5017ebe-c823-4357-aa08-e055c430acd8
2015-02-09
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SVM179-B
April, 2011
LN-25™ PRO WIRE FEEDER
For use with machines having Code Numbers: 11387, 11388
11507, 11508
11620, 11621
11716, 11717
11746, 11747
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 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.
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SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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
SAFETY
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i
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
The engine exhaust from this product contains
are known to the State of California to cause canchemicals known to the State of California to cause
cer, birth defects, and other reproductive harm.
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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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
Lincoln 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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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.
____________________________________________________
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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.
___________________________________________________
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:
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.
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
possible to the area being welded.
___________________________________________________
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.
LN-25™ PRO
2.d.5. Do not work next to welding power source.
SAFETY
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ii
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
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.
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.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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.
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ii
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 Items 6.c. and 8.
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. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) 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. In confined spaces or in some circumstances,
outdoors, a respirator may 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 PEL
and ACGIH TLV 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.
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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
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
LN-25™ PRO
SAFETY
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iii
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.
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CYLINDER may explode
if damaged.
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 adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
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.
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
1235 Jefferson Davis Highway, Arlington, VA 22202.
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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.
iii
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.
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.
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6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
LN-25™ PRO
SAFETY
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iv
iv
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
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 metallique ou des grilles metalliques, principalement dans
les 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 defonctionnement.
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.
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
galvanisées 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 produits 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
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 rayonnement 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.
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.
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.
LN-25™ PRO
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-557
LN-25™ PRO
I
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A-1
TABLE OF CONTENTS - INSTALLATION SECTION
A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Frequency Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
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Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Wire Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Changing The Gun Receiver Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Procedure To Install Drive Rolls and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Pressure Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Loading Spools of Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Gun Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
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Power Source to LN-25™ PRO Cable Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7/A-8
MACHINES COVERED IN THIS MANUAL
PRODUCT NAME
PRODUCT
NUMBER
CODE
NUMBERS
LN-25™PRO
(NORMAL SPEED)
K2613-1
11387, 11507
11620, 11716
LN-25™PRO
(EXTRA TORQUE)
K2613-2
11388, 11508
11621, 11717
LN-25™PRO
(NORMAL SPEED)
K2613-5
11746
LN-25™PRO
(EXTRA TORQUE)
K2613-7
11747
LN-25™ PRO
INSTALLATION
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A-2
A-2
TECHNICAL SPECIFICATIONS – LN-25™ PRO (K2613-1, -2, -5, and -7)
INPUT VOLTAGE and CURRENT
INPUT VOLTAGE ± 10%
INPUT AMPERES
15-110 VDC
(24-42 VAC with remote voltage control kit installed)
4A
RATED OUTPUT @ 104°F (40°C)
DUTY CYCLE
INPUT AMPERES
60% rating
450
100% rating
325
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GEARING - WIRE FEED SPEED RANGE-WIRE SIzE
GMAW
GEARING
FCAW
WFS RANGE
WIRE SIzES
WFS RANGE
WIRE SIzES
Extra torque
K2613-2 & K2613-7
50 – 400 ipm
(0.8 – 10.1m/min)
.023 – 1/16"
(0.6 – 1.6mm)
30 – 400 ipm
(0.8 – 10.1m/min)
.030 - 3/32”
(10.3 – 2.4mm)
Normal Speed
K2613-1 & K2613-5
50 – 700 ipm
(1.3 – 17.7m/min)
.023 – 1/16"
(0.6 – 1.6mm)
50 – 700 ipm
(1.3 – 17.7m/min)
.030 - 5/64
(0.8 - 2.0mm)
PHYSICAL DIMENSIONS
HEIGHT
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14.8 Inches
(376 mm)
Handle folded down
WIDTH
DEPTH
8.7 Inches
(221 mm)
22.2 Inches
(589 mm)
TEMPERATURE RANGE
OPERATION:
STORAGE:
-40°F to 104°F (-40°C to 40°C)
-40°F to 185°F (-40°C to 85°C)
LN-25™ PRO
WEIGHT
36 lbs
(16 kg)
INSTALLATION
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A-3
SAFETY PRECAUTIONS
A-3
The LN-25™ PRO is rated IP23 and is suitable for
outdoor use.
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box
before attempting to connect or
disconnect input power lines, output cables or control cables.
• Only qualified personnel should
perform this installation.
• Do not touch metal portions of the LN-25™ PRO
work clip when the welding power source is on.
• Do not attach the work clip to the wire feeder.
• Connect the work clip directly to the work, as
close as possible to the welding arc.
• Turn power off at the welding power source
before disconnecting the work clip from the
work.
• Only use on power sources with open circuit
voltages less than 110 VDC.
------------------------------------------------------------------------
LOCATION
For best wire feeding performance, place the LN25™ PRO on a stable and dry surface. Keep the
wire feeder in a vertical position. Do not operate the
wire feeder on an angled surface of more than 15
degrees.
The handle of the LN-25™ PRO is intended for
moving the wire feeder about the work place only.
When suspending a wire feeder, insulate the
hanging device from the wire feeder enclosure.
HIGH FREQUENCY PROTECTION
CAUTION
Locate the LN-25™ PRO away from radio controlled
machinery. The normal operation of the LN-25™
PRO may adversely affect the operation of RF controlled equipment, which may result in bodily injury
or damage to the equipment.
--------------------------------------------------------------------------
WELD CABLE SIzE
Table A.1 Located below are copper cable sizes recommended for various 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 voltage drop in the cables.
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Do not submerge the LN-25™ PRO.
TABLE A.1
RECOMMENDED CABLE SIzES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES PERCENT
0 to 50Ft.
50 to 100Ft.
100 to 150 Ft.
150 to 200 Ft.
200 to 250 Ft.
DUTY
(0 to15m)
(15 to 30m)
(30 to 46m)
(46 to 61m)
(61 to 76m)
CYCLE
200
200
225
225
250
250
250
250
300
325
350
400
400
500
60
100
20
40 & 30
30
40
60
100
60
100
60
60
100
60
2
2
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
2
2
3
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
2
2
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
1
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).
LN-25™ PRO
INSTALLATION
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A-4
CABLE CONNECTIONS
There is one circular connector for the gun trigger on
the front of the LN-25™ PRO.
Table A.2
Function
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5-pin trigger
connector for
push-guns
only.
Pin
Wiring
A
B
C
D
E
Trigger
Not used
Common
Not used
Not used
C
E
5. Attach one end of the inlet hose to the outlet fitting of
the flow regulator. Attach the other end to the welding
system shielding gas inlet. Tighten the union nuts with
a wrench.
6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.
A
7. Standing to one side, open the cylinder valve slowly a
fraction of a turn. When the cylinder pressure gage
stops moving, open the valve fully.
SHIELDING GAS CONNECTION
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WARNING
8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making a weld.
CYLINDER may explode if
damaged.
WIRE DRIVE CONFIGURATION
• Keep cylinder upright and
chained to support.
(See Figure A.1)
• 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 circuits.
• BUILD UP OF SHIELDING GAS MAY
HARM HEALTH OR KILL.
• Shut off shielding gas supply when not in
use.
• See American National Standard z-49.1, "Safety
in Welding and Cutting” Published by the
American Welding Society.
-----------------------------------------------------------------------Maximum inlet pressure is 100 psi. (6.9 bar.)
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
2. Remove the cylinder cap. Inspect the cylinder valves
and regulator for damaged threads, dirt, dust, oil or
grease. Remove dust and dirt with a clean cloth. DO
NOT ATTACH THE REGULATOR IF OIL, GREASE
OR DAMAGE IS PRESENT! Inform your gas supplier
of this condition. Oil or grease in the presence of high
pressure oxygen is explosive
.
3. Stand to one side away from the outlet and open the
cylinder valve for an instant. This blows away any dust
or dirt which may have accumulated in the valve outlet.
4. Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. Note: if
connecting to 100% CO2 cylinder, insert regulator
adapter between regulator and cylinder valve. If
adapter is equipped with a plastic washer, be sure it is
seated for connection to the CO2 cylinder.
B
D
A-4
CHANGING
BUSHING
THE
GUN
RECEIVER
WARNING
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 trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform maintenance work.
------------------------------------------------------------------------
LN-25™ PRO
INSTALLATION
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A-5
PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES
Tools required:
• 1/4" hex key wrench.
WARNING
1. Turn power off at the welding power source.
2. Remove the welding wire from the wire drive.
3. Remove the thumb screw from the wire drive.
4. Remove the welding gun from the wire drive.
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5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.
IMPORTANT:
Do not attempt to completely remove the socket
head cap screw.
6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the precision fit, light tapping may be required to remove
the gun bushing.
7. Disconnect the shielding gas hose from the gun
bushing, if required.
8. Connect the shielding gas hose to the new gun
bushing, if required.
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9. Rotate the gun bushing until the thumb screw hole
aligns with the thumb screw hole in the feed plate.
Slide the gun receiver bushing into the wire drive
and verify the thumb screw holes are aligned.
• 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 trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform maintenance work.
-----------------------------------------------------------------------1. Turn power off at the welding power source.
2. Release the idle roll pressure arm.
3. Remove the outer wire guide by turning the knurled
thumbscrews counter-clockwise to unscrew them
from the feed plate. See Figure A.2.
4. Rotate the triangular lock and remove the drive rolls.
5. Remove the inner wire guide
6. Insert the new inner wire guide, groove side out,
over the two locating pins in the feed plate.
7. Install a drive roll on each hub assembly secure with
the triangular lock.
10. Tighten the socket head cap screw.
11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
NOTE: Some gun bushings do not require the use of
the thumb screw.
8. Install the outer wire guide by aligning it with the pins
and tightening the knurled thumbscrews.
9. Close the idle arm and engage the idle roll pressure
arm. Adjust the pressure appropriately.
FIGURE A.1
THUMB SCREW
FIGURE A.2
GUN RECEIVER BUSHING
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OUTER WIRE GUIDE
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A-5
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN
TIGHTEN
LN-25™ PRO
INSTALLATION
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A-6
1. Squeeze the release bar on the retaining collar and
remove it from the spindle.
PRESSURE ARM ADJUSTMENT
WARNING
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 trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform maintenance work.
-----------------------------------------------------------------------The pressure arm controls the amount of force the
drive rolls exert on the wire. Proper adjustment of the
pressure arm gives the best welding performance.
Set the pressure arm as follows:
(See Figure A.3)
Aluminum wires
between 1 and 3
Cored wires
between 3 and 4
Steel, Stainless wires between 4 and 6
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FIGURE A.3
6
Al
Fe, CrNi
Fe, CrNi
ALUMINUM WIRES
CORED WIRES
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2. Place the spindle adapter on the spindle, aligning
the spindle brake pin with the hole in the adapter.
3. Place the spool on the spindle and align the adapter
brake tab with one of the holes in the back side of
the spool. An indicator mark on the end of the spindle shows the orientation of the brake tab. Be certain the wire feeds off of the spool in the proper
direction.
4. Re-install the retaining collar. Make sure that the
release bar snaps out and that the retaining collar
fully engages the groove on the spindle.
GUN CONNECTION
WARNING
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 trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform maintenance work.
-----------------------------------------------------------------------The LN-25™ PRO comes with a K1500-2 gun adapter
installed. (See Figure A.4)
STEEL, STAINLESS WIRES
LOADING SPOOLS OF WIRE
WARNING
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A-6
• Keep hands, hair, clothing and tools
away from rotating equipment.
• Do not wear gloves when threading
wire or changing wire spool.
• Only qualified personnel should install,
use or service this equipment.
-----------------------------------------------------------------------Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.
To install a gun,
1. Turn power OFF.
2. Remove the thumb screw.
3. Push the gun the completely into the gun bushing.
4. Secure the gun in place with the thumb screw.
5. Connect the trigger cable from the gun to the trigger
connector on the front of the feeder.
Note: Not all gun bushings require the use of the
thumb screw.
FIGURE A.4
A K468 spindle adapter is required for loading 2"
(51mm) wide spools on 2" (51mm) spindles. Use a
K468 spindle adapter for loading 2-1/2" (64mm) wide
spools.
LN-25™ PRO
THUMB
SCREW
GUN
INSTALLATION
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A-7
A-7
POWER SOURCE TO LN-25™ PRO
CABLE CONNECTION DIAGRAMS
ACROSS THE ARC SET-UPS
CC Power Sources with Output Terminals Always
Hot (See Figure A.5)
CC Power Source
Ranger 250, 250 LPG
Ranger 305G, 305D
FIGURE A.5
Commander 300
Vantage 300, 400, 500
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Air Vantage 500
Ranger 10,000
LN-25 PRO
Electrode
(Across the Arc)
Ranger 3 phase
SAE 400 with CV adapter
Work clip
Engine Driven welder with
Wire Feed Module
Work
If the power source has a Remote/Local switch, place
the switch in the Local position.
Place the Power Source CC/CV switch (if present) or
Range Switch in the CV position if possible.
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Set the CV/CC switch in the feeder to match the power
source.
K#
Description
K2613-1
K2613-2
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum Literature
LN-25™ PRO Wire Feeder
LN-25™ PRO Extra Torque
K1803-1
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Welding Gun
CC power Source
Welding Cables
CV Power Sources with Stud Connectors and
Remote/Local Switch (See Figure A.6)
CV-655
CV-400
DC-400
DC-600
DC-655
V450-Pro
FIGURE A.6
LN-25 PRO
Electrode
(Across the Arc)
Work clip
Work
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Drive Roll Kit
Place the power source Remote/Local switch in the
Local position.
Place CV/CC switch in the feeder in the "CV" position.
K#
Description
K2613-1
K2613-2
KP1695-XX
KP1696-XX
KP1697-XX
See magnum Literature
LN-25™ PRO Wire Feeder
LN-25™ PRO Extra Torque
K1803-1
LN-25™ PRO
Drive Roll Kit
Welding Gun
CV power Source
Welding Cables
INSTALLATION
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A-8
A-8
CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.7)
FIGURE A.7
LN-25 PRO
Electrode
V350-Pro
(Across the Arc)
Wor k clip
Work
K#
Description
K2613-1
K2613-2
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum Literature
LN-25™ PRO Wire Feeder
LN-25™ PRO Extra Torque
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K1841
Jumper
Welding Gun
CC power Source
Welding Cables
FIGURE A.8
CV-250
CV-300
CV-305
LN-25 PRO
Electrode
(Across the Arc)
Wor k clip
Work
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Place CV/CC switch in the feeder in the "CV" position.
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Drive Roll Kit
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.8)
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Place CV/CC switch in the feeder in the "CV" position.
K#
Description
K2613-1
K2613-2
KP1695-XX
KP1696-XX
KP1697-XX
See Magnum Literature
LN-25™ PRO Wire Feeder
LN-25™ PRO Extra Torque
K1841K484
LN-25™ PRO
Drive Roll Kit
Welding Gun
CV power Source
Welding Cables
Jumper Plug kit
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B-1
TABLE OF CONTENTS - OPERATION SECTION
B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions and Graphic Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4 / B-8
CV Wire Feed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
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CC Wire Feed Speed Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
CV Wire Feed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Constant Current vs Constant Voltage Wire Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Internal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Description of Internal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10 / B-11
Rear Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-12
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Gas Purge/Flow Meter/Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13
LN-25™ PRO
OPERATION
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SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
B-2
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
INPUT POWER
WARNING
• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive
mechanism are always electrically energized and could
remain energized several seconds after the welding ceases..
• Do not touch electrically live part or electrode
with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards
removed or open.
--------------------------------------------------------------------• FUMES AND GASSES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
--------------------------------------------------------------------• WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
---------------------------------------------------------------------ARC RAYS can burn.
• Wear eye, ear and body protection.
--------------------------------------------------------------------SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MANUAL.
----------------------------------------------------------------------
ON
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
INPUT POWER
DIRECT CURRENT
U0
OPEN CIRCUIT
VOLTAGE
U1
INPUT VOLTAGE
U2
OUTPUT VOLTAGE
I1
INPUT CURRENT
I2
OUTPUT CURRENT
PROTECTIVE
GROUND
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B-2
WARNING OR
CAUTION
LN-25™ PRO
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B-3
OPERATION
General Functional Description
DEFINITION OF WELDING TERMS
The LN-25™ PRO as designed is a simple, robust
feeder. Standard features include a calibrated wire
feed speed dial, 2 step/trigger interlock switch, CV-CC
switch, Gas Purge and Cold Feed. Some newer codes
also have a Wire Speed range switch for more precise
setting at lower speeds.
WFS
• Wire Feed Speed
CC
• Constant Current
CV
• Constant Voltage
RECOMMENDED PROCESSES
• GMAW
• FCAW
GMAW
• Gas Metal Arc welding
PROCESS LIMITATIONS
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SMAW
• Shielded Metal Arc welding
Return to Section TOC
B-3
• GMAW-P procedures must be qualified by the customer.
• Across-the-Arc models are not recommended for
stitch or spot welding.
FCAW
• Flux Core Arc Welding
GENERAL DESCRIPTION
EQUIPMENT LIMITATIONS
General Physical Description
The LN-25™ PRO is specially engineered to be the
most rugged portable wire feeder available. The models covered by this manual are designed for “across
the arc” operation only.
Several models of the LN-25™ PRO are offered to
best meet individual welder needs. The Extra Torque
model features additional torque gearing for reliable
feeding of large diameter FCAW wires. The Standard
model features wire drive gearing for optimal performance for both FCAW and GMAW wires of common
sizes. All of the models include a gas solenoid and
flow meter for the flexibility to run most wire processes.
The plastic case is molded from a high impact, flame
retardant plastic for durability and low weight. The
patent pending design keeps the internal components
protected and dry.
The heart of the LN-25™ PRO is the 2 roll MAXTRAC™ drive. The patented features on the wire drive
offer tool-less changing of the drive rolls and wire
guides for quick spool changes. A tachometer controlled motor powers the patent pending drive rolls for
smooth, steady feeding without slippage.
• The duty cycle of the wire feeder is 325A, 100% and
450A, 60%. Duty cycle is based upon the amount of
welding performed in a 10 minute period.
• The maximum spool size is 45 lb, 12" diameter.
• Maximum FCAW gun length is 15 ft.
• Maximum GMAW gun length is 25 ft.
• Push-pull guns do not work with the wire feeder.
• K2330-1 Timer kits do not work with this feeder, use
K2330-2 kits
RECOMMENDED POWER SOURCES
•
•
•
•
•
•
•
•
•
•
CV-305
CV-400
CV-655
DC-400
DC-600
DC-655
Invertec V-350 PRO
Invertec V-450 PRO
Multi-Weld 350
Ranger 10,000
With only one p.c. board, the LN-25™ PRO is
designed to be simple, reliable and easy to service.
The p.c. board is mounted with Lincoln’s leading environmental design protection that consists of mounting
the board in a plastic tray and potting it with epoxy.
With a 325 amp 100% duty cycle rating, these feeders
are ready for heavy duty welding.
LN-25™ PRO
•
•
•
•
•
•
•
•
•
•
Ranger 3 Phase
Ranger GXT
Ranger 250
Ranger 305
SAE-400
Pipeliner 200G
Classic 300
Vantage 300
Vantage 400
Vantage 500
OPERATION
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B-4
B-4
FIGURE B.1
5
5
1
1
6
6
2
2
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7
3
3
4
4
K2613-1 & K2613-2
K2613-5 & K2613-7
CASE FRONT CONTROLS (See Figure B.1)
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ITEM
1.
2.
3.
4.
5
6.
7.
Models with analog voltmeters have a calibrated
scale printed around the wire feed speed knob using
"in/min" units. A separate decal with "m/min" units is
included with these models wire feeder. Units with a
range switch have two calibrated scales.
DESCRIPTION
Analog Voltmeter
Wire Feed Speed Control
5-Pin Gun Trigger Receptacle
Work Sense Lead Connector
Thermal LED (Motor Overload)
Polarity LED
Wire Feed Speed Range Switch
Wire Feed Speed, CV Operation
1. ANALOG VOLTMETER
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The analog voltmeter shows the voltage between
electrode and work. The voltmeter shows open circuit voltage when the wire feeder is not welding. As
a result, it is not unusual to see the needle “pegged”
when not welding. The voltmeter is polarity insensitive and the range is 0 - 40VDC.
When Across the Arc models are operated with CV
power sources, the wire feed speed will remain a constant value, independent of arc voltage changes, as
long as the arc voltage does not drop below the minimum values per the following table.
TABLE B.1 - CV OPERATION
Minimum
Arc Voltage
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.
LN-25™ PRO
Maximum WFS Maximum WFS
(Standard)
(Extra Torque)
15 V
280”/min.
210”/min.
17V
340”/min.
235”/min.
21V
440”/min.
400”/min.
24V
520”/min.
400”/min.
27V
600”/min
400”/min.
OPERATION
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B-5
B-5
Wire Feed Speed, CC Operation (See Figure B.2 or
See Table B.2)
When Across the Arc models are operated with CC
power sources, the wire feed speed changes as the arc
voltage changes. When the arc voltage increases, the
wire feed speed will increase; and when the arc voltage
decreases, the wire feed speed will decrease.
4. Determine the vertical line representing the CC
representing the CC Wire Feed Speed setting
where the above two lines cross. (See Figure B.2
arrow line for 450.) Set the LN-25™ PRO wire feed
speed knob to this value.
To preset the wire feed speed on CC power sources:
CC WFS dial setting = desired WFS x 35
Arc Volts
1. Set the Wire Feed Mode switch inside the LN-25™
PRO to "CC".
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Example:
2. Refer to the Figure B.2 graph for the setting for the
wire feed speed knob setting. Select the horizontal line representing the Desired Wire Feed Speed.
(See Figure B.2 arrow for 375 in/min.)
3. Select the diagonal line representing the Arc Volts.
(See Figure B.2 for 29 volts.)
375 in/min. (Horizontal Line) x 35
29 Arc Volts (Diagonal Line)
=
13125 = 452-5 (Vertical Line)
29
Set the Wire Speed Control at 450”/min.,
and when welding at 29 volts the average
actual speed should be approximately
375“/min.
FIGURE B.2
35
700
33
650
31
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600
29
550
27
500
25
23
450
21
400
19
17
350
15
300
250
200
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150
100
50
50
100
150 200 250 300 350 400 450 500 550 600 650 700
CC
LN-25™ PRO
V
OPERATION
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B-6
B-6
TABLE B.2 - VV (CC) WIRE SPEED SETTING
Desired
In/Min
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
380
400
420
440
460
480
500
520
540
560
580
600
620
640
660
680
700
16
109
131
153
175
197
219
241
263
284
306
328
350
372
394
416
438
459
481
503
525
547
569
591
613
634
656
678
700
18
97
117
136
156
175
194
214
233
253
272
292
311
331
350
369
389
408
428
447
457
486
506
525
544
564
583
603
622
642
661
681
700
20
88
105
123
140
158
175
193
210
228
245
263
280
298
315
333
350
368
385
403
420
438
455
473
490
508
525
543
560
578
595
613
630
666
700
Arc Volts Used
22
24
26
28
80
73
67
63
95
88
81
75
111 102 94
88
127 117 108 100
143 131 121 113
159 146 135 125
175 160 148 138
191 175 162 150
207 190 175 163
223 204 188 175
239 219 202 188
255 233 215 200
270 248 229 213
286 263 242 225
302 277 256 238
318 292 269 250
334 306 283 263
350 321 296 275
366 335 310 288
382 350 323 300
398 365 337 313
414 379 350 325
430 394 365 338
445 408 377 350
461 423 390 363
477 438 404 375
493 452 417 388
509 467 431 400
525 481 444 413
541 496 458 425
557 510 471 438
572 526 484 450
604 554 512 472
636 584 538 500
668 612 566 526
700 642 592 550
670 620 576
700 646 600
674 626
700
LN-25™ PRO
650
676
700
30
58
70
82
93
105
117
128
140
152
163
175
187
198
210
222
233
245
257
268
280
292
303
315
327
338
350
362
373
385
397
408
420
444
466
490
514
536
560
584
32
55
66
77
88
98
109
120
131
142
153
164
175
186
197
208
219
230
241
252
263
273
284
295
306
317
328
339
350
361
372
383
394
416
438
460
482
504
526
546
34
51
62
72
82
93
103
113
124
134
144
154
165
175
185
196
206
216
226
237
247
257
268
278
288
299
309
319
329
340
350
360
370
392
412
432
452
472
494
514
606
630
654
676
700
568
590
612
634
656
678
700
536
556
576
598
618
638
658
680
700
OPERATION
B-7
B-7
CONSTANT CURRENT VS CONSTANT
VOLTAGE WIRE WELDING
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 typically specify limitations on the current, voltage, heat input and
preheat temperature based on the material to be welded. The intention is to assure that proper weld material properties will develop.
Welding is sometimes performed using constant current power sources. The operation can be more convenient because it may allow the use of an existing
stick (SMAW) power source and the power source can
be placed at a distant location without any provision for
adjusting the output settings.
For constant current operation, the power source is set
to deliver the specified current. The power source regulates this current regardless of changes in the welding circuit, including cable length, electrode diameter,
wire feed speed, contact tip to work distance, etc.
Changes in the wire feed speed (WFS) or contact tip to
work distance (CTWD) affect the arc voltage when
constant current power sources are used. Lowering
the wire feed speed raises the voltage, raising the wire
feed speed lowers the voltage. Lengthening the contact tip to work distance raises the voltage, shortening
the contact tip to work distance lowers the voltage.
(See Figure B.3)
If the contact tip to work distance is properly maintained, a satisfactory operating voltage range may be
achieved, and a sound weld may result. However,
when a welder uses a longer contact tip to work distance, an arc-sensing wire feeder compensates by
increasing the wire feed speed to regulate the voltage.
Even if the voltage and current remain unchanged, the
increased wire feed speed may result in a deposition
rate well beyond the specified range of the electrode.
Under these conditions, the specified weld metal properties may not be achieved.
Constant voltage power sources deliver large current
surges to stabilize the arc when the electrode is shorted or the arc length is very short. However, a constant
current power source does not provide such a
response to stabilize the arc. It may be difficult to
achieve required weld metal properties, or to achieve
the required quality of welds needed to pass nondestructive tests, when such welds are made under constant current operation.
For these reasons, Lincoln Electric does NOT recommend constant current semiautomatic welding for
applications which need to meet specified weld metal
chemical or mechanical property requirements or weld
quality requirements.
FIGURE B-3
Current
+
Wire
Feeder
CTWD
WFS
Constant Current
Power Source
-
Current
LN-25™ PRO
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B-8
OPERATION
3. 5-PIN GUN TRIGGER CONNECTOR
(See Figure B.1)
4. WORK SENSE LEAD
(See Figure B.1)
Must be connected for the drive motor to operate.
5. THERMAL LED, MOTOR OVERLOAD
(See Figure B.1)
The thermal light illuminates (yellow)
when the wire drive motor draws too
M
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 (and conduit). Clean and make repairs as necessary. Start welding again when the problem has
been safely resolved.
For best results, keep the gun cable and conduit as
straight as possible. Perform regular maintenance
and cleaning on the gun liner, conduit and gun.
Always use quality electrode, such as L-50 or L-56
from Lincoln Electric.
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6. POLARITY LED
(See Figure B.1)
The Polarity LED
lights (green) when
the wire feeder is
connected for positive polarity. and is
not lit in Negative
Polarity. Use the polarity LED to verify the wire
feeder is connected properly for the process being
used.
NOTE: Both LED’s will flash briefly when power is
applied to the feeder.
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7. WIRE FEED SPEED RANGE SWITCH (K2613-5
and K2613-7 only.)
Used to select either HIGH or LOW range for the
Wire Feed Speed Control. LOW range allows for
more precise setting at lower feed rates. On the
Standard Torque models, selecting the LOW range
DOES NOT increase the torque of the wire drive
system.
LN-25™ PRO
B-8
OPERATION
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B-9
B-9
INTERNAL CONTROLS
FIGURE B.4
5
4
3
2
1
8
7
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9
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
10
11
12
DESCRIPTION
2 Step Trigger Interlock Switch
CV / CC Switch
Pressure Adjustment Arm
Optional Timer Kit (See Accessories Section)
Spool Retainer
Spindle Brake
Gun Bushing
Thumb Screw for securing the welding Gun
Socket Head Cap Screw for securing the Gun Bushing
Drive Hubs
Inlet Wire Guide
Cold Feed Pushbutton
LN-25™ PRO
6
OPERATION
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B-10
INTERNAL CONTROLS DESCRIPTION
(See Figure B.4)
CV/CC SWITCH
(See Figure B.4)
2 STEP - TRIGGER INTERLOCK
SWITCH
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.
The 2 Step - Trigger Interlock
switch changes the function of the
gun trigger. 2 Step trigger operation turns welding on and off in
direct response to the trigger.
Trigger Interlock operation allows
welding to continue when the trigger is released for comfort on long
welds.
In the CC position, the wire feed
speed varies during welding. The
arc length is maintained by changing the wire feed speed.
Place the toggle switch in the DOWN position for 2
Step operation or in the UP position for Trigger
Interlock operation.
2 Step Trigger
2 Step trigger operation is the most common. When
the gun trigger is pulled, the welding power source
energizes the electrode output and the wire feeder
feeds wire for welding. The power source and wire
feeder continue welding until the trigger is released.
COLD FEED PUSHBUTTON
(See Figure B.4)
When cold feeding, the wire drive
will feed electrode but neither the
power source nor the gas solenoid
will be energized. Adjust the speed
of cold feeding by rotating the WFS
knob. Cold feeding, or “cold inching”
the electrode is useful for threading
the electrode through the gun.
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Trigger Interlock
Trigger Interlock operation provides for operator comfort when making long welds. When the gun trigger is
first pulled, the welding power source energizes the
output and the wire feeder feeds wire for welding. The
gun trigger is then released while the weld is made. To
stop welding, the gun trigger is pulled again, and when
it is released the welding power source output turns off
and the wire feeder stops feeding wire.
CAUTION
If the arc goes out while welding with
trigger interlock operation, the electrode output from the welding power
source remains energized and the wire
feeder will continue to feed wire until
the gun trigger is again pulled and
then released.
------------------------------------------------------------------------
LN-25™ PRO
B-10
CC
CV
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B-11
OPERATION
OPTIONAL PREFLOW, BURNBACK AND
POSTFLOW TIMER KIT (K2330-2)
The preflow, Burnback and Postflow Timer Kit gives
you control over the shielding gas at the beginning and
end of the weld and prepares the end of the wire for
the next arc start. Additional shielding gas protection
is often required when welding aluminum, stainless
steel or exotic alloys.
NOTE: When stitch welding, set the postflow time to
maximum for best results.
Preflow Timer
The preflow timer range is OFF to 10 seconds.
Preflow time is the time delay from when the trigger is
pulled to when the wire starts to feed and is energized.
Preflow is used purge the welding gun with shielding
gads and helps to maximize porosity at the start of the
weld.
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Burnback Timer
The Burnback timer range is OFF to 0.25 seconds.
The burnback timer controls the additional amount of
time the power source output remains ON after the
wire drive has stopped feeding wire. Burnback adjustment prevents the wire from sticking to the weld at the
end of a weld and helps to condition the wire for the
next weld.
To set the burnback time, adjust the knob to approximately 0.03 seconds and then decrease or increase
the time as desired.
Postflow Timer
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The postflow timer range is OFF to 10 seconds.
Postflow is the time from when the power source output turns OFF until the postflow timer expires. Use
postflow to protect the weld while the weld cools.
LN-25™ PRO
B-11
OPERATION
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B-12
B-12
REAR CONTROLS:
FIGURE B.5
1
3
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2
4
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5
6
ITEM
1
2
3
4
5
6
DESCRIPTION
Gas Purge Pushbutton
Flow Meter Ball
Flow Meter Valve
Shielding Gas Inlet
Electrode Lead
Optional Water cooled gun
connections
LN-25™ PRO
OPERATION
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B-13
GAS PURGE PUSHBUTTON
POWER-UP SEQUENCE
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 and for purging the
lines.. Flow meters should always be adjusted while
the shielding gas is flowing.
For feeders with analog voltmeters, the thermal LED
and the Polarity LED will light breifly during power-up.
If the gun trigger is activated during power up, the feeder will not operate unless the gun trigger is released
and re-activated.
FLOW METER
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The flowmeter shows the flow rate of shielding gas and
has a valve to adjust the flow. The flow meter is scaled
for CO2, Ar, and Ar/CO2 blends. The middle of the ball
indicates the flow rate of shielding gas.
Adjust the flow rate while depressing the GAS PURGE
switch by turning the valve at the bottom of the meter.
Most weld procedures require 25-40 scfh (11.8 - 18.9
lpm) for sufficient shielding gas coverage. Gun angle,
nozzle diameter, joint configuration and wind conditions may effect the amount of shielding gas required.
When using a wire feeder with
a flow meter, adjust the regulator at the shield gas bottle or
supply to a flow rate that is
higher than the flow rate indicated on the feeder flow meter.
Note that most regulators are
calibrated based upon having
low restrictions on the outlet.
The valve on the feeder flow
meter creates a high restriction and may cause errors in
the readings at the supply regulator. Set the gas flow rate
using the feeder flow meter
reading and not the supply
regulator reading.
SCFH
10
20
30
40
50
60
70
80
B-13
Liter/Min.
4.7
9.4
14.2
18.9
23.6
28.3
33.1
37.8
LN-25™ PRO
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B-14
NOTES
LN-25™ PRO
B-14
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C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Factory Installed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3/C-5
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Installation of the K590-6 Water Cooling Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
LN-25™ PRO
ACCESSORIES
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C-2
FACTORY INSTALLED EQUIPMENT
• K1500-2 Gun Receiver Bushing.
DRIVE ROLL KITS
WIRE TYPE
Steel Wires:
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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" (2.0mm)
3/32” (2.4mm)
.035" (0.9 mm)
.040" (1.0mm)
3/64" (1.2mm)
1/16" (1.6mm)
KP KIT
KP1696-030S
KP1696-035S
KP1696-045S
KP1696-052S
KP1696-1/16S
KP1696-1
KP1696-2
KP1697-035C
KP1697-045C
KP1697-052C
KP1697-1/16C
KP1697-068
KP1697-5/64
KP1697-3/32
KP1695-035A
KP1695-040A
KP1695-3/64A
KP1695-1/16A
LN-25™ PRO
Includes: 2 V groove
drive rolls and inner
wire guide.
Includes: 2 Knurled
drive rolls and inner
wire guide.
Includes: 2 polished
U groove drive rolls,
outer wire guide and
inner wire guide.
C-2
ACCESSORIES
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C-3
K2596-1
Aluminum Case
K2596-2
Plastic Case
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K1796-xx
K2593-xx
K1803-1
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K1842-xx
Includes: a complete engineered plastic case. Decals
and latches are all preassembled.
AWG 1/0 Co-Axial Power Cable
Includes: 1/0 Coaxial weld
cable of length "xx". Ends of
the weld cable have lug connections. Use for Pulse welding.
AWG #1 Coaxial Power Cable
Includes: AWG #1 Coaxial
weld cable of length "xx".
Ends of the weld cable have
lug connections. Use for
Pulse or STT™ welding.
Includes: Twist-Mate to Lug
2/0 cable 14' (1.2m) long with
Work and Feeder Cables Package Ground Clamp, and TwistMate to Lug 2/0 Cable 9'
(2.7m) long.
Weld Power Cable, Twist-Mate to
Lug
Weld Power Cable, Lug to Lug
Includes: Twist-Mate to Lug,
1/0 cable of length "xx".
Includes: Lug to Lug, 3/0
Cable of length "xx" for
lengths up to 60' (18.3m).
Lug to Lug, 4/0 Cable of
length "xx" for lengths greater
than 60' (18.3m).
K484
Jumper Plug Kit
Includes: 14 pin circular connector with jumper for leads 24. For use in power sources
for turning the weld terminals
"ON" at all times.
K2330-2
Timer Kit
Includes Panel and harness.
Provides adjustable Preflow,
post flow and Burnback.
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K1840-xx
Includes: a complete aluminum case. Decals, skids,
insulation and latches are all
preassembled.
LN-25™ PRO
C-3
ACCESSORIES
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C-4
K910-1
Ground Clamp
Includes: One 300 Amp
Ground Clamp.
K910-2
Ground Clamp
Includes: One 500 Amp
Ground Clamp.
K1500-1
Gun Receiver Bushing (for guns
with K466-1 Lincoln gun connectors; Innershield and Subarc guns)
Includes: Gun receiver bushing, set screw and hex key
wrench.
K1500-2
Gun Receiver Bushing (for guns
with K466-2, K466-10 Lincoln gun
connectors; Magnum 200/300/400
guns and compatible with Tweco®
#2-#4)
Includes: Gun receiver bushing with hose nipple, set
screw and hex key wrench.
K1500-3
Gun Receiver Bushing (for guns
with K613-7 Lincoln gun connectors; Magnum 550 guns and compatible with Tweco® #5)
Includes: Gun receiver bushing with hose nipple, set
screw and hex key wrench.
LN-25™ PRO
C-4
ACCESSORIES
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K1500-4
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C-5
Includes: Gun receiver bushing with hose nipple, set
screw and hex key wrench.
K1500-5
Gun Receiver Bushing (compatible Includes: Gun receiver bushing
with hose nipple, 4 guide tubes,
with Oxo® guns.)
set screw and hex key wrench.
K489-7 *
Gun Receiver Bushing (for Lincoln
Fast-Mate guns.)
Includes: Gun receiver bushing
with trigger connector.
K435
Spindle Adapter, for mounting 14
lb. (6.4 kg) Innershield Coils on 2
in (51 mm) spindles.
Includes: Spindle Adapter made
from 2 coil retainers. (Electrode
not included.)
K468
Spindle Adapter, for mounting 8in
(203mm) diameter spools on 2 in
(51 mm) spindles.
Includes: 2 Spindle Adapters,
one for 2" wide spools and the
other for 3" wide spools.
K590-6
Water Connection Kit (for
European and Control cable models only)
Includes: 2 hoses with female
quick connectors at each end, 2
male connectors for 3/16" ID
hose, 2 male connectors for _" ID
hose, and mounting hardware.
K586-1
Deluxe Adjustable Gas Regulator
Includes: Deluxe Gas Regulator
for Mixed Gases, Adapter for
CO2 and 10' (3.0m) Hose.
Not compatible with K2613-5 & K2613-7 feeders (Codes 11746, & 11747)
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*
Gun Receiver Bushing (for gun
with K466-3 Lincoln gun connectors; compatible with Miller®
guns.)
LN-25™ PRO
C-5
ACCESSORIES
Tools required:
• 3/8" wrench
• 5/16" nut driver
• medium flat bladed screw driver
• cutting tool
5. Install the fitting and hose assembly to the case
front. Route the hoses along the bottom of the inner
module and out through the cutout of the cover.
Slide the module back into the case.
1. Turn power off at the welding power source.
2. Remove the screws securing the case to the inner
module using a 3/8" wrench.
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20
01
20
01
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3. Remove the module from the case by lifting the front
of the module approximately .25" (6 mm) and then
sliding forward.
he
re
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6. Secure the module to the case with the screws.
(Shown in Step 2)
7. Install the fitting assembly to the rear of the case
wa
s
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ELECTRIC SHOCK can kill.
• Turn the input power OFF at the disconnect switch before working on
this equipment.
• Do not touch electrically hot parts.
• Only qualified personnel should
install, use or service this equipment.
-----------------------------------------------------------------------The K590-6 components are rated up to 70 psi (5 bar)
and 158°F (70°C). Use a coolant fluid that is compatible with the water cooler and the gun.
jo
e
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WARNING
he
re
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4. Use a 5/16" nut driver to remove the screws holding
the water cooling cover on the case front of the inner
module and on the rear of the case.
wa
s
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INSTALLATION OF THE K590-6 WATER
COOLING KIT
C-6
jo
e
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C-6
ALUMINUM CASE
PLASTIC CASE
8. Slide the hose clamps on to the hoses. Trim the
hoses to length so that they lay flat on the case bottom. Slide hose clamps on the hose. Slide the hoses
on to the fittings on the case rear and secure with
the hose clamps.
LN-25™ PRO
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D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Calibration Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Wire Feed Speed Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
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Flow Meter Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
LN-25™ PRO
MAINTENANCE
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D-2
SAFETY PRECAUTIONS
5. Energize the output circuit of the power source.
Adjust the power source output to 20±1 VDC as
measured on the reference meter.
WARNING
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.
----------------------------------------------------------------------
ROUTINE MAINTENANCE
• Check weld cables and gas hoses for cuts.
• Clean and tighten all weld terminals.
• Clean drive rolls and inner wire guide and replace if
worn.
• Blow out or vacuum the inside of the feeder.
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Voltmeter Validation, Across the Arc Analog Meter
Models
Flow Meter Validation
Tools required:
• Flow meter reference standard.
• Constant voltage DC welding power source (DC400, V-350, CV-400 or equivalent).
2. Connect the LN-25™ PRO to the constant voltage
DC welding power source. The work lead of the
LN-25™ PRO must be connected to the work terminal of the power source.
3. Connect a supply of CO2 to the wire feeder. Do not
exceed the maximum inlet pressure of the wire
feeder.
4. Disconnect the shielding gas hose that connects to
the gun bushing.
5. Connect the shielding gas hose to flow meter reference standard.
Tools required:
• DC voltmeter reference standard
• Constant voltage DC welding power source with
adjustable no-load voltage (DC-400, V-350, CV-400
or equivalent).
6. Orient the LN-25™ PRO in a vertical position.
7. Turn power ON.
8. Adjust the flow meter on the LN-25™ PRO to 40
scfh while pressing the GAS PURGE button.
To verify the analog voltmeter accuracy:
1. Turn power OFF.
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If the voltmeter reading is out of range, check for loose
connections or replace the voltmeter. There is no calibration adjustment for the LN-25™ PRO voltmeter.
1. Turn power OFF.
PERIODIC MAINTENANCE
The voltmeter and flow meter are not calibrated and
are for reference purposes only.
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6. Verify that LN-25™ PRO voltmeter reads between
19 and 21 volts.
To verify the flow meter accuracy:
CALIBRATION SPECIFICATION
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D-2
9. Measure the gas flow with the calibrated flow meter
while pressing the GAS PURGE button.
2. Connect the LN-25™ PRO to the constant voltage
DC welding power source. The work lead of the
LN-25™ PRO must be connected to the work terminal of the power source.
10. The measured flow rate should be between 35
and 45 scfh.
3. Connect the reference voltmeter between the brass
block of the LN-25™ PRO and the work lead.
The LN-25™ PRO flow meter cannot be calibrated. If
the flow meter reads incorrectly, check for leaks or
kinks in the gas hose. Replace the flow meter if necessary.
4. Turn power ON.
LN-25™ PRO
MAINTENANCE
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D-3
D-3
Wire Feed Speed Validation
To change the wire feed speed calibration:
(See Figure D.1)
Calibration of the LN-25™ PRO 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.
(See Figure D.2)
Tools required:
Tools required:
• RPM meter
• Constant voltage DC welding power source (DC-400,
V-350, CV-400 or equivalent)
• 7/16" open end wrench
• 5/16" nut driver
• RPM meter
• Shorting plug. LE CO.part # S18250-982 - The shorting plug shorts pins 4 & 8 of connector J3 on the Control
P.C. Board. J3 is an 8 pin Molex connector.
1. Turn power OFF.
2. Remove the 4 screws holding the rear cover inside the
feeder and remove the cover.
To verify if calibration is necessary:
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3. Open the idle arm.
1. Turn power OFF.
4. Set the wire feed speed per the table.
2. Set the wire feed speed per the table.
Model gearing Wire Feed Speed Acceptable Range
Normal Speed 400 in/min
69 - 77 rpm
Extra Torque
150 in/min
25 - 31 rpm
3. Remove the plastic cover from the lower portion of the
wire drive with a 7/16" wrench.
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4. Connect the LN-25™ PRO to the constant voltage DC
welding power source. The work lead of the LN-25™
PRO must be connected to the work terminal of the
power source.
Model gearing Wire Feed Speed
Normal Speed 400 in/min
Extra Torque
150 in/min
5. Connect the LN-25™ PRO to the constant voltage DC
welding power source. The work lead of the LN-25™
PRO must be connected to the work terminal of the
power source.
6. Turn power ON.
7. Insert the shorting plug into connector J3 on the Control
P.C. Board. The shorting plug shorts pins 4 & 8.
5. Turn power ON.
8. Remove the shorting plug.
6. Measure the motor rpm when the COLD FEED button
is pressed.
9. Turn power OFF.
7. Verify the rpm is within the acceptable range.
10. Replace the cover and secure with the screws.
FIGURE D.2
FIGURE D.1
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COVER
MOTOR
SHAFT
COVER
P.C. BOARD
LN-25™ PRO
MAINTENANCE
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D-4
D-4
FIGURE D.3. - MAJOR COMPONENT LOCATION
1.
2.
3.
4.
5.
FRONT PANEL ASSEMBLY
CONTROL BOX ASSEMBLY
SPINDLE & MAST ASSEMBLY
WIRE DRIVE ASSEMBLY
CASE ASSEMBLY
5
2
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3
1
4
LN-25™ PRO
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E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Trigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Feedback and Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
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Optional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Digital Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
FIGURE E.1 — BLOCK LOGIC DIAGRAM.
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ELECTRODE
INPUT
INPUT
67
CONTACTOR CURRENT TRANSDUCER
SOLENOID
POLARITY
VM
FEEDPLATE
TIMER OPTION
MOTOR
GUN
ARMATURE
CONTROL BOARD
21
1
TACH FEEDBACK
GUN TRIGGER
WIRE
SPEED
14 PIN AMPHENOL
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TACH
MOTOR
OVERLOAD
COLD
FEED
21
RUN IN
CC
CV
TRIGGER
INTERLOCK
DIGITAL
DISPLAY
BOARD
LN-25™ PRO
GAS
PURGE
REMOTE
VOLTAGE
THEORY OF OPERATION
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E-2
E-2
FIGURE E.2 — GENERAL DESCRIPTION
ELECTRODE
INPUT
INPUT
67
CONTACTOR CURRENT TRANSDUCER
SOLENOID
POLARITY
VM
FEEDPLATE
TIMER OPTION
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
CONTROL BOARD
21
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1
TACH FEEDBACK
GUN TRIGGER
WIRE
SPEED
14 PIN AMPHENOL
21
RUN IN
CC
CV
COLD
FEED
TRIGGER
INTERLOCK
REMOTE
VOLTAGE
GAS
PURGE
DIGITAL
DISPLAY
BOARD
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GENERAL DESCRIPTION
Several models of the LN-25™ PRO are offered to best
meet the individual welders needs. The Extra Torque
model features additional torque for reliable feeding of
large diameter FCAW wire. The standard and control
cable models feature wire drive gearing for optimal performance with both FCAW and GMAW wires of common sizes. All the models include a gas solenoid and
flow meter for the flexibility to run most wire processes.
Control Cable models also includes digital meters and
remote voltage control.
The plastic case is molded from high impact, flame
retardant plastic for durability and low weight. The
patent pending design keeps the internal components
protected and dry.
The heart of the LN-25™ PRO is a 2 roll MAXTRAC
wire drive system. The patented features on the wire
drive offer tool-less changing of the drive rolls and wire
guides for quick changeovers. A tachometer controlled
motor powers the patent pending drive rolls for smooth,
steady feeding without slippage.
With only one p.c. board, the LN-25™ PRO is designed
to be simple, reliable and easy to service. The p.c.
board is manufactured with Lincoln’s industry leading
environmental design protection which involces mounting the board in a plastic tray and potting it with epoxy.
With a 325 amp, 100% duty cycle rating, these feeders
are ready for heavy duty welding.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
LN-25™ PRO
THEORY OF OPERATION
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E-3
E-3
FIGURE E.3 — INPUT POWER & TRIGGER CIRCUIT
ELECTRODE
INPUT
INPUT
67
CONTACTOR CURRENT TRANSDUCER
SOLENOID
POLARITY
VM
FEEDPLATE
TIMER OPTION
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
CONTROL BOARD
21
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1
TACH FEEDBACK
GUN TRIGGER
WIRE
SPEED
14 PIN AMPHENOL
COLD
FEED
21
RUN IN
CC
CV
TRIGGER
INTERLOCK
REMOTE
VOLTAGE
GAS
PURGE
DIGITAL
DISPLAY
BOARD
INPUT POWER
TRIGGER CIRCUIT
The DC input voltage is applied from the power source
via the electrode cable and the work sensing lead on
the across the arc model. With the control cable model
24 to 42VDC is supplied from the power source via the
control cable and the work sense lead.
When the gun trigger is closed, the control board is signaled to apply armature voltage to the drive motor and
to activate any auxiliary circuits that may be incorporated within the LN-25PRO.
This voltage is applied through a bridge rectifier and an
analog voltmeter (across the arc), or digital meter (control cable) and then is supplied to the control board.
Trigger interlock is used for long welds. When an arc
is established the trigger can be released. To stop
welding, the gun trigger is pulled again, and when it is
released the second time, the welding power source
output turns off and the wire speed stops.
The control board the regulates and disperses the various supply voltages needed for machine operation.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
LN-25™ PRO
THEORY OF OPERATION
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E-4
E-4
FIGURE E.4 — FEEDBACK & CONTROL CIRCUITS
ELECTRODE
INPUT
INPUT
67
CONTACTOR CURRENT TRANSDUCER
SOLENOID
POLARITY
VM
FEEDPLATE
TIMER OPTION
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
CONTROL BOARD
21
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1
TACH FEEDBACK
GUN TRIGGER
WIRE
SPEED
14 PIN AMPHENOL
COLD
FEED
21
RUN IN
CC
CV
TRIGGER
INTERLOCK
REMOTE
VOLTAGE
GAS
PURGE
DIGITAL
DISPLAY
BOARD
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FEEDBACK AND CONTROL CIRCUITS
The wire speed pot provides command signal to the
control board indicating the desired wire speed. The
tachometer transforms the motor RPM to a digital frequency that is fed back to the control board.
When operating in constant voltage (CV) mode, the
control board monitors the feedback signal, compares
it to the command signal and delivers the appropriate
voltage to the wire drive motor.
When operating in constant current (CC) mode, a variable wire speed is desirable to compensate for the
varying arc voltages associated with the constant current process. To accomplish this, the control board
monitors the command voltage, the feedback signal
from the tach and the arc voltage.
These three factors are monitored and compared, then
the appropriate armature voltage is applied to the wire
drive motor.
When the Run-in Switch is on, the wire speed is
reduced until an arc is struck. When it is off the run-in
wire speed is the same as the welding wire feed speed.
Pressing the cold feed button activates the drive rolls
but neither the power source nor the gas solenoid will
be activated.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
LN-25™ PRO
THEORY OF OPERATION
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E-5
E-5
FIGURE E.5 — OPTIONAL CIRCUITS & DIGITAL DISPLAY BOARD
ELECTRODE
INPUT
INPUT
67
CONTACTOR CURRENT TRANSDUCER
SOLENOID
POLARITY
VM
FEEDPLATE
TIMER OPTION
MOTOR
TACH
GUN
MOTOR
OVERLOAD
ARMATURE
CONTROL BOARD
21
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1
TACH FEEDBACK
GUN TRIGGER
WIRE
SPEED
14 PIN AMPHENOL
21
RUN IN
CC
CV
COLD
FEED
TRIGGER
INTERLOCK
REMOTE
VOLTAGE
GAS
PURGE
DIGITAL
DISPLAY
BOARD
DIGITAL DISPLAY BOARD
(control cable models only)
OPTIONAL CIRCUITS
When the wire feeder is not welding, the left display
shows the wire feed speed. The default units are
“in/min” and may be changed to “m/min” through the
setup menu. During welding the left display shows the
average welding current, and will continue to hold the
last value for 5 seconds after the trigger is released.
The preflow, burnback, and postflow timer kit gives
control over the shielded gas at the beginning and end
of the weld and prepares the end of the wire for the
next arc start.
When the wire feeder is in idle the right display shows
the preset voltage. This voltage will change with different power sources and can be changed through the
setup menu. During welding, the right display shows
the average welding voltage, and will hold the last
value for 5 seconds after the trigger is released.
The preflow timer range is zero to 10 seconds. Preflow
is used to purge the welding gun with shielding gas and
helps to minimize porosity at the start of a weld.
The burnback timer range is zero to 0.25 seconds.
Burnback controls the additional amount of time the
power source output remains on after the wire drive
has stopped feeding wire.
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The postflow timer range is zero to 10 seconds. Use
postflow to protect the weld while it cools.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
LN-25™ PRO
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E-6
NOTES
LN-25™ PRO
E-6
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F-1
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
F-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
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Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Gas Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11
Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Drive Motor and Tach Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Motor Overload Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17
Contactor Removal and Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Front Panel Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Wire Drive Motor and Gear Box Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
PC Board Removal and Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
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Gas Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31
LN-25™ PRO
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F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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 all safety notes and precautions
detailed throughout this manual.
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This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, wire feeding problems, and welding
problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject component is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
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LN-25™ PRO
F-2
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F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK
can kill.
• Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
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CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
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F-3
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity.
- Remove your body’s static
charge before opening the staticshielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
to a grounded part of the
ATTENTION
Static-Sensitive equipment frame.
Devices
- If you don’t have a wrist strap,
Handle only at touch an un-painted, grounded,
Static-Safe
part of the equipment frame. Keep
Workstations
touching the frame to prevent
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
LN-25™ PRO
TROUBLESHOOTING & REPAIR
Return to Master TOC
Return to Section TOC
F-4
F-4
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Fault Code
Description
Possible Adjustment
1. The wire drive motor has overheated.
1. Remove any bends in the gun.
Thermal LED Lit
Motor overloaded, long term
(Err 81 on Digital Models)
2. Check to see if the wire moves
smoothly through the gun and
cable.
3. Check the tightness of the spindle brake.
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Return to Section TOC
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4. Wait for the motor to cool and
the error to reset.
Thermal LED Lit
Motor overloaded, short term
(Err 82 on Digital Models)
1. The wire drive motor is in a
locked state causing the motor
to exceed it’s maximum amperage draw.
Return to Master TOC
2. Verify that the drive system is
free of dirt and debris.
3. Perform the MOTOR OVERLOAD TEST.
OUTPUT PROBLEMS
The work sense lead has an
open or poor connection
(across the arc model).
The feeder does not power up - no
display (Digital Models) - no cold
feed.
1
NOTE: Both LED’s should flash
briefly when power is
applied.
2. The power source is off.
2. Turn on the power source.
3. The circuit breaker for the feeder on the power source may
have tripped. (Control cable
model).
3. Reset the circuit breaker.
The wire feeder powers up but
there is no welder output when the
gun trigger is pulled. The shielding
gas flows and the drive rolls turn.
1. The contactor coil connections
are loose.
1. Verify the connections.
2. The contactor has failed.
(Across the arc models)
Return to Section TOC
1. Verify that the motor can move
freely when the pressure arm is
released.
1. Connect the work sense lead to
the work in a location free of dirt
or paint.
2. Check for opens in the leads.
3. Perform the CONTACTOR
TEST, replace if necessary.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LN-25™ PRO
TROUBLESHOOTING & REPAIR
Return to Master TOC
Return to Section TOC
F-5
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Inconsistent wire feeding or wire not
feeding but the drive rolls are turning.
1. The gun cable is kinked.
2. The wire is jammed in the gun
cable.
3. The gun liner is dirty or worn.
4. The electrode is rusty or dirty.
5. The gun tip is worn or has splatter.
6. Improper gun liner, tip, drive
rolls, or wire guides.
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F-5
7. Incorrect pressure on the wire
drive rolls.
8. Spindle brake to tight.
9. Worn drive rolls.
1. Keep the gun as straight as
possible. Avoid sharp corners
or bends in the gun cable.
2. Remove the gun and clear the
jam.
3. Clear liner with pressurized air
(40 PSI) or less. Change liner if
worn.
4. Use only clean electrode. Use
only quality electrode, like L-50
or L-56 from the Lincoln
Electric.
5. Replace the contact tip.
6. Verify the proper parts are
installed.
7. Adjust the tension arm per the
manual. Most electrodes feed
well with the tension at around
“3”.
8. Verify the spool moves with
minimal effort.
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9. Replace the drive rolls if needed.
Wire feed speed consistently operates at the wrong value. The speed
changes when the control knob is
adjusted.
1. The jumper lead for normal
speed / extra torque is connected improperly.
2. The wrong gear is installed in
the wire drive unit.
1. Properly connect the jumper.
2. Install the proper pinion fear in
the wire drive unit.
3. Replace the motor/gearbox
assembly.
3. The motor brushes are worn.
This wire feeds but cannot be controlled with the wire speed pot.
1. The tachometer is connected
improperly.
1. Verify that tachometer leads
are properly connected.
2. The tachometer has failed.
2. Perform the MOTOR AND
TACHOMETER TEST. Replace
the tachometer if necessary.
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3. Possible control board problem.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LN-25™ PRO
TROUBLESHOOTING & REPAIR
Return to Master TOC
Return to Section TOC
F-6
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Variable or “hunting” arc.
1. Wrong size, worn or melted tip.
1. Replace the tip.
2. Worn work cable or poor connection.
2. Verify all the work and electrode connections are tight and
in good condition Clean if necessary and replace.
3. Wrong polarity’
4. The gas nozzle is extended
beyond the contact tip or the
wire stickout is too long.
Return to Master TOC
5. Poor gas shielding on processes requiring gas.
Return to Section TOC
F-6
3. Adjust polarity to recommended
procedure verify DIP switch 7
setting matches the electrode
polarity.
4. Adjust the gas nozzle and
shorten the stickout to 1/2 to
3/4 inches.
5. Check gas flow and mixture.
Remove or block sources of
drafts.
Perform the GAS
SOLENOID TEST, replace if
necessary.
When the trigger is pulled, the wire
feeds slowly.
The Run-in switch is “ON”
Turn the run-in switch to the “OFF”
position.
The preset voltage calibration in the
feeder has been selected for a different power source.
Use the setup menu to change the
preset voltage in the feeder to
match the power source.
Improper procedures or techniques.
See “Gas metal arc welding guide”
(GS-100)
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(Digital display models)
The preset voltage does not match
the power source voltage.
(Digital display models)
Poor arc starts with sticking or “
Blast-offs”, weld porosity, narrow or
ropy looking beads.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LN-25™ PRO
TROUBLESHOOTING & REPAIR
Return to Master TOC
Return to Section TOC
F-7
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
No shielding gas.
1. The gas supply is off or empty.
2. The gas hose is cut or crushed.
4. There is a loose connection at
the solenoid.
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5. The solenoid has failed.
Return to Section TOC
RECOMMENDED
COURSE OF ACTION
GAS SHIELDING ISSUES
3. The flow meter is closed. Dirt
or debris is in the solenoid.
Return to Section TOC
F-7
1. Verify the gas supply is ON and
flowing.
2. Reroute the gas hose to avoid
sharp corners and make sure
nothing is on it. Repair or
replace damaged hoses.
3. Open the flow meter valve.
4. Apply 80 psi of filtered air to the
solenoid to remove dirt and
debris.
5. Remove the cover and verify
that all the connections are in
good condition.
6. Perform the GAS SOLENOID
TEST, replace if necessary.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LN-25™ PRO
Return to Section TOC
Return to Master TOC
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F-8
NOTES
LN-25™ PRO
F-8
Return to Master TOC
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F-9
TROUBLESHOOTING & REPAIR
CASE REMOVAL PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the molded case
ssembly
MATERIALS NEEDED
Misc. Hand Tools
LN-25™ PRO
F-9
TROUBLESHOOTING & REPAIR
CASE REMOVAL PROCEDURE (CONTINUED)
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Return to Section TOC
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F-10
FIGURE F.1 – CASE REMOVAL
PROCEDURE
1. Remove the input power from the LN25 PRO
unit.
2. Using the 1/4-20 nut driver, remove the 8
screws holding the control box. Loosen the
cord grip connector, and slide the control box
assembly out of the case. See Figure F.1
LN-25™ PRO
F-10
Return to Master TOC
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F-11
TROUBLESHOOTING & REPAIR
GAS SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the gas solenoid circuit is faulty.
MATERIALS NEEDED
1/4-20 Nut driver
#10-24 Nut driver
Digital meter
LN-25™ PRO
F-11
TROUBLESHOOTING & REPAIR
Return to Section TOC
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F-12
F-12
GAS SOLENOID TEST (CONTINUED)
FIGURE F.2 – GAS SOLENOID
GAS SOLENOID
CONTROL BOX
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CONTROL BOX COVER
PROCEDURE
6. If high voltage is seen (Approx. 35 volts) the
solenoid coil is open.
1. Perform the Case Removal Procedure.
2. Remove the five #10-24 x .50 screws holding
the control box cover and access the solenoid
leads. See Figure F2.
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3. Apply the correct input voltage (15-110vdc) to
the unit.
4. While pressing the gas purge button or activating the gun trigger, check for approximately 4VDC is present at the solenoid leads. If
the 4VDC is present the solenoid should activate. If the 8VDC is present but the solenoid
does not activate the solenoid may be faulty.
7. Normal solenoid coil resistance is 22 ohms.
8. The solenoid can also be checked by disconnecting the leads and applying 12VDC directly to the terminals. If the solenoid does not
activate the solenoid is faulty.
9. If the solenoid fails any of the above tests
replace it.
10. Reassemble the feeder in reverse order.
5. If the 4VDC is missing or low, check the leads
and connections between the solenoid and
the control board. See the Wiring Diagram.
If the leads and connections are ok, the control board may be faulty.
LN-25™ PRO
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F-13
TROUBLESHOOTING & REPAIR
CONTACTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the contactor is faulty.
MATERIALS NEEDED
1/4-20 Nut driver
#10-24 Nut driver
Digital meter
LN-25™ PRO
F-13
TROUBLESHOOTING & REPAIR
Return to Master TOC
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Return to Section TOC
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F-14
CONTACTOR TEST (CONTINUED)
FIGURE F.3 – CONTACTOR
CONTROL BOX
CONTACTOR
PROCEDURE
1. Perform the Case Removal Procedure.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
leads. See Figure F.2.
3. Apply the correct input voltage (15-110vdc) to
the LN25 PRO unit.
Return to Master TOC
4. Check for the correct voltage at leads 507 and
578 at the contactor. Look for 0VDC when the
trigger is open and about 3VDC when it is
closed. See wiring diagram.
Return to Section TOC
F-14
5. If the 3VDC is missing or low, check the leads
and connections between the Contactor and
the control board. See the Wiring Diagram.
If the leads and connections are ok, the control board may be faulty.
6. If high voltage is seen (Approx. 35 volts) the
Contactor coil is open.
7. Normal solenoid coil resistance is 4 ohms.
8. The Contactor can also be checked by disconnecting the leads and applying 12VDC
directly to the terminals. If the solenoid does
not activate the solenoid is faulty.
9. If the contactor does not pass all the above
tests it needs to be replaced. See contactor
removal and replacement procedures.
10. Reassemble the feeder in reverse order.
LN-25™ PRO
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F-15
TROUBLESHOOTING & REPAIR
DRIVE MOTOR AND TACH FEEDBACK TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the motor and tach circuit is faulty.
MATERIALS NEEDED
1/4-20 nut driver
#10-24 nut driver
Digital meter
LN-25™ PRO
F-15
TROUBLESHOOTING & REPAIR
Return to Section TOC
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DRIVE MOTOR AND TACH FEEDBACK TEST (CONTINUED)
FIGURE F.4 – CONTROL BOX ASSEMBLY
CASE
PROCEDURE
1. Perform the Case Removal Procedure.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
leads. See Figure F.2.
3. Remove the 5 #10-24 screws holding the control box cover, and locate the two motor leads
and the 3 tach leads See the Wiring
Diagram.
Return to Master TOC
4. Apply the correct input voltage (15-110vdc) to
the unit.
Return to Section TOC
F-16
CONTROL BOX ASSEMBLY
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F-16
5. With trigger activated and the motor running
check for 2.6VDC min. to 32VDC max.
between the black and white motor leads
(pins 7 and 8).
NOTE: If the tach feedback is missing the board
will limit the motor voltage to 10VDC no
matter where the w/s pot is set.
6. Check for 1.5 ohms of resistance between the
black and white leads. Also make sure there
is at least 550k ohms of resistance between
both leads and the motor shell.
7. With the trigger activated and the motor running check for 15.6VDC input on the black
and red tach leads. Check for 6.2vdc at any
speed or ≈72hz (min.). to ≈1.2Khz (max). on
the black and blue return leads.
8. For further testing on the drive motor you can
use an isolated source and apply between
2.6VDC and 32VDC to the motor leads.
9. If all the above voltages are not there the
motor or tach needs to be replaced. See Wire
Drive Motor and Gear Box Removal and
Replacement.
LN-25™ PRO
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F-17
TROUBLESHOOTING & REPAIR
MOTOR OVERLOAD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the motor overload circuit is faulty.
MATERIALS NEEDED
1/4-20 nut driver
#10-24 nut driver
Digital meter
LN-25™ PRO
F-17
TROUBLESHOOTING & REPAIR
Return to Master TOC
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Return to Section TOC
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F-18
F-18
MOTOR OVERLOAD TEST (CONTINUED)
FIGURE F.5 – CONTROL BOX ASSEMBLY
CASE
CONTROL BOX ASSEMBLY
PROCEDURE
1. Perform the Case Removal Procedure.
6. If the amperage exceeds 3.2 amps for more
than 8 seconds the motor will be disabled.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
leads. See Figure F.2.
7. If the motor armature current is normal and
the motor still shuts down the control board
may be faulty.
3. Remove the five #10-24 screws holding the
control box cover, and locate the two motor
leads and 3 tach leads. See the Wiring
Diagram.
8. If the current is high check for restrictions in
the feed system. They can be caused by a
clogged liner, spindle tightness, drive rolls to
tight, fault drive motor or a faulty gearbox.
4. Apply the correct input voltage (15-110vdc) to
the unit.
9. After testing replace faulty parts and reassemble the feeder in reverse order of disassembly.
5. With the trigger activated and the motor running check the motor armature current.
Normal armature current is less then 3 amps.
LN-25™ PRO
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F-19
TROUBLESHOOTING & REPAIR
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the contactor.
MATERIALS NEEDED
1/4-20 nut driver
#10-24 nut driver
Adjustable wrench
Torque wrench
LN-25™ PRO
F-19
TROUBLESHOOTING & REPAIR
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F-20
F-20
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.6 – CONTROL BOX
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CONTROL BOX
REMOVAL PROCEDURE
1.
Perform the Case Removal Procedure.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
leads. See Figure F.2.
3. Disconnect both of the buss bar connectors.
DO NOT loosen the mounting block before
loosening the buss bar. See Figure F.6.
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4. Remove the five #10-24 x .50 screws from the
wire drive panel, and separate the panel from
the control box.
5. Remove the two #10-24 x .50 screws at the
base of the control box that holds the contactor and remove the contactor.
6.
Disconnect the coil leads, and the buss bars
from the contactor.
LN-25™ PRO
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F-21
TROUBLESHOOTING & REPAIR
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.7 – BUSS BAR AND MOUNTING BLOCK
BUSS BAR
MOUNTING BLOCK
REPLACEMENT PROCEDURE
1. Loosely connect the buss bars to the new
contactor.
5. Slide the wire drive panel into place and reattach using the five screws.
2. Reconnect the coil leads. Slide the buss bar
into the mounting block and start the 1/2-13
bolt.
6. Reconnect the gas hose and tighten the other
two buss bar connections.
3. Using the two #10-24 x .50 screws reattach
the contactor to the control box.
7. Slide the control box into the case and
reassemble in reverse order.
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4. Tighten the buss bars to the contactor to 15fp.
Return to Section TOC
F-21
LN-25™ PRO
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F-22
NOTES
LN-25™ PRO
F-22
TROUBLESHOOTING & REPAIR
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F-23
FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the front panel.
MATERIALS NEEDED
1/4-20 Nut driver
LN-25™ PRO
F-23
TROUBLESHOOTING & REPAIR
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F-24
F-24
FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.8 – FRONT PANEL
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FRONT PANEL
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Connect the work lead that was previously
removed.
1. Perform the Case Removal Procedure.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
leads. See Figure F.2.
3. Remove the two 1/4-20 screws that hold the
front panel and lift it out. See Figure F.8.
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4. Disconnect the molex plugs from the control
harness. See wiring diagram.
2. Reconnect the molex plugs.
3. Slide the front panel into the control box and
attach it with two 1/4-20 screws.
4. Slide the control box into the case and attach
it with the remaining 1/4-20 screws.
5. Disconnect the work lead and set it aside to
use with the new panel.
LN-25™ PRO
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F-25
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND GEAR BOX
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the wire drive
motor and gear box.
MATERIALS NEEDED
Return to Section TOC
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1/4-20 Nut driver
#10-24 Nut driver
3/8 nut driver
Phillips head screwdriver
LN-25™ PRO
F-25
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F-26
TROUBLESHOOTING & REPAIR
F-26
WIRE DRIVE MOTOR AND GEAR BOX
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.9 – BUSS BAR AND GAS HOSE REMOVAL
Gas Hose
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Gas Solenoid
Buss Bar
REMOVAL PROCEDURE
7. Remove the tach and motor leads by disconnecting the P9 connector. see wiring diagram.
1. Perform the Case Removal Procedure.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
leads. See Figure F.2.
3. Disconnect the gas hose and the buss bar
from the drive deck. See Figure F.9.
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Return to Section TOC
4. Remove the four #10-24 x .50 screws holding
the control box cover.
8. Remove the three M6 x 1.00 phillips pan head
screws holding the motor to the motor panel
and lift out the motor.
9. Remove the four 1/4-20 x .50 screws from the
back of the motor panel and remove the drive
deck. Note screw locations for reassembly.
5. Remove the five #10-24 x .50 screws from the
wire drive panel, and separate the panel from
the control box. See Figure F.10.
6. Remove the plastic drive gear cover and with
a phillips head screwdriver remove the drive
gear. See Figure F.10.
LN-25™ PRO
TROUBLESHOOTING & REPAIR
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F-27
F-27
WIRE DRIVE MOTOR AND GEAR BOX
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.10 – WIRE DRIVE PANEL REMOVAL
CONTROL BOX
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WIRE DRIVE PANEL
DRIVE GEAR COVER
REPLACEMENT PROCEDURE
1. Line up the gear box with the four holes on the
panel. Replace and tighten the four 1/4-20 x
.50 screws.
2. Insert the drive motor through the panel and
gear box. Line up and tighten the three M6 x
1.00 in. phillips pan head screws.
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3. Replace the drive gear and secure in place
using the screw and lock washer previously
removed.
7. Reconnect the gas hose and the buss bar
assembly.
8. Replace the control box cover using the four
#10-24 x .50 screws.
9. Slide the control box into the case and secure
it in reverse order.
10. Reinstall the gun.
4. Replace the drive rolls and secure the locking
rings.
5. Reconnect the motor and tach leads to harness.
6. Reassemble the wire drive panel and the control box using the five #10-24 x .50 screws.
LN-25™ PRO
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F-28
NOTES
LN-25™ PRO
F-28
Return to Master TOC
Return to Section TOC
F-29
TROUBLESHOOTING & REPAIR
PC BOARD REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the Control PC
Board.
MATERIALS NEEDED
1/4-20 Nut driver
#10-24 Nut driver
3/8 Nut driver
LN-25™ PRO
F-29
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F-30
TROUBLESHOOTING & REPAIR
F-30
PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.11 – CONTROL PC BOARD LOCATION
CONTROL BOX
CONTROL BOARD
CONTROL BOX COVER
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
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1. Perform the Case Removal Procedure.
1. Remove the new control board from the static
bag and place it on the 4 studs.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
leads. See Figure F.2.
2. Reassemble the 4 nuts and tighten hand tight.
3. Reassemble the harness plugs.
3. Disconnect the gas hose and the buss bar
from the drive deck.
4. Remove the five #10-24 x .50 screws from the
wire drive panel and separate the panel from
the box to access the control board.
4. Replace the wire drive panel and control box
assembly in reverse order.
5. Reconnect the buss bar and the gas hose.
6. Replace the control box cover.
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5. Locate the control board and remove the harness plugs on the control board. Observe static electricity precautions. Label plugs for
reassembly. See Figure F.11.
7. Slide the control box into the case and secure
it in reverse order.
6. Remove the 4 nuts holding the board using
the 3/8 inch nut driver, and remove the board.
LN-25™ PRO
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F-31
TROUBLESHOOTING & REPAIR
GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the gas solenoid.
MATERIALS NEEDED
#10-24 nut driver
Adjustable pliers
LN-25™ PRO
F-31
TROUBLESHOOTING & REPAIR
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F-32
F-32
GAS SOLENOID
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.12 – SOLENOID NUT AND HOSE
GAS SOLENOID
GAS HOSE
CONTROL BOX
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LOCK NUT
CONTROL BOX COVER
PROCEDURE
1. Perform the Case Removal Procedure.
8. Reconnect the gas hose.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor
leads. See Figure F.2.
9. Reconnect the wires to the solenoid coil.
10. Replace the control box cover.
3. Remove the 2 wires on the solenoid coil. See
wiring diagram.
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4. Using the pliers remove the gas hose. Be
careful not to damage the hose. See Figure
F.12.
5. Remove the lock nut holding the solenoid.
See Figure F.12.
6. Remove the solenoid from the unit.
7. Install the new solenoid with the attached
hardware.
LN-25™ PRO
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F-33
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Retest a machine :
• If it is rejected under test for any reason that requires you to
remove any part which could affect the machine’s electrical characteristics.
OR
• If you repair or replace any electrical components.
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Return to Master TOC
Return to Section TOC
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SET UP
1. Connect a supply of filtered compressed air at 80 psi to the gas inlet.
2. Supply 15 to 110 VAC to the machine.
3. Connect the gun to the connector block and connect the trigger.
OPERATION VERIFICATION
WIRE FEED SPEED (Standard) ...................50 through 700 IPM
WIRE FEED SPEED (Ext. Torque)...................50 through 400 IPM
VOLTMETER (Analog)..............Must read Inpit Voltage +/-2%
VOLTMETER (Digital)...............Must operate at 3 TO 12 VDC input volts
GAS SOLENOID.......................Must operate when Gun Trigger is activated.
CONTACTOR............................Must operate when Gun Trigger is activated
or after Pre-flow time if Timer Kit is installed.
LN-25™ PRO
F-33
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F-34
NOTES
LN-25™ PRO
F-34
TABLE OF CONTENTS - DIAGRAM SECTION
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G-1
G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram - Code 11387, 11388 (G5681) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram - Code 11507, 11508 (G5681-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram - Code 11620, 11621,11716,11717 (G5681-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Wiring Diagram - Code 11746, 11747 (G5681-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Return to Master TOC
Schematic - Complete Machine - Code 11387, 11388 (G5683) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6 / G-7
Schematic - Complete Machine - Code 11507, 11508 (G5683-1) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8 / G-9
Schematic - Complete Machine - Code 11620, 11621,11716, 11717 (G5683-2) . . . . . . . . . . . . . .G-10 / G-11
Schematic - Complete Machine - Code 11746, 11747 (G5683-3) . . . . . . . . . . . . . . . . . . . . . . . . .G-12 / G-13
Schematic - Control PC Board* - Code 11387/8, 11507/8 (G4745-1) . . . . . . . . . . . . . . . . . . . . . .G-14 / G-18
Schematic - Control PC Board* - Code 11620/1, 11716/7, 11746/7 (G4783-1) . . . . . . . . . . . . . . .G-19 / G-23
Schematic - Motor Filter PC Board* - Code 11746, 11747 (S27505-1) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-24
Schematic - K2330-2 Timer Kit PC Board* - All Codes (M21341-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-25
Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered
and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.
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* NOTE:
LN-25™ PRO
WIRING DIAGRAM
ANALOG DISPLAY CASE FRONT
YELLOW
THERMAL
LED
WIRE FEED SPEED
CONTROL RHEOSTAT
POLARITY 2W 2B
LED
1W 1B
N.A.
10K2W
VM
667B
721
Return to Master TOC
721
500A
622A
21A
575A
576A
577A
BRIDGE
RECTIFIER
AC
21B
TO WORK CLIP
N.D.
667A
667B
1B
1W
2B
2W
D1
AC
-
67B
621A
CONNECTS TO J17
ON HARNESS
67B
667A
21A
621A
Return to Master TOC
67
MOTOR /
GEARBOX
10K2W
R1
R2
577A
576A
575A
77A
RUNIN
N.C.
75A
N.B., N.C.
75B
76A
P17
CONNECT TO J18
ON HARNESS
1 2 3 4
P18
622A
707A
575A
576A
577A
708
75
76
77
41B 41C
BRIDGE
RECTIFIER
AC
AC
42B
42C
621B
622A
500A
BRIDGE
RECTIFIER 621B
TO WORK CLIP
21B
667B
D2
AC
-
21
21A
667B
667A
+
P14
76
-
TRIGGER
CONNECTOR
A
B
C
D
E
500A
+
42C
41C
75
77
AC
621A 67
D1
67B
P11
CONNECTS TO J11
ON HARNESS
CONNECTS TO J7
ON HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
J17
P7
R
U
B
667A
21A
621A
1
2
3
4
5
6
CONTROL P.C. BOARD
601
509B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
4B
605
606
608
607
J6
1 2 3 4 5 6 7 8 9 10
J1
J2
B
W
1
2
3
4
5
6
7
8
9
10
J4
J5
L5
551
550
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7
601
606
608
J3
9 10 11 12
GAS
SOLENOID
605
607
EXTRA
TORQUE
690
N.E.
691
1
2
3
4
5
6
7
8
L4
531
537
534
667
622
707
575
576
577
708
75C
76C
77C
1B
1W
2B
2W
BLACK
FAN
RED
L7
667D
667C
21G
621C
1
2
3
4
5
6
667
21C
621
1 2 3 4 5 6 7 8
605 608
601
509B 4B 606 607
P17
TO P60 ON
HARNESS
1
2
3
4
42
41
76C 21E 4A 42
67E 75C 77C 2A 41
P15
67
75D
76D
77D
21F
2
4
41A
42A
67F
1 2 3 4
67D
67E
INPUT ELECTRODE
CABLE CONNECTION
L6
N.C.
NOTES:
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE
LEAD OF LED SOCKET.
N.B. TOGGLE SWITCHES SHOWN FROM REAR CONNECTION SIDE OF SWITCH.
N.C. PRESENT ON CONTROL CABLE MODELS ONLY.
N.D. PRESENT ON ACROSS THE ARC MODELS ONLY.
N.E. CONNECT "EXTRA" TO "TORQUE" ON EXTRA TORQUE MODELS ONLY.
N.F. NOT PRESENT ON ALL MODELS.
CONTACTOR
N.D.
J15 1 2 3 4 5 6 7 8 9 10
14 PIN CIRCULAR CONNECTOR
TO POWER SOURCE
1
2
3
4
5
6
7
8
9
10
CONTACTOR COIL
J11
CONNECTS TO P18
ON CASE FRONT
BURNBACK
578
67C
67C
J18
J60
CURRENT
TRANSDUCER
21C
CONNECTS TO P17
ON CASE FRONT
POST-FLOW
550 690 507 537 531 575
551 691 577 578 534 576
507
21E
4B
67G
1
2
3
4
5
6
2A 721A 67F
4A 21D 621
21D
3B
TIMER KIT (OPTIONAL)
CONNECTS TO J17
ON HARNESS
67B
N.B.
CONNECTS
TO TIMER
KIT
1
2
3
4
5
6
7
8
N.O.
721A
500
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
702
SHOWN OFF
TACH
R
U
B
509B
+
76B
701
1
2
3
4
P60
1
2
3
4
5
6
7
8
509
612
610
3B
P9
CONNECTS TO
P7 ON CASE
FRONT
805
804
801
802
509
587
523
530
530 523 509A 707 500 2W
612 587 708 610 622 1W
W B
J7
10K2W
FLEX
CONNECTS TO J8
ON PRESET P.C. BD.
509A
1
2
3
4
FEED
PLATE
75B
805 702
21 701 708 76B 77B
S5
509C
587A
523A
530A
509E
530A
P7
FLEX
REMOTE
CONTROL
VOLTAGE
RHEOSTAT
SHOWN IN CV
N.O.
CONNECTS TO J1
ON CONTROL BD
WIRE FEED
SPEED
CONTROL
RHEOSTAT
523A
N.B.
S3
COLD
FEED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
801 707A
802 804
42B
77B
Return to Master TOC
1
2
3
4
5
6
N.B.
GAS PURGE
PUSHBUTTON
SWITCH
+
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6
41B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DIGITAL DISPLAY CASE FRONT
PRESET P.C. BOARD J10
J8
J12
S4
P16
+
Return to Section TOC
P14
509D
509C
CC / CV
SHOWN IN 2 STEP
CONNECTS TO
J7 ON HARNESS
622A
500A
A
B
C
D
E
S2
509D
509E
587A
N.B., N.F.
TRIGGER
CONNECTOR
+
S1
TRIGGER
INTERLOCK /
2 STEP
N.A.
577A
575A
ARC
576A
VOLTMETER
Return to Section TOC
LN-25 PRO
8
Return to Master TOC
WiriNG DiaGram - lN-25 prO - CODEs 11387, 11388 (G5681)
R1
Return to Section TOC
G-2
ElECTriCal DiaGrams
-
Return to Section TOC
G-2
J19
2
4
77D
76D
75D
21F
41A
42A
67
A
B
C
D
E
F
G
H
I
J
K
L
M
N
CONNECTS TO 14 PIN
CIRCULAR CONNECTOR
REMOTE
VOLTAGE
CONTROL
42VAC
E
D
OUTPUT
CONTROL
A
J14
C
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B - BLACK
W - WHITE
CAVITY NUMBERING SEQUENCE
B
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
J
A
J12
C
H
N
L
D
G
2
4
F
1
3
4
6
1
5
6
10
1
4
5
8
J3, J5, J9, J60
J12, J17
J1, J2, J8, J15
M
E
1
3
J11, J16, J18
I
K
B
1
6
1
8
9
16
J6, J7, J10
J4
7
N.B.
12
C
G5681
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
WIRING DIAGRAM
S1
TRIGGER
INTERLOCK /
2 STEP
S2
509D
509E
LN-25 PRO
509D
S4
509C
CC / CV
587A
SHOWN IN 2 STEP
SHOWN IN CV
FLEX
P16
N.B.
509C
587A
523A
530A
S3
COLD
FEED
509E
530A
Return to Master TOC
Return to Section TOC
FEED
PLATE
MOTOR /
GEARBOX
YELLOW
THERMAL
LED
WIRE FEED SPEED
CONTROL RHEOSTAT
1W 1B
N.A.
10K2W
ARC
VOLTMETER
667B
P14
A
B
C
D
E
622A
500A
622A
21A
21B
TO WORK CLIP
AC
AC
-
N.D.
575A
576A
577A
BRIDGE
RECTIFIER
667A
667B
621A
D1
67B
1B
1W
2B
2W
CONNECTS TO J17
ON HARNESS
67B
667A
21A
621A
R
U
B
CONNECTS TO
P7 ON CASE
FRONT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
P7
P17
J7
J17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
721A
500
1
2
3
4
5
6
67C
B
W
4B
605
606
608
607
J6
1 2 3 4 5 6 7 8 9 10
J1
J2
1 2 3 4 5 6 7 8
2A 721A 67F
4A 21D 621
1 2 3 4 5 6 7
507
21E
4B
CURRENT
TRANSDUCER
21C
601
606
608
605
607
EXTRA
TORQUE
9 10 11 12
690
N.E.
691
1
2
3
4
5
6
7
8
J3
GAS
SOLENOID
BLACK
FAN
RED
550 690 507 537 531 575
551 691 577 578 534 576
21D
3B
578
CONTACTOR COIL
67F
67C
1 2 3 4
67D
67E
INPUT ELECTRODE
CABLE CONNECTION
J11
667
621
CONNECTS TO P17
ON CASE FRONT
L7
J60
CONNECTS TO P18
ON CASE FRONT
605 608
601
509B 4B 606 607
1
2
3
4
42
41
76C 21E 4A 42
67E 75C 77C 2A 41
P15
1
2
3
4
5
6
7
8
9
10
67
75D
76D
77D
21F
2
4
41A
42A
L6
N.C.
NOTES:
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE
LEAD OF LED SOCKET.
N.B. TOGGLE SWITCHES SHOWN FROM REAR CONNECTION SIDE OF SWITCH.
N.C. PRESENT ON CONTROL CABLE MODELS ONLY.
N.D. PRESENT ON ACROSS THE ARC MODELS ONLY.
N.E. CONNECT "EXTRA" TO "TORQUE" ON EXTRA TORQUE MODELS ONLY.
N.F. NOT PRESENT ON ALL MODELS.
CONTACTOR
N.D.
J15 1 2 3 4 5 6 7 8 9 10
14 PIN CIRCULAR CONNECTOR
TO POWER SOURCE
BURNBACK
1 2 3 4 5 6 7 8
J18
667E
TIMER KIT (OPTIONAL)
TO P60 ON
HARNESS
J4
J5
L5
551
550
667C
21C
POST-FLOW
1
2
3
4
5
6
7
8
9
10
L4
531
537
534
667
622
707
575
576
577
708
75C
76C
77C
1B
1W
2B
2W
667D
Return to Master TOC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
+
Return to Master TOC
721
500A
TRIGGER
CONNECTOR
601
509B
CONNECTS
TO TIMER
KIT
1
2
3
4
5
6
7
8
J19
2
4
77D
76D
75D
21F
41A
42A
67
A
B
C
D
E
F
G
H
I
J
K
L
M
N
N.O.
N.B.
CONTROL P.C. BOARD
P9
CONNECTS TO
J7 ON HARNESS
+
Return to Section TOC
721
+
509B
3B
+
VM
576A
TACH
R
U
B
POLARITY 2W 2B
LED
N.A.
575A
P60
1
2
3
4
5
6
7
8
509
530 523 509A 707 500 2W
612 587 708 610 622 1W
W B
R1
577A
509
587
523
530
612
610
CONNECTS TO J8
ON PRESET P.C. BD.
509A
1
2
3
4
N.O.
ANALOG DISPLAY CASE FRONT
GAS PURGE
PUSHBUTTON
SWITCH
523A
N.B.
8
Return to Master TOC
WiriNG DiaGram - lN-25 prO - CODEs 11507, 11508 (G5681-1)
N.B., N.F.
Return to Section TOC
G-3
ElECTriCal DiaGrams
-
Return to Section TOC
G-3
CONNECTS TO 14 PIN
CIRCULAR CONNECTOR
REMOTE
VOLTAGE
CONTROL
42VAC
E
D
OUTPUT
CONTROL
A
J14
C
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B - BLACK
W - WHITE
CAVITY NUMBERING SEQUENCE
B
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
1
J
A
K
B
J12
C
G
E
F
1
5
6
10
1
4
5
8
J3, J5, J9, J60
4
4
J1, J2, J8, J15
M
3
J12, J17
3
H
N
L
D
1
2
J11, J16, J18
I
6
1
6
7
12
1
8
9
16
J6, J7, J10
J4
B
G5681-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
WIRING DIAGRAM- LN-25 PRO ANALOG
MOTOR FILTER P.C. BOARD
S1
TRIGGER
INTERLOCK /
2 STEP
S2
509D
509E
CC / CV
587A
667D B1
667E B2
523A
N.B.
(SHOWN IN 2 STEP)
(SHOWN IN CV)
509A
P16/J16
N.B.
509C
587A
523A
530A
S3
COLD
FEED
509E
530A
509
587
523
530
1
2
3
4
Return to Master TOC
Return to Section TOC
N.O.
FEED
PLATE
MOTOR /
GEARBOX
ANALOG DISPLAY CASE FRONT
WIRE FEED SPEED
CONTROL RHEOSTAT
YELLOW
THERMAL
LED
1W 1B
N.A.
10K2W
ARC
VOLTMETER
R
U
B
667B
P14
Return to Master TOC
575A
B
W
A
B
C
D
E 622B
622A
500A
555A
AC
AC
-
TO WORK CLIP
575A
576A
577A
WORK A
BRIDGE
RECTIFIER
WORK B
667A
667B
621A
D1
67B
1B
1W
2B
2W
67B
667A
WORK A
621A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
721A
500
555
622
707
575
576
577
708
75C
76C
77C
1B
1W
2B
2W
1
2
3
4
5
6
67C
TIMER KIT (OPTIONAL)
Return to Master TOC
J60
J6
605 608
601
509B 4B 606 607
1
2
3
4
5
6
7
8
9
10
1 2 3 4 5 6 7 8 9 10
J1
J2
B2
601
606
608
605
607
EXTRA
TORQUE
N.D.
555
CONTROL P.C. BOARD
GAS PURGE
PUSHBUTTON
SWITCH
B1
1
2
3
4
5
6
7
8
612
610
S4
1
2
3
4
5
6
7
8
J4
J5
L5
551
550
J3
1 2 3 4 5 6 7 8
667
2A 721A 67F
4A 821B 621
1 2 3 4 5 6 7
9 10 11 12
N.B.
BLACK
FAN
RED
550 690 507 537 531 575
551 691 577 578 534 576
690
GAS
SOLENOID
691
507
3B
578
CONTACTOR COIL
67F
67C
4B
67D
67E
667
CONTACTOR
667D
667E
J18
1
2
3
4
42
41
INPUT ELECTRODE
CABLE CONNECTION
76C 21E 4A 42
67E 75C 77C 2A 41
J15 1 2 3 4 5 6 7 8 9 10
CAVITY NUMBERING SEQUENCE
D
E
A
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
J14
NOTES:
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE
LEAD OF LED SOCKET.
N.B. SWITCHES SHOWN FROM REAR CONNECTION SIDE OF SWITCH.
N.D. CONNECT "EXTRA" TO "TORQUE" ON EXTRA TORQUE MODELS ONLY.
N.O.
L4
531
537
534
BURNBACK
1 2 3 4 5 6 7 8
TO P60 ON
HARNESS
4B
605
606
608
607
CONNECTS
TO TIMER
KIT
667C
821B
21E
621
P17/J17
POST-FLOW
601
509B
P7/J7
721
500A
555A
622A
TRIGGER
CONNECTOR
3B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P20/J20
POLARITY 2W 2B
LED
N.A.
+
Return to Section TOC
721
+
TACH
R
U
B
509B
530 523 509A 707 500 2W
612 587 708 610 622 1W
+
VM
576A
P60
1
2
3
4
5
6
7
8
509
W B
R1
577A
J61
1 2 3 4
509D
509C
8
Return to Master TOC
WiriNG DiaGram - lN-25 prO - CODEs 11620, 11621, 11716, 11717 (G5681-2)
N.B.
Return to Section TOC
G-4
ElECTriCal DiaGrams
-
Return to Section TOC
G-4
C
1
B
2
J11, J16,
J18, J61
1
3
4
6
J12, J17
3
4
5
8
1
4
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B - BLACK
W - WHITE
1
4
5
8
J3, J5, J9,
J20, J60
J19
1
5
6
10
J1, J2, J15
1
6
7
12
1
8
9
16
J6, J7
J4
A
G5681-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
WIRING DIAGRAM- LN-25 PRO ANALOG
MOTOR FILTER P.C. BOARD
S1
TRIGGER
INTERLOCK /
2 STEP
S2
509D
509E
CC / CV
587A
667D B1
667E B2
523A
N.B.
(SHOWN IN 2 STEP)
(SHOWN IN CV)
509A
P16/J16
N.B.
Return to Master TOC
Return to Section TOC
1W 1B
N.A.
509E
530A
FEED
PLATE
2W 2B
MOTOR /
GEARBOX
P60
TACH
R
U
B
1
2
3
4
5
6
7
8
509
509B
530 523 509A 707 500 2W
612 587 708 610 622 1W
3B
601
509B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
4B
605
606
608
607
J6
1
2
3
4
5
6
7
8
9
10
1 2 3 4 5 6 7 8 9 10
J1
J2
B2
CONNECTS
TO TIMER
KIT
601
606
608
605
607
EXTRA
TORQUE
N.D.
555
CONTROL P.C. BOARD
GAS PURGE
PUSHBUTTON
SWITCH
W B
721
+
667B
576A
575A
A
B
C
D
E
721
500A
555A
622A
622A
500A
BRIDGE
RECTIFIER
667A
667B
+
AC
AC
-
TO WORK CLIP
575A
576A
577A
WORK A
WORK B
B
W
621A
D1
67B
1B
1W
2B
2W
67B
667A
WORK A
621A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
721A
500
555
622
707
575
576
577
708
75C
76C
77C
1B
1W
2B
2W
1
2
3
4
5
6
67C
TIMER KIT (OPTIONAL)
POST-FLOW
J60
J5
L5
551
550
J3
1 2 3 4 5 6 7 8
667
2A 721A 67F
4A 821B 621
1 2 3 4 5 6 7
605 608
601
509B 4B 606 607
9 10 11 12
N.B.
BLACK
FAN
RED
550 690 507 537 531 575
551 691 577 578 534 576
690
GAS
SOLENOID
691
507
3B
578
CONTACTOR COIL
67F
67C
4B
67D
67E
667
CONTACTOR
667D
667E
J18
1
2
3
4
42
41
INPUT ELECTRODE
CABLE CONNECTION
76C 21E 4A 42
67E 75C 77C 2A 41
J15 1 2 3 4 5 6 7 8 9 10
CAVITY NUMBERING SEQUENCE
D
E
A
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
J14
NOTES:
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE
LEAD OF LED SOCKET.
N.B. SWITCHES SHOWN FROM REAR CONNECTION SIDE OF SWITCH.
N.D. CONNECT "EXTRA" TO "TORQUE" ON EXTRA TORQUE MODELS ONLY.
N.O.
S4
1
2
3
4
5
6
7
8
J4
BURNBACK
1 2 3 4 5 6 7 8
TO P60 ON
HARNESS
531
537
534
667C
821B
21E
621
P17/J17
612
610
L4
P7/J7
622B 555A
TRIGGER
CONNECTOR
P14
Return to Master TOC
R1
1
2
3
4
5
6
7
8
+
VM
R
U
B
10K2W
577A
B1
P20/J20
WIRE FEED SPEED
CONTROL
POTENTIOMETER
WFS RANGE
SWITCH
S5
ARC
VOLTMETER
Return to Master TOC
509
587
523
530
1
2
3
4
N.O.
N.A.
N.B.
Return to Section TOC
POLARITY
LED
509C
587A
523A
530A
S3
COLD
FEED
YELLOW
THERMAL
LED
J61
1 2 3 4
509D
509C
8
Return to Master TOC
WiriNG DiaGram - lN-25 prO - CODEs 11746, 11747 (G5681-3)
N.B.
Return to Section TOC
G-5
ElECTriCal DiaGrams
-
Return to Section TOC
G-5
C
B
1
2
3
4
J11, J16,
J18, J61
1
3
4
6
J12, J17
5
8
1
4
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B - BLACK
W - WHITE
1
4
5
8
J3, J5, J9,
J20, J60
J19
1
5
6
10
J1, J2, J15
1
6
1
8
9
16
J6, J7
J4
7
12
A.01
G5681-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
Return to Master TOC
G-6
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11387, 11388 - (G5683) pG1
G5683
Return to Section TOC
G-6
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: REVISED LEADS GOING TO P17.
LN-25 PRO WIRE FEEDER
PRESET P. C. BOARD CIRCUIT
SCHEMATIC = G4748
(LOCATED ON CASE FRONT)
Return to Master TOC
Return to Section TOC
TIMER P. C. BOARD CIRCUIT
MOTOR
THERMAL
3 LEDs
Timer Board Summary
Has potentiometers for Burnback, Preflow and Postflow.
Preflow range from 0ms to 10s.
Burnback range from 0 to 250 ms.
Postflow range from 50ms to 10 s.
Receives “Gas Flow Enable” signal.
Outputs 16 ms pulses to turn Gas Flow On / Off.
(LOCATED BEHIND WIRE
REEL COVER)
(LOCATED ON CASE FRONT)
ADJUST KNOB
+5V
10K
BURNBACK
POT.
ARC VOLTAGE
MEASUREMENT
FOR DISPLAY
COM
15V SIGNAL
15 ms PULSES
Return to Master TOC
OUTPUT
Return to Section TOC
J10-10
WFS
AMPS
set=WFS
actual = AMPS
702
VOLTS
SIGNALS TO
DISPLAY & LED
J10-11
SERIAL SPI
COMMUNICATION
77B
J10-16
76B
J10-14
75B
J10-15
SPI (10 leads)
+
-
MICROCONTROLLER
VOLTAGE
MEASUREMENT
OF REMOTE
VOLTS
POTENTIOMETER
+
MICROCONTROLLER
{
ELECTRODE
67
J10-6
WORK
21
J10-8
805
804
801
J10-9
J10-4
J10-1
802
J10-2
15V
TOGGLE GAS FLOW
ON/OFF
ARC CURRENT MEASUREMENT
FOR DISPLAY & ARC ESTABLISHED
5V
COM
5V SIGNAL
GAS FLOW
ENABLE
J60-8
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
INPUT
POWER
607
608
606A
605
TO J1
CONTROL
PC BOARD
SETUP
PUSHBUTTON
SETUP
LED
10K
COM
COM
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
{
{
701
VOLTS DISPLAY
+5V
PREFLOW
POT.
POSTFLOW
POT.
TO REMOTE VOLTS
POTENTIOMETER R2
AND POWER SOURCE
ADJUST KNOB
ADJUST KNOB
CW= +5
CCW= 0V
0V = RUN IN ENABLED
TO SWITCH S5 RUN IN
WFS/AMPS DISPLAY
7 SEGMENT
DISPLAYS
(2 each)
4B
NOT
USED
509B
{
{
+15V
-15V
ARC CURRENT
FEEDBACK
COM
CONTROL CABLE
INPUT POWER
DETECTION
(<18 VAC TO DETECT)
708
J10-12
+4V = +500A
-4V = -500A
ARC ESTABLISHED OUTPUT
IF V> 10V RELATIVE TO COMMON
0V= ARC NOT ESTABLISHED
TO CONTROL BOARD (VIA P7)
J12-1
41
42
SETUP
PUSHBUTTON
(BOARDMOUNTED )
ARC VOLTAGE
FEEDBACK
J12-4
-15V
707
J6-8
FROM CONTROL BOARD (VIA P7)
601
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056 CONTROL:
CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ddietz
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
ENYEDY
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
APPROVED:
-
SCALE:
NONE
IF PRINTED
@ A2 SIZE
UNITS:
DO NOT SCALE THIS DRAWING
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
LN-25 PRO
MACHINE SCHEMATIC
APPROVAL
11/16/2007
DATE:
PROJECT
NUMBER:
2
2 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
CRM39437
-
DOCUMENT
REVISION:
G5683
C
SOLID EDGE
Return to Master TOC
Return to Section TOC
TO CONTROL BD. (VIA P60 plug)
Insight
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
G-7
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11387, 11388 - (G5683) pG2
G5683
Return to Section TOC
G-7
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: REVISED LEADS GOING TO P17.
LN-25 PRO WIRE FEEDER
PRESET P. C. BOARD CIRCUIT
SCHEMATIC = G4748
(LOCATED ON CASE FRONT)
Return to Master TOC
Return to Section TOC
TIMER P. C. BOARD CIRCUIT
MOTOR
THERMAL
3 LEDs
Timer Board Summary
Has potentiometers for Burnback, Preflow and Postflow.
Preflow range from 0ms to 10s.
Burnback range from 0 to 250 ms.
Postflow range from 50ms to 10 s.
Receives “Gas Flow Enable” signal.
Outputs 16 ms pulses to turn Gas Flow On / Off.
(LOCATED BEHIND WIRE
REEL COVER)
(LOCATED ON CASE FRONT)
ADJUST KNOB
+5V
10K
BURNBACK
POT.
ARC VOLTAGE
MEASUREMENT
FOR DISPLAY
COM
15V SIGNAL
15 ms PULSES
Return to Master TOC
OUTPUT
Return to Section TOC
J10-10
WFS
AMPS
set=WFS
actual = AMPS
702
VOLTS
SIGNALS TO
DISPLAY & LED
J10-11
SERIAL SPI
COMMUNICATION
77B
J10-16
76B
J10-14
75B
J10-15
SPI (10 leads)
+
-
MICROCONTROLLER
VOLTAGE
MEASUREMENT
OF REMOTE
VOLTS
POTENTIOMETER
+
MICROCONTROLLER
{
ELECTRODE
67
J10-6
WORK
21
J10-8
805
804
801
J10-9
J10-4
J10-1
802
J10-2
15V
TOGGLE GAS FLOW
ON/OFF
ARC CURRENT MEASUREMENT
FOR DISPLAY & ARC ESTABLISHED
5V
COM
5V SIGNAL
GAS FLOW
ENABLE
J60-8
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
INPUT
POWER
607
608
606A
605
TO J1
CONTROL
PC BOARD
SETUP
PUSHBUTTON
SETUP
LED
10K
COM
COM
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
{
{
701
VOLTS DISPLAY
+5V
PREFLOW
POT.
POSTFLOW
POT.
TO REMOTE VOLTS
POTENTIOMETER R2
AND POWER SOURCE
ADJUST KNOB
ADJUST KNOB
CW= +5
CCW= 0V
0V = RUN IN ENABLED
TO SWITCH S5 RUN IN
WFS/AMPS DISPLAY
7 SEGMENT
DISPLAYS
(2 each)
4B
NOT
USED
509B
{
{
+15V
-15V
ARC CURRENT
FEEDBACK
COM
CONTROL CABLE
INPUT POWER
DETECTION
(<18 VAC TO DETECT)
41
42
SETUP
PUSHBUTTON
(BOARDMOUNTED )
ARC VOLTAGE
FEEDBACK
708
J10-12
+4V = +500A
-4V = -500A
ARC ESTABLISHED OUTPUT
IF V> 10V RELATIVE TO COMMON
0V= ARC NOT ESTABLISHED
TO CONTROL BOARD (VIA P7)
J12-1
J12-4
-15V
707
J6-8
FROM CONTROL BOARD (VIA P7)
601
Return to Master TOC
Return to Section TOC
TO CONTROL BD. (VIA P60 plug)
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056 CONTROL:
CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ddietz
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
ENYEDY
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
APPROVED:
-
SCALE:
NONE
IF PRINTED
@ A2 SIZE
UNITS:
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
LN-25 PRO
MACHINE SCHEMATIC
APPROVAL
11/16/2007
DATE:
PROJECT
NUMBER:
2
2 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
CRM39437
-
DOCUMENT
REVISION:
G5683
C
I
i h
lN-25™ prO
CHANGE DETAIL: MISC. UPDATES PER SERVICE DEPARTMENT.
667A
6 1 of 2 P17
621
21A
621A
WORK CLIP
P17 4
2 of 2
D1
21B
667B
67B
-
21C
1
L4
551
550
Located on
Case front
case front
strain relief
1
2
3
4
5
6
7
8
531
537
534
67C
L12081 2.6 V @ 50 IPM
27 V @ 700 IPM
Return to Master TOC
9
10
5 77C
4 76C
3 75C
1
6
2
7
8
667D
J15
LINE FILTER FOR NOISE ON
INVERTER INPUT POWER.
LOCATED ABOVE CONTROL
BOARD ON TOP CENTER OF
CONTROL BOX ASSEMBLY
10
11
12
575A
576A
577A
WIRE FEED SPEED
CONTROL
POTENTIOMETER
2
P16
Located on
top of motor
4
2
1
3
Located under
Wire Drive Panel
534
531
J4-11 J4-12 J4-6
J5-1
100K
ohm
J4-9
537
551
ISOLATED 2-4 TO
POWER SOURCE
21D
550
721
67F
530
J4-7 J4-10 J4-2 J4-1 J5-7 J5-6 J5-5
J6-2
587
523
509A
J6-3
J6-4
J6-6
+5V
+15V SPI
+5V SPI
-15V
+15V ISO
+5VDC
COM
.05 uF
600 V
METER
COMPENSATION
CIRCUIT
MOTOR
SUPPLY
POWER
SUPPLY
J4-3
COM
MOTOR
DRIVE
CIRCUIT
Recommended
all CV
operation.
Recommended for
CV operation.
(Wire Feed
Module Required)
Ranger 250, 305
Commander 300,400,500
(Common Analog
Controls)
Recommended for CV
operation.
J3-8 J3-6
FAN
-
K2613-1
K2613-2
K2613-3
(LOCATED INSIDEOF
CONTROLBOX)
Classic
605
601
EXTRA
TORQUE
J2-6 J2-3
J2-2
J2-5
J2-1
J2-7
J2-8
+5V
100K
ohm
COM
0V = OFF
20msec ---- 250msec
+5V
GAS
FLOW
ENABLE
TACH
FEEDBACK
YELLOW THERMAL LED
+5V SPI
POLARITY LED
J6-14
COM
J3-7
Control Board Summary
Converts arc power to a usable control circuit voltage.
Receives switch signals from Trigger, Cold Feed, Gas Purge
Reads WFS potentiometer.
Communicates with optional timer kit.
Controls motor speed with PWM.
Turns Gas Solenoid on, off, PWM.
Reads the motor tachometer.
Operating Voltage= 15-110 VDC.
Shut down Voltage= 130 VDC.
Thermal light turns on when shutdown voltage exceeded.
Code and Serial numbers are below Wire Drive on plastic
housing Nameplate.
Thermal “Yellow” Light
Motor Over Current
Motor and trigger disabled for 30 seconds.
Must retrigger to start welding after 30 seconds pass.
Shutdown Voltage exceeded
May occur with some inverters.
May occur with some CC machines with high
inductance.
Polarity “Green” Light
On= Positive Polarity
Off= Negative Polarity
15
2B
B
13
1B
WIRE FEED
SPEED
COM
ARC ESTABLISHED
FLEXIBLE POWER P.C. BOARD
SCHEMATIC = G4745
COM
FAN BLOWS AIR ACROSS
CONTROL PC BOARD
CONTINOUSLY AT 6200 RPMS.
Ranger 8,9
606
PROGRAM
+5V SPI
ADJUST VALVE
608
J4-4
+
FLOW METER
J4-8 J4-5
607
GAS SOLENOID
(LOCATED AT REAR
OF FEEDER)
GOOD FOR Ar, CO2,
CO2/Ar BLENDS
P60
BRAKE
GAS PURGE
BALL FLOAT
USE MIDDLE OF
BALL TO SET
1
4B
MOTOR VOLTAGE
MOTOR CURRENT
0V = MIN SPEED
5V = MAX SPEED
+35V
J3-1
J3-2
J3-3
J3-4
J3-5
25 TO 35
NORMAL
FLOW RATE
2
GAS
ON - OFF
BURNBACK
0-5V PULSE SIGNAL
FREQUENCY = SPEED
22 O COIL
691
0 VDC OPEN
4 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
3
DRIVE
13.5 VDC WHEN
NOT DEPRESSED
Model
POLARITY
SENSE
-15
BRAKE
0.05K
ohm
GAS
SOLENOID
4
DRIVE
PWM
+15V
J6-7
J6-1
690
MACHINE
OUTPUT
ENABLE CONTACTOR DRIVE
+15
(OUTSIDE BACK
OF CASE)
Not present
on K2613-3
+35V
507
20
ohm
MICRO
CONTROLLER
COM
610
612
5
COLD FEED
721 IS DRIVEN NEGATIVE TO COMPENSATE
FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE
OVER
VOLTAGE
PROTECTION
MOV
CC/VV
578
J5-4 J5-3
+15V
+15V
TRIGGER INTERLOCK / 2 STEP
667
J5-8
J6-9 J6-10
+15V
TRIGGER
35VDC
ISO
S4
6
CONTACTOR
2
500
10K
ohm
LED
(LOCATED AT
OUTSIDE REAR
OF FEEDER)
7
4
622
+15V
COM
POWER
SUPPLY
GAS PURGE
PUSHBUTTON
SWITCH (N.O.)
8
700
400*
Maximum WFS
Feeder Input Volts Standard Gear Extra Torque
15
280
210
17
340
235
21
440
400
24
520
400
27
600
400
JUMPER TOGETHER FOR
EXTRA TORQUE MACHINE
Connector
located
behind case
front
MOTOR
SUPPLY
621
509B 601
607 608 606A 605 4B
530
257*
The WFS range of the LN-25 PRO
Normal Speed = 40- 700 IPM.
Extra Torque = 25- 400 IPM.
WFS limited by arc voltage when operating across the arc
1 of 4
4 O COIL
0 VDC OPEN
3 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
370
180*
*Extra Torque
3 of 4
575A
576A
577A
0 VDC MIN. WFS
5 VDC MAX. WFS
4.5
TIMER KIT P.C. BOARD
(OPTIONAL)
SCHEMATIC = M21341
SEE PAGE 2
509B
4
622
500
P7
576A
577A
R1
Return to Master TOC
CC
CV
509C
575A
10K/2W
After 2-20-2009
Current
Level
P7-1
76C
77C
6
7
8
Preset
WFS
Preset
WFS
15V=CV
0V=CC
523
75C
3.5
TRIGGER CONNECTOR
J14
TRIGGER
A
622A
INPUT
B
500A
Located
on
C
Case Front
0V.=TRIGGER
D
CLOSED
E
15VDC.=TRIGGER
OPEN
721
Located on
Case Front
Return to Master TOC
gun connector
509D
S2
667B
40V MAX.
4.5
case back
strain relief
3.5
S3
N.O.
ANALOG
VOLTMETER
Before 2-20-2009
Current
Level
509B
509E
530A
21E
Motor overcurrent limit varies with WFS.
From Power Source
(Electrode Connection)
weld cable
copper bar
EXTRA TORQUE
COLD FEED
0V=COLD FEED
(N.O.)
+
-
P7
4 of 4
Return to Section TOC
67C
67D
copper bar
587
Trigger Interlock does not stop
welding when the arc is broken.
Pull and release to end the weld. 2-STEP
IN HARNESS
CENTER BASE
AREA
667E
Return to Section TOC
J18
If the feeder is powered-up with the trigger depressed, welding will
not start until the trigger is released and then depressed again.
Notes:
TRIGGER INTERLOCK
(NOT PRESENT ON K2613-3)
S1, S2 & S3 Located
S1
15V=2 STEP
on Wire Drive Panel
0V=TRIGGER
509E
INTERLOCK
L5
NOT
USED
On power-up, the LN-25 PRO will light the motor thermal LED and
polarity LED 2-3 seconds.
PLASTIC HOUSED BOLTED
CONNECTION (BASE CENTER)
B
TAKEN WITH 40 V INPUT
IN CV MODE.
67C & 67D
L13084 2.6 V @ 25 IPM
32 V @ 400 IPM
Located on Wire
Drive Panel
R
U
W
Leads Pass
through
toroid 2 times.
14 PIN REMOTE
LEADS ARE
PRESENT BUT
NOT USED IN
THIS UNIT.
Gearbox ratio is 23.5:1
Motor resistance
Motor case is at
is 1.5 ohms
electrode potential
Motor is located
behind
glastic panel
FEED
PLATE
MOTOR /
GEARBOX
B
P9
Start-Up
LN-25 PRO WIRE FEEDER
72 HZ TO 1.2 KHZ
R-B 15.0 VDC
B-U 6.2 VDC ANY SPEED
(METER DEPENDENT)
Top of motor
Leads Pass through
toroid 2 times.
531
537
534
When tach feed back is lost,
the voltage to the motor is a
constant 10VDC.
(controlled by software)
J1-10
CS0
CS1
CS2
CS3
SCLK
3
667C
P7 = 16 PIN
P17 = 6 PIN (Both are located on lower front)
MISO
MOSI
ENGINEERING CONTROLLED
MANUFACTURER: No
J1-7
J1-9
J1-3
J1-4
J1-5
J1-6
J1-8
G5683-1
Return to Master TOC
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11507, 11508 - (G5683-1) pG1
67B
Return to Section TOC
G-8
ElECTriCal DiaGrams
+
Return to Section TOC
G-8
+5V SPI +15V
J6-11
1W
J6-12
2W
(LOCATED AT TOP
FRONT OF FEEDER)
YELLOW
MOTOR
THERMAL
LED
14
16
J6-5
708
J6-8
707
GREEN
POLARITY
LED
9
-15V
5
2 of 4
P7
J1-2 J1-1
RED
PROGRAMMING PCB
FACTORY USE ONLY
BLACK
V350
(Common Digital
Controls)
Recommended
for CV
operation.
May be used for
pulse welding if
the welding
procedure is
qualified by the
customer.
DC-400, 600
Recommended
for CV and CC
operation.
Square Wave TIG 300/355
Not recommended for CC operation
because the customer may
experience short contactor life from
inductive nature of the power source.
Not recommended with high frequency
TIG starti ng.
SPI DIGITAlL COMMUNICATION
Miller Inverters
Recommended
for CV voltage
sense operation.
Not
recommended for
use when pulse
welding.
STT II
Note:
Most semiautomatic wire
welding processes perform
better using constant voltage
Not recommended power sources. Be sure the
for STT operation. proper power source is used
for your application. Contactor
life may be shortened in
applications using CC
machines with high OCV.
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
tpearn
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
MATERIAL TOLERANCE (" t ") TO AGREE
ENYEDY
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: SCHOLTI
SCALE:
NONE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
LN-25 PRO
MACHINE SCHEMATIC
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
2/12/2010
PROJECT
NUMBER:
CRM40936
2
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
G5683
G5683-1
DOCUMENT
REVISION:
C
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
G-9
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11507, 11508 - (G5683-1) pG2
G5683-1
Return to Section TOC
G-9
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: MISC. UPDATES PER SERVICE DEPARTMENT.
LN-25 PRO WIRE FEEDER
Timer Board Summary
Has potentiometers for burnback, postflow and preflow.
Preflow range is 0 to 10 sec.
Burnback range is 0 to 0.25 sec.
Postflow range is 0.25 to 10 sec.
Receives “Gas Flow Enable” signal.
Outputs 100 msec pulses to turn Gas Flow On, Gas Flow Off.
Return to Master TOC
(LOCATED BEHIND WIRE
REEL COVER)
(LOCATED ON CASE FRONT)
ADJUST KNOB
+5V
ADJUST KNOB
ADJUST KNOB
CW= +5
CCW= 0V
+5V
10K
BURNBACK
POT.
PREFLOW
POT.
POSTFLOW
POT.
10K
COM
COM
COM
15V SIGNAL
15 ms PULSES
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
OUTPUT
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
MICROCONTROLLER
15V
TOGGLE GAS FLOW
ON/OFF
5V
COM
5V SIGNAL
GAS FLOW
ENABLE
J60-8
607
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
608
606A
605
4B
NOT
USED
509B
601
TO CONTROL BD. (VIA P60 plug)
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056 CONTROL:
CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
tpearn
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
ENYEDY
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
APPROVED:
SCHOLTI
SCALE:
NONE
IF PRINTED
@ A2 SIZE
UNITS:
DO NOT SCALE THIS DRAWING
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
LN-25 PRO
MACHINE SCHEMATIC
APPROVAL
2/12/2010
DATE:
PROJECT
NUMBER:
2
2 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
CRM40936
G5683
DOCUMENT
REVISION:
G5683-1
C
SOLID EDGE
Return to Section TOC
TIMER P. C. BOARD CIRCUIT
Insight
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
P7 = 16 PIN
P17 = 6 PIN (Both are located on lower front)
667A
21A
621A
21B
case front
strain relief
667D
D1
21C
L4
531
537
534
551
550
67C
B2
B1
J62-1 J62-2
Trigger Interlock does not stop
welding when the arc is broken.
Pull and release to end the weld.
J15
USED TO DISCHARGE
POWER SUPPLY CAP
AFTER A HIGH VOLTAGE
TRANSIENT. LATER
RELOCATED TO THE
CONTROL BOARD.
ANALOG
VOLTMETER
21E
10
11
12
P7
4 of 4
575A
576A
577A
Located on Case Front
575A
10K/2W
WIRE FEED SPEED
CONTROL
POTENTIOMETER
B1
534
J4-11 J4-12 J4-6
100K
ohm
J4-9
721
67F
530
J4-7 J4-10 J4-2 J4-1 J5-7 J5-6 J5-5
2
1
3
Located under
Wire Drive Panel
J6-2
J6-3
523
J6-4
J6-6
J6-9 J6-10
+15V
METER
COMPENSATION
CIRCUIT
721 IS DRIVEN NEGATIVE TO COMPENSATE
FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE
35VDC
C2
Model
K2613-1
K2613-2
COM
MOTOR
DRIVE
CIRCUIT
J4-4
Recommended for
CV operation.
(Wire Feed
Module Required)
P60
507 555
J4-8 J4-5
20
ohm
J2-10
607
608
606
605
601
EXTRA
TORQUE
J2-6 J2-3
J2-2
J2-5
J2-1
J2-7
J2-8
+5V
100K
ohm
COM
0V = OFF
20msec ---- 250msec
+5V SPI
+5V
COM
V350
(Common Digital
Controls)
Recommended
for CV
operation.
May be used for
pulse welding if
the welding
procedure is
qualified by the
customer.
DC-400, 600
Recommended
for CV and CC
operation.
J3-8 J3-6
FAN
GAS
FLOW
ENABLE
YELLOW THERMAL LED
+5V SPI
POLARITY LED
J6-14
COM
15
2B
B
WIRE FEED
SPEED
13
COM
ARC ESTABLISHED
FLEXIBLE POWER P.C. BOARD
SCHEMATIC = G4783
J3-7
Control Board Summary
Converts arc power to a usable control circuit voltage.
Receives switch signals from Trigger, Cold Feed, Gas Purge
Reads WFS potentiometer.
Communicates with optional timer kit.
Controls motor speed with PWM.
Turns Gas Solenoid on, off, PWM.
Reads the motor tachometer.
Operating Voltage= 15-110 VDC.
Shut down Voltage= 130 VDC.
Thermal light turns on when shutdown voltage exceeded.
Code and Serial numbers are below Wire Drive on plastic
housing Nameplate.
Thermal “Yellow” Light
Motor Over Current
Motor and trigger disabled for 30 seconds.
Must retrigger to start welding after 30 seconds pass.
Shutdown Voltage exceeded
May occur with some inverters.
May occur with some CC machines with high
inductance.
Polarity “Green” Light
On= Positive Polarity
Off= Negative Polarity
1B
PROGRAM
FAN BLOWS AIR ACROSS
CONTROL PC BOARD
CONTINOUSLY AT 6200 RPMS.
Ranger 250, 305
Commander 300,400,500
(Common Analog
Controls)
Recommended for CV
operation.
TACH
FEEDBACK
GAS PURGE
(LOCATED INSIDEOF
CONTROL BOX)
691
Recommended
all CV
operation.
1
GAS SOLENOID
J4-3
(LOCATED AT REAR
OF FEEDER)
Classic
2
BRAKE
MOTOR VOLTAGE
MOTOR CURRENT
+35V
690
Ranger 8,9
3
4B
BURNBACK
J3-1
J3-2
J3-3
J3-4
J3-5
COM
MACHINE
OUTPUT
ENABLE CONTACTOR DRIVE
-15
0V = MIN SPEED
5V = MAX SPEED
+
22 O COIL
0 VDC OPEN
4 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
4
GAS
ON - OFF
0-5V PULSE SIGNAL
FREQUENCY = SPEED
GAS
SOLENOID
5
DRIVE
0.05K
ohm
GOOD FOR Ar, CO2,
CO2/Ar BLENDS
6
POLARITY
SENSE
DRIVE
PWM
POWER
SUPPLY
BRAKE
J5-8
+15V
J6-7
J6-1
MOV
+15
MOTOR
SUPPLY
OVER
VOLTAGE
PROTECTION
+35V
J5-4 J5-3
+15V
+15V
CC/VV
578
MICRO
CONTROLLER
(OUTSIDE
BACK OF
CASE)
FLOW METER
7
COLD FEED
C1
610
612
2
.05 uF
600 V
LED
ISO
ADJUST VALVE
8
J1-10
+5V SPI +15V
700
400*
Maximum WFS
Feeder Input Volts Standard Gear Extra Torque
15
280
210
17
340
235
21
440
400
24
520
400
27
600
400
4
500
509A
TRIGGER
COM
621
612
CONTACTOR
530
257*
The WFS range of the LN-25 PRO
Normal Speed = 40- 700 IPM.
Extra Torque = 25- 400 IPM.
WFS limited by arc voltage when operating across the arc
509B 601
607 608 606A 605 4B
370
180*
*Extra Torque
JUMPER TOGETHER FOR
EXTRA TORQUE MACHINE
622
587
TRIGGER INTERLOCK / 2 STEP
+15V SPI
+5V SPI
-15V
+15V ISO
+5VDC
POWER
SUPPLY
610
4 O COIL
0 VDC OPEN
3 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
21D
550
551
-
Return to Master TOC
4
+15V
C2
25 TO 35
NORMAL
FLOW
RATE
3
1 of 4
523
10K
ohm
B2
BALL FLOAT
USE MIDDLE
OF BALL TO
SET
Return to Master TOC
509C
509B
2
555
+5V
COM
B1
537
C1
Return to Section TOC
622
ISOLATED 2-4 TO
POWER SOURCE
575A
576A
577A
J5-1
13.5 VDC WHEN
NOT DEPRESSED
3.5
TIMER KIT P.C. BOARD
(OPTIONAL)
SCHEMATIC = M21341
SEE PAGE 2
Connector located
behind case front
6
7
8
MOTOR
SUPPLY
(LOCATED AT OUTSIDE
REAR OF FEEDER)
4.5
Preset
WFS
4
500
Located on
top of motor
After 2-20-2009
Current
Level
0V.=TRIGGER
CLOSED
15VDC.=TRIGGER
OPEN
76C
77C
0 VDC MIN. WFS
5 VDC MAX. WFS
B2
E
622B
P7
531
667
555A
CV
40V MAX.
75C
Preset
WFS
TRIGGER CONNECTOR
J14
TRIGGER
A
INPUT
B
Located on
C
Case Front
D
622A
15V=CV
0V=CC
CC
530A
P16
3.5
509D
S2
721
576A
577A
R1
509E
P7-1
4.5
509B
COLD FEED
3 of 4
NOT PRESENT
ON S27505
GAS PURGE
PUSHBUTTON
SWITCH (N.O.) S4
2-STEP
Before 2-20-2009
Current
Level
case back
strain relief
509E
0V=COLD FEED
(N.O.)
+
-
weld cable
copper bar
S1, S2 & S3 Located
on Wire Drive Panel
S3
667B
copper bar
587
Motor overcurrent limit varies with WFS.
From Power Source
(Electrode Connection)
gun connector
500A
S1
15V=2 STEP
0V=TRIGGER
INTERLOCK
9
10
5 77C
4 76C
3 75C
1
6
2
7
8
67C
67D
EXTRA TORQUE
TRIGGER INTERLOCK
(NOT PRESENT ON K2613-3)
L5
If the feeder is powered-up with the trigger depressed, welding will
not start until the trigger is released and then depressed again.
Notes:
B
Located on Wire
Drive Panel
On power-up, the LN-25 PRO will light the motor thermal LED and
polarity LED 2-3 seconds.
PLASTIC HOUSED BOLTED
CONNECTION (BASE CENTER)
W
L13084 2.6 V @ 25 IPM
32 V @ 400 IPM
J18
R
U
TAKEN WITH 40 V INPUT
IN CV MODE.
67C & 67D
L12081 2.6 V @ 50 IPM
27 V @ 700 IPM
Leads Pass
through
toroid 2 times.
NOT
USED
Gearbox ratio is 23.5:1
Motor resistance
Motor case is at
is 1.5 ohms
electrode potential
Motor is located
behind
glastic panel
FEED
PLATE
MOTOR /
GEARBOX
B
P9
USED FOR FILTERING
INVERTER NOISE
667E
1
2
3
4
5
6
7
8
531
537
534
67B
J61-4
Return to Master TOC
Top of motor
Leads Pass through
toroid 2 times.
667D
14 PIN REMOTE
LEADS ARE
PRESENT BUT
NOT USED IN
THIS UNIT.
72 HZ TO 1.2 KHZ
R-B 15.0 VDC
B-U 6.2 VDC ANY SPEED
(METER DEPENDENT)
667B
IN HARNESS
CENTER BASE
AREA
J61-3
Return to Section TOC
1
67B
-
Located on
Case front
J61-2
621
P17 4
2 of 2
Start-Up
LN-25 PRO WIRE FEEDER
CS0
CS1
CS2
CS3
SCLK
6 1 of 2 P17
When tach feed back is lost,
the voltage to the motor is a
constant 10VDC.
(controlled by software)
MISO
MOSI
3
667C
WORK
CLIP
CHANGE DETAIL: RELEASED A.03 FROM "X".
ENGINEERING CONTROLLED
MANUFACTURER: No
J1-7
J1-9
J1-3
J1-4
J1-5
J1-6
J1-8
G5683-2
Return to Master TOC
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11620, 11621, 11716, 11717 - (G5683-2) pG1
MOTOR FILTER P.C.
BOARD SCHEMATIC=
S27592 BEFORE 6/15/2009
S27505 AFTER 6/15/2009
J61-1
Return to Section TOC
G-10
ElECTriCal DiaGrams
+
Return to Section TOC
G-10
J6-11
1W
J6-12
2W
(LOCATED AT TOP
FRONT OF FEEDER)
YELLOW
MOTOR
THERMAL
LED
14
16
J6-5
708
J6-8
707
GREEN
POLARITY
LED
9
-15V
5
2 of 4
P7
J1-2 J1-1
RED
BLACK
Square Wave TIG 300/355
Not recommended for CC operation
because the customer may
experience short contactor life from
inductive nature of the power source.
Not recommended with high frequency
TIG starti ng.
PROGRAMMING PCB
FACTORY USE ONLY
Miller Inverters
Recommended
for CV voltage
sense operation.
Not
recommended for
use when pulse
welding.
SPI DIGITAlL COMMUNICATION
STT II
Note:
Most semiautomatic wire
welding processes perform
better using constant voltage
Not recommended power sources. Be sure the
for STT operation. proper power source is used
for your application. Contactor
life may be shortened in
applications using CC
machines with high OCV.
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
tpearn
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
MATERIAL TOLERANCE (" t ") TO AGREE
ENYEDY
WITH PUBLISHED STANDARDS.
APPROVED:
BS
DO NOT SCALE THIS DRAWING
SCALE:
NONE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
LN-25 PRO ANALOG
MACHINE SCHEMATIC
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
11/6/2009
PROJECT
NUMBER:
CRM40943
2
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
G5683-1
G5683-2
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
G-11
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11620, 11621, 11716, 11717 - (G5683-2) pG2
G5683-2
Return to Section TOC
G-11
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: RELEASED A.03 FROM "X".
LN-25 PRO WIRE FEEDER
Return to Master TOC
Return to Section TOC
TIMER P. C. BOARD CIRCUIT
Timer Board Summary
Has potentiometers for burnback, postflow and preflow.
Preflow range is 0 to 10 sec.
Burnback range is 0 to 0.25 sec.
Postflow range is 0.25 to 10 sec.
Receives “Gas Flow Enable” signal.
Outputs 100 msec pulses to turn Gas Flow On, Gas Flow Off.
(LOCATED BEHIND WIRE
REEL COVER)
(LOCATED ON CASE FRONT)
ADJUST KNOB
+5V
ADJUST KNOB
ADJUST KNOB
CW= +5
CCW= 0V
+5V
10K
BURNBACK
POT.
PREFLOW
POT.
POSTFLOW
POT.
10K
COM
COM
COM
15V SIGNAL
15 ms PULSES
Return to Master TOC
Return to Section TOC
OUTPUT
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
MICROCONTROLLER
15V
TOGGLE GAS FLOW
ON/OFF
5V
COM
5V SIGNAL
GAS FLOW
ENABLE
J60-8
607
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
608
606A
605
4B
NOT
USED
509B
601
Return to Master TOC
Return to Section TOC
TO CONTROL BD. (VIA P60 plug)
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056 CONTROL:
CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
tpearn
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
ENYEDY
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
APPROVED:
BS
SCALE:
NONE
IF PRINTED
@ A2 SIZE
UNITS:
DO NOT SCALE THIS DRAWING
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
LN-25 PRO ANALOG
MACHINE SCHEMATIC
APPROVAL
11/6/2009
DATE:
PROJECT
NUMBER:
2
2 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
CRM40943
G5683-1
DOCUMENT
REVISION:
G5683-2
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
P7 = 16 PIN
P17 = 6 PIN (Both are located on lower front)
667A
21A
621A
21B
case front
strain relief
667D
D1
551
550
67C
B1
J15
621
P7
4 of 4
575A
576A
577A
Located on Case Front
575A
10K/2W
CC
COLD FEED
509B
CV
40V MAX.
P16
Located on
top of motor
4
2
555
J4-11 J4-12 J4-6
100K
ohm
J4-9
537
21D
550
551
721
67F
530
J4-7 J4-10 J4-2 J4-1 J5-7 J5-6 J5-5
J6-2
J6-3
523
J6-4
TRIGGER
COM
721 IS DRIVEN NEGATIVE TO COMPENSATE
FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE
35VDC
13.5 VDC WHEN
NOT DEPRESSED
MOTOR
DRIVE
CIRCUIT
COM
+5V SPI
+5V
(LOCATED INSIDEOF
CONTROL BOX)
FAN BLOWS AIR ACROSS
CONTROL PC BOARD
CONTINOUSLY AT 6200 RPMS.
Multiweld, Rangers,
Vantages, Flextec
Recommended for CV
and CC operation.
V350
Recommended
for CV
operation.
May be used for
pulse welding if
the welding
procedure is
qualified by the
customer.
DC-400, 600
Recommended
for CV and CC
operation.
J3-8 J3-6
FAN
J3-1
J3-2
J3-3
J3-4
J3-5
COM
-
Classic
Recommended for
CV operation.
(Wire Feed
Module Required)
2
1
P60
J4-8 J4-5
J2-10
607
608
606
605
601
EXTRA
TORQUE
J2-6 J2-3
J2-2
J2-5
J2-1
J2-7
J2-8
+5V
100K
ohm
COM
0V = OFF
20msec ---- 250msec
GAS
FLOW
ENABLE
YELLOW THERMAL LED
+5V SPI
POLARITY LED
J6-14
COM
15
13
1B
COM
ARC ESTABLISHED
FLEXIBLE POWER P.C. BOARD
SCHEMATIC = G4783
J3-7
Control Board Summary
Converts arc power to a usable control circuit voltage.
Receives switch signals from Trigger, Cold Feed, Gas Purge
Reads WFS potentiometer.
Communicates with optional timer kit.
Controls motor speed with PWM.
Turns Gas Solenoid on, off, PWM.
Reads the motor tachometer.
Operating Voltage= 15-110 VDC.
Shut down Voltage= 130 VDC.
Thermal light turns on when shutdown voltage exceeded.
Code and Serial numbers are below Wire Drive on plastic
housing Nameplate.
Thermal “Yellow” Light
Motor Over Current
Motor and trigger disabled for 30 seconds.
Must retrigger to start welding after 30 seconds pass.
Shutdown Voltage exceeded
May occur with some inverters.
May occur with some CC machines with high
inductance.
Polarity “Green” Light
On= Positive Polarity
Off= Negative Polarity
2B
B
WIRE FEED
SPEED
PROGRAM
J4-4
691
Recommended
all CV
operation.
3
GAS SOLENOID
J4-3
(LOCATED AT REAR
OF FEEDER)
TACH
FEEDBACK
GAS PURGE
+35V
690
Ranger 8,9
4
BRAKE
MOTOR VOLTAGE
MOTOR CURRENT
0V = MIN SPEED
5V = MAX SPEED
+
Model
K2613-5
K2613-7
5
4B
BURNBACK
0-5V PULSE SIGNAL
FREQUENCY = SPEED
22 O COIL
0 VDC OPEN
4 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
6
GAS
ON - OFF
-15
COM
0.05K
ohm
GAS
SOLENOID
7
DRIVE
(OUTSIDE
BACK OF
CASE)
FLOW METER
509B 601
POLARITY
SENSE
+15
DRIVE
PWM
POWER
SUPPLY
BRAKE
J5-8
+15V
J6-7
J6-1
+35V
507 555
20
ohm
MICRO
CONTROLLER
METER
COMPENSATION
CIRCUIT
MOTOR
SUPPLY
OVER
VOLTAGE
PROTECTION
MACHINE
OUTPUT
ENABLE CONTACTOR DRIVE
700
400*
Maximum WFS
Feeder Input Volts Standard Gear Extra Torque
15
400
220
17
450
250
21
570
300
24
650
350
27
700
400
COLD FEED
.05 uF
600 V
LED
610
612
MOV
CC/VV
578
J5-4 J5-3
+15V
+15V
TRIGGER INTERLOCK / 2 STEP
+15V SPI
+5V SPI
-15V
+15V ISO
+5VDC
ISO
J6-9 J6-10
+15V
10K
ohm
+15V
621
J6-6
2
500
509A
530
257*
WFS limited by arc voltage when operating across the arc
4
622
587
+5V
COM
(LOCATED AT OUTSIDE
REAR OF FEEDER)
GOOD FOR Ar, CO2,
CO2/Ar BLENDS
High Range
(Red)
50-700
50-400
JUMPER TOGETHER FOR
EXTRA TORQUE MACHINE
534
POWER
SUPPLY
ADJUST VALVE
Low Range
(White)
50-200
50-200
Normal Speed
Extra Torque
ISOLATED 2-4 TO
POWER SOURCE
575A
576A
577A
B1
612
*Extra Torque
Connector located
behind case front
6
7
8
J5-1
610
Preset
WFS
370
180*
CONTACTOR
8
B2
BALL FLOAT
USE MIDDLE
OF BALL TO
SET
4.5
3.5
607 608 606A 605 4B
Located under
Wire Drive Panel
P7
76C
77C
MOTOR
SUPPLY
25 TO 35
NORMAL
FLOW
RATE
3
1 of 4
1
3
case back
strain relief
TIMER KIT P.C. BOARD
(OPTIONAL)
SCHEMATIC = M21341
SEE PAGE 2
4 O COIL
0 VDC OPEN
3 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
2
500
523
509B
4
622
509C
75C
B1
GAS PURGE
PUSHBUTTON
SWITCH (N.O.) S4
15V=CV
0V=CC
S2
530A
P7-1
0 VDC MIN. WFS
5 VDC MAX. WFS
B2
WFS RANGE
SWITCH
509D
721
531
667
509E
After 2-20-2009
Current
Level
TRIGGER Located on
INPUT Case Front
0V.=TRIGGER
CLOSED
15VDC.=TRIGGER
OPEN
Located on
Case Front
622B
587
2-STEP
0V=COLD FEED
(N.O.)
+
-
555A
509E
S3
576A
577A
R1
WIRE FEED SPEED
CONTROL
POTENTIOMETER
TRIGGER
CONNECTOR
J14
A
B
C
D
E
622A
S1, S2 & S3 Located
on Wire Drive Panel
S1
3 of 4
10
11
12
copper bar
500A
TRIGGER INTERLOCK
Motor overcurrent limit varies with WFS.
From Power Source
(Electrode Connection)
weld cable
gun connector
EXTRA TORQUE
Trigger Interlock does not stop
welding when the arc is broken.
Pull and release to end the weld.
21E
67C
67D
L13084-1 2.6 V @ 25 IPM
32 V @ 400 IPM
J18
ANALOG
VOLTMETER
If the feeder is powered-up with the trigger depressed, welding will
not start until the trigger is released and then depressed again.
Notes:
W
15V=2 STEP
0V=TRIGGER
INTERLOCK
667B
On power-up, the LN-25 PRO will light the motor thermal LED and
polarity LED 2-3 seconds.
PLASTIC HOUSED BOLTED
CONNECTION (BASE CENTER)
copper bar
TAKEN WITH 40 V INPUT
IN CV MODE.
67C & 67D
L12081-1 2.6 V @ 50 IPM
27 V @ 700 IPM
L5
9
10
5 77C
4 76C
3 75C
1
6
2
7
8
R
U
B
P9
NOT
USED
Gearbox ratio is 23.5:1
Motor resistance
Motor case is at
is 1.5 ohms
electrode potential
Motor is located
behind
glastic panel
FEED
PLATE
MOTOR /
GEARBOX
B
Located on Wire
Drive Panel
14 PIN REMOTE
LEADS ARE
PRESENT BUT
NOT USED IN
THIS UNIT.
667E
1
2
3
4
5
6
7
8
531
537
534
Leads Pass
through
toroid 2 times.
B2
Return to Master TOC
L4
531
537
534
USED FOR FILTERING
INVERTER NOISE
J61-4
Return to Master TOC
Leads Pass through
toroid2 times.
21C
667D
J61-3
Return to Master TOC
Top of motor
67B
J61-2
Return to Section TOC
1
67B
-
Located on
Case front
72 HZ TO 1.2 KHZ
R-B 15.0 VDC
B-U 6.2 VDC ANY SPEED
(METER DEPENDENT)
667B
IN HARNESS
CENTER BASE
AREA
J61-1
Return to Section TOC
P17 4
2 of 2
Start-Up
LN-25 PRO WIRE FEEDER
J1-10
CS0
CS1
CS2
CS3
SCLK
6 1 of 2 P17
When tach feed back is lost,
the voltage to the motor is a
constant 10VDC.
(controlled by software)
MISO
MOSI
3
667C
WORK
CLIP
CHANGE DETAIL: A.02, COMPLETELY REVISED
ENGINEERING CONTROLLED
MANUFACTURER: No
J1-7
J1-9
J1-3
J1-4
J1-5
J1-6
J1-8
G5683-3
Return to Master TOC
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11746, 11747 - (G5683-3) pG1
MOTOR FILTER P.C.
BOARD SCHEMATIC=
S27505
Return to Section TOC
G-12
ElECTriCal DiaGrams
+
Return to Section TOC
G-12
+5V SPI +15V
J6-11
1W
J6-12
2W
(LOCATED AT TOP
FRONT OF FEEDER)
YELLOW
MOTOR
THERMAL
LED
14
16
J6-5
708
J6-8
707
GREEN
POLARITY
LED
9
-15V
5
2 of 4
P7
J1-2 J1-1
RED
BLACK
Square Wave TIG 300/355
Not recommended for CC operation
because the customer may
experience short contactor life from
inductive nature of the power source.
Not recommended with high frequency
TIG starting.
PROGRAMMING PCB
FACTORY USE ONLY
Miller Inverters
Recommended
for CV voltage
sense operation.
SPI DIGITAlL COMMUNICATION
STT II
Note:
Most semiautomatic wire
welding processes perform
Not recommended better using constant voltage
power
sources. Be sure the
for STT operation.
proper power source is used
for your application. Contactor
life may be shortened in
applications using CC
machines with high OCV.
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: T. PEARN
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
MATERIAL TOLERANCE (" t ") TO AGREE
ENYEDY
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED:
SCALE:
NONE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
LN-25 PRO ANALOG
MACHINE SCHEMATIC
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
1/26/2011
PROJECT
NUMBER:
XM6214-C
2
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
G5683-2
G5683-3
DOCUMENT
REVISION:
A.02
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
G-13
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11746, 11747 - (G5683-3) pG2
G5683-3
Return to Section TOC
G-13
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: A.02, COMPLETELY REVISED
LN-25 PRO WIRE FEEDER
Return to Master TOC
Return to Section TOC
TIMER P. C. BOARD CIRCUIT
Timer Board Summary
Has potentiometers for burnback, postflow and preflow.
Preflow range is 0 to 10 sec.
Burnback range is 0 to 0.25 sec.
Postflow range is 0.25 to 10 sec.
Receives “Gas Flow Enable” signal.
Outputs 100 msec pulses to turn Gas Flow On, Gas Flow Off.
(LOCATED BEHIND WIRE
REEL COVER)
(LOCATED ON CASE FRONT)
ADJUST KNOB
+5V
ADJUST KNOB
ADJUST KNOB
CW= +5
CCW= 0V
+5V
10K
BURNBACK
POT.
PREFLOW
POT.
POSTFLOW
POT.
10K
COM
COM
COM
15V SIGNAL
15 ms PULSES
Return to Master TOC
Return to Section TOC
OUTPUT
TIMER KIT
(OPTIONAL)
SCHEMATIC =
M21342
MICROCONTROLLER
15V
TOGGLE GAS FLOW
ON/OFF
5V
COM
5V SIGNAL
GAS FLOW
ENABLE
J60-8
607
J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
608
606A
605
4B
NOT
USED
509B
601
Return to Master TOC
Return to Section TOC
TO CONTROL BD. (VIA P60 plug)
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056 CONTROL:
CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: T. PEARN
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
ENYEDY
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
APPROVED:
-
SCALE:
NONE
IF PRINTED
@ A2 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
LN-25 PRO ANALOG
MACHINE SCHEMATIC
APPROVAL
1/26/2011
DATE:
PROJECT
NUMBER:
2
2 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
XM6214-C
G5683-2
DOCUMENT
REVISION:
G5683-3
A.02
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 1
3 J1
6 J1
9 J1
8 J1
R185
332
R186
332
R69
332
R187
332
R51
332
R68
332
/SS_P
MOSI_P
SCK_P
7 J1 MISO_P
475
0.1W
R35
C24
22pF
50V
R34
2
R30
3
13V_SENSE
R48
SPIBUS
221
0.1W
RXD
4.75K
0.1W
10 J1
GND
D55
0.2A
30V
3
3
1 2
475
0.1W
R50
DZ13
5.1V
0.5W
TXD
DATA
DATA
SCLK
SCLK
XRES
XRES
GAS_FLOW
D6
0.2A
30V
1 2
GND
1
GND
3
+5V
1
D53
0.2A
30V
3
10K
0.063W
2
D54
0.2A
30V
+5SPI
CS1
R188
100 0.1W
CS2
R189
100 0.1W
SS
R67
100 0.1W
CS3
R190
100 0.1W
SPI_MOSI
R49
100 0.1W
SPI_SCLK
R66
100 0.1W
1
2 A
5
VCC
LVC1G14GW
Y 4
X1
GND
RS232_RX
RXD
RS232_TX
RS232_TX
TXD
10K
0.063W
4
DATA
J3
3
SCLK
J3
J3
2
C21
0.1uF
50V
R231
R230
L2
600 OHMS J2
C72
0.1uF
50V
1
+5V
+15V
5
100K
0.1W
100
0.1W
BB
POT
+15V
J2
1.82K
D5
0.2A
30V
R9
R58
R156
150K
GND
10K
0.063W
C66
0.1uF
50V
1
OCI1
4
S
2
2
1
OCI1
100
0.1W
10K
0.063W
100
0.1W
GND
R24
100
0.1W
J2
6
GAS FLOW
ENABLE
80J
MOV2
150V
80J
Q13
0.115A
60V
R95
200
Q14
0.115A
60V
Q12
0.115A
60V
R15
20
5W
+5V
J5
4
J5
3
+35V_SENSE
J6 13
J6 12
R96
200
+35V
2
10K
0.063W
GND
J6 14
J6 11
R94
200
GND
OUTPUT4
Q11
0.115A
60V
+5SPI
10K
0.063W
5
6
10K
0.063W
GND
GND
1.82K
ARC SENSE
155.0V = 5.00V
R146
1
R157
2
OUTPUT2
+5V
3
100
0.1W
1
GND
7
667
150K
CW
J2
R25
100
0.1W
+5V
2
GND
R27
10K
0.1W
XRES
PROGRAMMING
10K
0.063W
STATUS_LED
+5V
2
RS232
GND
5
R32
1K
0.063W
D2
0.2A
30V
1
GND
3
+35V SUPPLY
VOLTAGE
SENSE
26.7K
45.2V = 5.00V
C23
0.1uF
50V
3.32K
0.063W
+15V
GND
C52
0.1uF
50V
11
Vdd
X7
2113
Vss
15
14
C51
0.1uF
50V
X8
HC132
7
C28
0.1uF
50V
15
Vcc
X2
MAX3221
GND
14
82 32 83 14
C38 AVDD VDD SMP
X3
0.1uF
CY8C29866
50V
VSS
15 34 65 84 85
4
3
Vcc
C33
0.1uF
50V
C54
0.1uF
50V
X7
2113
GND
2
C45
0.1uF
50V
LAST NO. USED
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
X6
33074ADT
C-
232 X- 14
73 Q- 14
D-
56
R-
LABELS
OCI- 1 T- 2
LED- 1 L- 3
DZ- 18 MOV- 2
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
11
COMMON CONNECTION
FRAME CONNECTION
MISO
C34
0.1uF
50V
NC GND
1 3
5 J3
6 J3
R106
200
R107
200
R108
200
+5V
J3
GND
RS232_RX
D4
0.2A
30V
475
R28
BURNBACK
16.5K
0.1W
GND
8 J3
1 J3
D3
0.2A
30V
R29
1K
0.063W
LED
OUT_2_4
TRIGGER
Q4
0.5A
40V
C43
0.1uF
50V
47.5K
0.1W
OUT_2_4
47.5K
0.1W
C22
0.1uF
50V
J4
SOL
R42
500
82.5K
0.1W
ARC_VSENSE
+5SPI
D9
0.2A
30V
C65
0.1uF
50V
35V_SENSE
COM_ISO2
4
Q2
47A
55V
+5V
LED
TRIGGER
V13_VSENSE
332
R82
R8
VM_LIM
J4
GND
38.2V = 5.00V
LED[1]
POLARITY_SENSE
+5V
4.75K
0.1W
2
GND
R219
+15V
500
1
1
R33
1K
0.063W
GND
J6 16
5V_ISO2
R4
3
+5SPI
CC_SENSE
10K
0.063W
R212
15 J6
COM_ISO2
3
8
CONT
Q3
47A
55V
667
R153
100K
100K
R218
5V_ISO2
J4
J4
R31
4 J1
5 J1
3
CC_SENSE
2
THERMAL_LED
624
+5V
D10
0.2A
30V
3
CONTACTOR_DRIVE
ARCV_SENSE
+15V
D12
1A/FR
400V
R57
200
R59
200
3
5VSPI_SUPPLY
+5SPI
2
D13
1A/FR
400V
+5V
D1
0.2A
30V
539
(WH)
+35V
MOTOR_SUPPLY
GND
1 J1
2 J1
PSOC
-15V +5V +5SPI
15VDC_SUPPLY
NEG15V_SUPPLY
2
0.05
5W
GND
SOLENOID_DRIVE
PWM_CONT
5.0VDC_SUPPLY
5.1V
3W
DZ3
+15V
Return to Master TOC
POWER_SUPPLY
667
C44
0.1uF
50V
D24
1A/FR
400V
C55
330pF
100V
35VDC_SUPPLY
667
J4
DZ15
18V
0.5W
26.7K
0.1W
R83
R213
R7
121
1W
CONFIG[3]
R80
R6
121
1W
15V_ISO_COM
MOTOR
CONFIG[0..3]
WFS_POT
+15V
BRAKE
Q9
26A
600V
R118
150
541
(BLK)
1
GND
1
PWM_SOL
WFS
+VM +35V
12
4.75K
0.063W
R217
475
R40
X6
14
33074ADT
R144
10 J6
500A
R3
121
1W
CONFIG[1]
CONFIG[2]
R23
1K 0.063W
3
ISO
J4
J4-1
R102
D31
15 1A/FR
400V
1K
0.063W
R84
R214
GND
R20
1K 0.063W
+5V
R21
1K 0.063W
20K
0.1W
2.67K
0.063W
R103
D23
0.2A
30V
C46
0.1uF
50V
2
DZ14
18V
0.5W
GND
13
R191
1
R22
1K 0.063W
D26
3A
600V
PWM
Q5
47A
600V
Q5-G
1K
GND
R109
1 J5
8 J5
R5
121
1W
1
COLD_FEED
R226
R38
TRIGGER
9 J2
10 J2
CONFIG[0..3]
CONFIG[0]
+15V_ISO
R81
Return to Master TOC
9 J6
622A
2
4 J2
15V_ISO
ARC VOLTS READ
5 J5
C49
0.1uF
50V
+5V
C30
0.1uF
50V
ELECTRODE ELECTRODE
C15
0.05uF
POLARITY_SENSE POLARITY_SENSE
600V
WORK
METER_COMP METER_COMP
WORK
6 J5
VIM_PEAK = ((+5V - (IPK*RS))*R2.67/(R2.67+R20+RS))
+ (IPK*RS)
IM_PEAK
15AMPS = 1.25VDC
+5V
R85
26.7K
0.1W
R216
2
GND
7 J5
HIGH TORQUE
8 J2
ISO
621
D25
0.2A
30V
3
IM_PEAK
Vs 6
LO 1
C75
82uF
35V
R215
D8
0.2A
30V
3
GND
INPUT POWER
C50
0.1uF
50V
2K
0.1W
GND
R39
10K
0.1W
100K
0.1W
667
IM_AVE
VAVE = 0.331*IAVE
+5V
GND
7 J2
GND
R230-R231
R110
100
R56
R44
C42
0.1uF
50V
2K
0.1W
R90
C41
0.1uF
50V
2K
0.1W
C48
0.1uF
50V
R91
2K
0.1W
R78
2K
0.1W
C73
0.1uF
50V
11 J4
1
D21
0.2A
30V
3
C53
0.1uF
50V
26.7K
0.1W
R105
CV_CC
L3
600 OHMS
12 J4
2
1
D20
0.2A
30V
3
TRIG_INLK_2_STEP
CW
WFS
POT
2
Vb 7
HO 8
2113
GND
BRAKE
GAS_PURGE
+5V
6 J4
1
D16
0.2A
30V
3
R100
100
X7
12 HIN
13 SD
14 LIN
Q7
0.115A
60V
GND
IM_AVE
2
1
D22
0.2A
30V
3
R88
COLD_FEED
10K
Return to Master TOC
CV_CC
11
X8
HC132
13
CUR_SENSE
R77
4.75K
R93
4.75K
R89
4.75K
R92
4.75K
R79
4.75K
3 J6
4 J6
2 J6
TRIG_INLK_2_STEP
2
1
D17
0.2A
30V
3
R76
5 J6
1 J6
CUR_SENSE
12
3.32K
0.1W
GAS_ON_OFF
C31
0.1uF
50V
1K
0.1W
X8
HC132
1
GND
2
Return to Section TOC
1
X8
HC132
5
PWM_MOTR
+5V
-15V
Return to Section TOC
GAS_ON_OFF
+15V
GAS_PURGE
PSOC
+5V
10K
D7
3 0.2A
70V
R43
2.21K
0.1W
TACH_IN
2
R87
TACH
X7-8
3
R154
8
X8
HC132
10
3 J2
GAS ON/OFF
GND
1K
R101
R99
100
6
2
R155
9
4
+VM
D30
1A/FR
400V
4.75K
0.063W
GND
R145
10 J4
BLACK
+15V_ISO
R26
7 J4
BLUE
1
D32
0.2A
30V
3
0.063W
10K
10K
0.063W
R98
C58
100pF
100V
R104
2
R225
9 J4
RED
+5V
+5V
+15V
TACHOMETER
6 J6
7 J6
8 J6
Return to Section TOC
G-14
ElECTriCal DiaGrams
R97
Return to Master TOC
Return to Section TOC
G-14
GND
GND
GND
MAIN
-15V
EARTH GROUND CONNECTION
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 01 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
PROJECT
MATERIAL
4745-1H0
A
G
XX-XX-XXX
CRM39801
NUMBER:
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: JPZ
10/20/2009
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: JPZ
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED:
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
Return to Section TOC
G-15
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 2
CC_SENSE
Return to Master TOC
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35V_SENSE
WFS_POT
BURNBACK
SCLK
SPIBUS
PWM_MOTR
SPI_MOSI
SPI_SCLK
PWM_SOL
IM_PEAK
IM_AVE
13V_SENSE
ARCV_SENSE
DATA
TACH_IN
PWM_CONT
POLARITY_SENSE
TRIGGER
BRAKE
MISO
CS1
CS2
CS3
SS
Return to Master TOC
XRES
Return to Section TOC
G-15
ElECTriCal DiaGrams
IM_PEAK 74 P0[0]
CC_SENSE 3 P0[1]
IM_AVE 77 P0[2]
35V_SENSE 99 P0[3]
13V_SENSE 79 P0[4]
WFS_POT 97 P0[5]
ARCV_SENSE 81 P0[6]
BURNBACK 95 P0[7]
DATA 44 P1[0]
SCLK 30 P1[1]
TACH_IN 45 P1[2]
PWM_MOTR 29 P1[3]
PWM_CONT 46 P1[4]
PWM_SOL 28 P1[5]
47 P1[6]
24 P1[7]
68 P2[0]
POLARITY_SENSE 7 P2[1]
69 P2[2]
6 P2[3]
TRIGGER
70 P2[4]
5 P2[5]
BRAKE 72 P2[6]
MISO
4 P2[7]
56 P3[0]
19 P3[1]
57 P3[2]
18 P3[3]
58 P3[4]
17 P3[5]
59 P3[6]
16 P3[7]
XRES 62 XRES
1 NC1
2 NC2
12 NC12
13 NC13
25 NC25
26 NC26
27 NC27
31 NC31
33 NC33
35 NC35
48 NC48
49 NC49
50 NC50
X3
CUR_SENSE
P4[0] 63 CUR_SENSE
GAS_PURGE
P4[1] 11 GAS_PURGE
TRIG_INLK_2_STEP
P4[2] 64 TRIG_INLK_2_STEP
CV_CC
P4[3] 10 CV_CC
COLD_FEED
P4[4] 66 COLD_FEED
P4[5] 9
LED
P4[6] 67
LED
P4[7] 8
THERMAL_LED
P5[0] 52
LED[1]
P5[1] 23
STATUS_LED
P5[2] 53
P5[3] 22
GAS_ON_OFF
P5[4] 54
GAS_FLOW
P5[5] 21
P5[6] 55
P5[7] 20
P6[0] 86 RXD
RXD
TXD
P6[1] 87 TXD
P6[2] 88
P6[3] 89
P6[4] 90 OUT_2_4
OUT_2_4
P6[5] 91
P6[6] 92
CONFIG[0..3]
P6[7] 93
CONFIG[0]
P7[0] 43
CONFIG[1]
P7[1] 42
CONFIG[2]
41
P7[2]
CONFIG[3]
P7[3] 40
P7[4] 39
P7[5] 38
P7[6] 37
P7[7] 36
NC51 51
NC60 60
NC61 61
NC71 71
NC73 73
NC75 75
NC76 76
NC78 78
NC80 80
NC94 94
NC96 96
NC98 98
NC100 100
CY8C29866
Return to Master TOC
Return to Section TOC
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SEE PAGE 1
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
PSOC
EARTH GROUND CONNECTION
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 02 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
PROJECT
MATERIAL
4745-1H0
A
G
9-12-2008 NUMBER: CRM39801
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: JPZ
9/24/2009
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: JPZ
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED:
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-16
G-16
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 3
RXD
RS232_TX
RXD
RS232_TX
+5V
R19
200
R37
3.32K
0.1W
MAX3221
9 ROUT
13 DOUT
10 INVALID X2
12 FORCEON
16 FORCEOFF
RIN 8
DIN 11
C2- 6
C2+ 5
V- 7
V+ 3
C1- 4
C1+ 2
EN 1
0.1uF 50V
C25
0.1uF
C29
R36
200
TXD
RS232_RX
RS232_RX
TXD
50V
C27
0.1uF
50V
C26
0.1uF
50V
GND
Return to Master TOC
Return to Section TOC
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SEE PAGE 1
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
RS232
EARTH GROUND CONNECTION
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 03 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
PROJECT
MATERIAL
4745-1H0
A
G
9-12-2008
CRM39801
NUMBER:
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: JPZ
9/24/2009
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: JPZ
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED:
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
Return to Master TOC
G-17
ElECTriCal DiaGrams
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 4
+15V
D50
0.2A
30V
3
2
+5V
1
-15V
ELECTRODE
R180
221K
R175
221K
R176
221K
2
X6
1
33074ADT
3
3
R177
221K
1
D51
0.2A
70V
2
R182
3.32K
3
221K
GND
WORK
R174
221K
R173
221K
R179
221K
-15V
3
6
5
GND
X6
7
33074ADT
GND
C70
0.1uF
50V
R183
3.32K
1
D52
0.2A
70V
2
METER_COMP
R170
20K
0.1W
3
R171
D14
0.2A
30V
1
1
GND
R178
221K
+15V
2
D18
0.2A
30V
2
POLARITY_SENSE
R184
2.21K
R181
Return to Section TOC
Return to Section TOC
G-17
475
R172
10K
C71 0.1W
0.1uF
50V
9
10
X6
+15V
8
3
33074ADT
D19
0.2A
30V
2
1
-15V
Return to Master TOC
Return to Section TOC
GND
Return to Master TOC
Return to Section TOC
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SEE PAGE 1
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
ARC VOLTS READ
EARTH GROUND CONNECTION
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 04 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
PROJECT
MATERIAL
4745-1H0
A
G
9-12-2008 NUMBER: CRM39801
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: JPZ
9/24/2009
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: JPZ
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED:
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 5
D28
3A
600V
R114
IN
R115
C2
82uF
35V
15VDC_SUPPLY
OUT
X5
78M15
GND
2K
2K
T1-10
R119
R120
1
1
1
1
1
1
R199
1
1
R202
1
R197
1
R200
C60
100pF
100V
3.32K
0.063W
R131
C61
0.0047uF
50V
R198
3
2
D41
1A
400V
3.01K
0.1W
3.01K
0.1W
R152
332
D27
3A
40V
C4
0.001F
35V
D33
1A
600V
C6
82uF
35V
2K
2K
100
C56
0.1uF
50V
GND
IN
D38
1A
400V
DZ11
15V
3W
1
100
C5
220uF
25V
DZ18
3.3V
0.5W
D40
1A
400V
332
R151
R195
C7
220uF
25V
D29
0.2A
30V
C59
150pF
100V
R121
1K
0.063W
5VSPI_SUPPLY
GND
4
R196
DZ5
17V
5W
VREF
RT/CT
VFB
COMP
2843BD1
CS
X10
3
DZ16
18V
0.5W
R192
7 VCC
6 OUT
5 GND
8
4
2
1
3
100K 0.063W
R122
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C19
0.1uF
630V
22.1K
0.063W
R128
2.21K 0.063W
R129
D39
1A
400V
Q8
20A
600V
33.2
R130
D47
3A
600V
1
2
R193
D43
1A
600V
L1
10uH
1.02A
R117
C12
0.0033uF
630V
R194
D48
15A
600V
T1
T1-9
5VSPI_SUPPLY
R116
R11
R13
5.1K
5W
GND
T1 10
9
58P6091
R127
D46
3A
600V
15VDC_SUPPLY
C3
220uF
25V
R126
624
R138
10 0.5W
R137
10 0.5W
R136
10 0.5W
R135
10 0.5W
624
5.1K
5W
Return to Section TOC
G-18
ElECTriCal DiaGrams
R143
10 0.5W
R142
10 0.5W
R141
10 0.5W
R140
10 0.5W
Return to Master TOC
Return to Section TOC
G-18
R220
100
LED1
IN
C10
82uF
35V
DZ10
15V
3W
X12
7805
GND
OUT
OUT
X9
79M15
NEG15V_SUPPLY
5.0VDC_SUPPLY
C9
82uF
35V
5
GND
T1-5
D34
1A
600V
15V_ISO
D34-C
6 T1
58P6091
C62
0.1uF
50V
C74
82uF
35V
DZ19
18V
0.5W
ISO
R169
10 0.5W
R168
10 0.5W
R165
10 0.5W
R164
10 0.5W
4
R167
10 0.5W
R166
10 0.5W
R163
10 0.5W
R162
10 0.5W
6 T2
TX06101B
C16
0.0033uF
630V
1K
DZ9
3.3V
3W
C18
82uF
35V
1
C67
100pF
100V
R12
2
3.92K
1W
301
0.1W
1A/FR
400V
D35
8
IN
C64
1uF
35V
X11
1
78L05A
OUT
GND
2 3 6 7
5V_ISO2
C11
1uF
35V
COM_ISO2
5V_ISO2
COM_ISO2
3.32K
0.063W
R149
C69
0.0047uF
50V
+5V
1
1
1
1
1
1
1
1
1
1
R111
C13
1uF
63V
R150
3
D44
0.2A
30V
MOTOR_SUPPLY
R148
1K
0.063W
R211
C20
180uF
350V
C68
150pF
100V
R209
DZ8
30V
3W
8
4
2
1
3
D56
DZ17
0.5A
18V
30V
0.5W
22.1K 0.1W
R161
2.21K 0.063W
R160
R210
OVERVOLTAGE
SHUTDOWN
113 - 126VDC
VREF
RT/CT
VFB
X13
COMP
2843BD1
CS
7 VCC
6 OUT
5 GND
T1-7
8 T1
58P6091
R207
DZ7
30V
3W
7
R208
GND
MOTOR_SUPPLY
C8
5.1K
470uF
5W
350V
GND
Q10
47A
600V
R227
15
R222
15
R205
DZ6
30V
3W
35VDC_SUPPLY
C17
0.012F
50V
R147
VS8 8
OUT7 7
OUT6 6
MIC4452YM GND5 5
X14
R206
1 VS1
2 IN
4 GND4
R203
DZ12
43V
1W
R201
D42
1A
400V
C14
470uF
350V
GND
R204
301
667
D45
8A
1000V
T2 1
3
TX06101B
D37
30A
600V
R14
D36
15A
600V
100K 0.063W
R159
R223
R224
2.67K
R139
Return to Master TOC
Return to Section TOC
15V_ISO_COM
2.67K
4.75K
0.063W
VM_LIM
GND
R112
33.2K
0.063W
Q6
0.5A
40V
R113
Return to Master TOC
Return to Section TOC
GND
39.2K
0.1W
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
C57
0.022uF
50V
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SEE PAGE 1
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
GND
FRAME CONNECTION
POWER SUPPLY
EARTH GROUND CONNECTION
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 05 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
PROJECT
MATERIAL
4745-1H0
A
G
XX-XX-XXXXNUMBER: CRM39801
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: JPZ
9/30/2009
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: JPZ
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED:
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 1
9 J1
8 J1
MOSI_P
SCK_P
R34
2
4.75K
0.1W
GND
D9
0.2A
30V
D55
0.2A
30V
3
1 2
D6
0.2A
30V
1 2
1
GND
2
D53
0.2A
30V
3
D54
0.2A
30V
5
VCC
LVC1G14GW
Y 4
X1
C34
0.1uF
50V
NC GND
1 3
GND
5 J3
6 J3
SPIBUS
TXD
DATA
DATA
SCLK
SCLK
XRES
XRES
GAS_FLOW
10K
0.063W
R106
200
R107
200
R108
200
+5V
10K
0.063W
J3
4
DATA
J3
3
SCLK
J3
J3
2
RS232_TX
RS232_TX
100K
0.1W
7
D5
0.2A
30V
+5V
+15V
+5V
R9
1
R58
R156
150K
GND
R230
+15V
10K
0.063W
J2
1
1.82K
100
0.1W
10K
0.063W
100
0.1W
1
OCI1
OCI1
4
S
6
R24
100
0.1W
J2
6
GAS FLOW
ENABLE
TP1
150V
80J
Q13
0.115A
60V
R95
200
Q14
0.115A
60V
Q12
0.115A
60V
R15
20
5W
+5V
J5
4
J5
3
+35V_SENSE
J6 13
J6 12
R96
200
+35V
2
10K
0.063W
GND
J6 14
J6 11
GND
OUTPUT4
Q11
0.115A
60V
GND
5
+5SPI
10K
0.063W
OUTPUT2
1
10K
0.063W
R94
200
GND
1.82K
ARC SENSE
155.0V = 5.00V
STATUS_LED
LED[1]
100
0.1W
2
RS232
GND
BB
POT
2
R25
100
0.1W
TXD
100
0.1W
+5V
PROGRAMMING
RXD
5
GND
3
2
CW
J2
XRES
GND
RS232_RX
C21
0.1uF
50V
2
GND
R27
10K
0.1W
667
150K
GND
R219
16.5K
0.1W
1
5
10K
0.063W
C66
0.1uF
50V
R212
BURNBACK
L2
600 OHMS J2
C72
0.1uF
50V
R218
13V_SENSE
475
R28
+5V
2
R217
35V_SENSE
3
V13_VSENSE
THERMAL_LED
OUT_2_4
D4
0.2A
30V
J4
SOL
R157
D3
0.2A
30V
R29
1K
0.063W
LED
47.5K
0.1W
RS232_RX
R32
1K
0.063W
D2
0.2A
30V
1
GND
3
+35V SUPPLY
VOLTAGE
SENSE
26.7K
45.2V = 5.00V
C23
0.1uF
50V
+15V
3.32K
0.063W
GND
LAST NO. USED
GENERAL INFORMATION
C52
0.1uF
50V
MISO
47.5K
0.1W
ARC_VSENSE
+15V
RXD
1
82.5K
0.1W
4
Q2
47A
55V
+5V
OUT_2_4
DUAL_P_TRIGGER
C22
0.1uF
50V
CS1
R188
100 0.1W
CS2
R189
100 0.1W
SS
R67
100 0.1W
CS3
R190
100 0.1W
SPI_MOSI
R49
100 0.1W
SPI_SCLK
R66
100 0.1W
R231
R56
C65
0.1uF
50V
J4
GND
38.2V = 5.00V
LED
TRIGGER
VM_LIM
8 J3
1 J3
2 A
GND
R213
POLARITY_SENSE
DUAL_P_TRIGGER
GND
10K
0.063W
GND
221
0.1W
+5SPI
1
R33
1K
0.063W
3
8
R146
CC_SENSE
CC_SENSE
R57
200
R59
200
J4
J4
CONT
Q3
47A
55V
667
R153
100K
100K
R214
J6 16
COM_ISO2
1
R87
+5V
+5SPI
3
+5V
CONTACTOR_DRIVE
ARCV_SENSE
Q1
0.5A
40V
C1
0.1uF
50V
DZ1
5.1V
3W
PWM_SOL
PWM_CONT
R216
15 J6
5V_ISO2
D12
1A/FR
400V
R42
332
R10
R13
D13
1A/FR
400V
2
539
(WH)
+35V
SOLENOID_DRIVE
D1
0.2A
30V
2
0.05
5W
GND
3
15VDC_SUPPLY
COM_ISO2
DZ15
18V
0.5W
C55
330pF
100V
3
MOTOR
J4
C44
0.1uF
50V
D24
1A/FR
400V
541
(BLK)
1
GND
1
R191
4.75K
0.1W
221
0.1W
12
4.75K
0.063W
BRAKE
Q9
26A
600V
26.7K
0.1W
R83
1K
0.063W
R84
MOTOR_SUPPLY
+5V
Q4
0.5A
40V
13
J4
J4-1
R118
150
GND
R144
5V_ISO2
3
ISO
R215
15V_ISO_COM
-15V +5V +5SPI
GND
3
475
0.1W
R50
DZ13
5.1V
0.5W
10 J1
R90
R91
R78
4.75K
0.1W
C43
0.1uF
50V
2
PSOC
WFS_POT
5VSPI_SUPPLY
+5V
500
1
+5V
TRIGGER
500
D10
0.2A
30V
3
CONFIG[3]
R20
1K 0.063W
+15V
D23
0.2A
30V
C46
0.1uF
50V
2
14
33074ADT
DZ14
18V
0.5W
1K
R102
D31
15 1A/FR
400V
D26
3A
600V
X6
PWM
Q5
47A
600V
Q5-G
CONFIG[1]
WFS
+VM +35V
20K
0.1W
2.67K
0.063W
R103
35VDC_SUPPLY
624
332
R82
3
+5SPI
475
0.1W
R35
C24
22pF
50V
GND
Vs 6
LO 1
C75
82uF
35V
GND
4 J2
475
R40
500
R8
R230-R231
R110
100
R31
R185
332
R186
332
R69
332
R187
332
R51
332
R68
332
/SS_P
7 J1 MISO_P
1
POWER BRAZER
GND
2
1
CONFIG[0]
NEG15V_SUPPLY
5.0VDC_SUPPLY
+5SPI
4 J1
5 J1
3 J1
6 J1
+5V
ISO
R4
R17
121
1W
1 J1
2 J1
HIGH TORQUE
8 J2
R21
1K 0.063W
9 J2
R22
1K 0.063W
C49
0.1uF
50V
POWER_SUPPLY
R16
121
1W
2
COLD_FEED
+15V_ISO
+5V
+15V
C50
0.1uF
50V
2K
0.1W
667
GND
10 J2
2
C30
0.1uF
50V
5.1V
3W
DZ3
DUAL_P_TRIGGER
D8
0.2A
30V
3
667
R7
121
1W
IM_PEAK
VIM_PEAK = ((+5V - (IPK*RS))*R2.67/(R2.67+R20+RS))
+ (IPK*RS)
IM_PEAK
15AMPS = 1.25VDC
+5V
R85
26.7K
0.1W
10K
R6
121
1W
D25
0.2A
30V
3
R109
500A
2K
0.1W
15V_ISO
R3
121
1W
GND
R226
10 J6
1
D21
0.2A
30V
3
R2
R5
121
1W
2
1
D20
0.2A
30V
3
7 J2
R1
622A
TRIGGER
C42
0.1uF
50V
R80
9 J6
2K
0.1W
C48
0.1uF
50V
R88
C41
0.1uF
50V
R81
5 J5
2
GND
1 J5
8 J5
667
621
IM_AVE
VAVE = 0.331*IAVE
+5V
R30
R39
10K
0.1W
100K
0.1W
R38
6 J5
Return to Master TOC
2K
0.1W
GND
ELECTRODE ELECTRODE
C15
0.05uF
POLARITY_SENSE POLARITY_SENSE
600V
WORK
METER_COMP METER_COMP
WORK
+15V
ARC VOLTS READ
7 J5
Return to Master TOC
2K
0.1W
GND
11 J4
1
D16
0.2A
30V
3
C53
0.1uF
50V
26.7K
0.1W
R105
CV_CC
C73
0.1uF
50V
12 J4
2
1
D22
0.2A
30V
3
Vb 7
HO 8
2113
GND
IM_AVE
GND
CW
INPUT POWER
13
R100
100
BRAKE
TRIG_INLK_2_STEP
L3
600 OHMS
6 J4
WFS
POT
11
X8
HC132
X7
12 HIN
13 SD
14 LIN
Q7
0.115A
60V
GND
GAS_PURGE
+5V
10K
Return to Master TOC
Return to Section TOC
COLD_FEED
12
3.32K
0.1W
CUR_SENSE
R77
4.75K
R93
4.75K
R89
4.75K
R92
4.75K
R79
4.75K
3 J6
4 J6
2 J6
CV_CC
2
1
D17
0.2A
30V
3
R76
5 J6
1 J6
TRIG_INLK_2_STEP
1
X7-8
3
X8
HC132
GAS_ON_OFF
C31
0.1uF
50V
1K
0.1W
6
GND
2
GAS_PURGE
5
PWM_MOTR
+5V
-15V
Return to Section TOC
GAS_ON_OFF
1
+15V
CUR_SENSE
PSOC
+5V
X8
HC132
R154
D7
3 0.2A
70V
R43
2.21K
0.1W
TACH_IN
2
R44
GND
1K
R101
3 J2
GAS ON/OFF
X8
HC132
10
TACH
2
R155
R99
100
8
4
R145
10 J4
BLACK
9
+VM
D30
1A/FR
400V
4.75K
0.063W
GND
R48
BLUE
+15V_ISO
R26
7 J4
1
D32
0.2A
30V
3
0.063W
10K
10K
0.063W
R98
C58
100pF
100V
R104
2
R225
9 J4
RED
+5V
+5V
+15V
TACHOMETER
6 J6
7 J6
8 J6
Return to Section TOC
G-19
ElECTriCal DiaGrams
R97
Return to Master TOC
Return to Section TOC
G-19
11
Vdd
X7
2113
Vss
15
GND
14
C51
0.1uF
50V
X8
HC132
7
C28
0.1uF
50V
15
Vcc
X2
MAX3221
GND
14
82 32 83 14
C38 AVDD VDD SMP
X3
0.1uF
CY8C29866
50V
VSS
15 34 65 84 85
C33
0.1uF
50V
C54
0.1uF
50V
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
4
3
Vcc
X7
2113
GND
2
C45
0.1uF
50V
X6
33074ADT
GND
LABELS
Q- 14
T- 2
TP- 1
X- 14
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
11
-15V
C-
COMMON CONNECTION
FRAME CONNECTION
MAIN
GND
232 DZ- 19
L- 3
73
LED- 1
D- 56 OCI- 1
R-
EARTH GROUND CONNECTION
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 01 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
MATERIAL
A
10-23-2009 PROJECT
NUMBER: CRM40617 G 4783-1C0
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: APM
9/3/2010
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: APM
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED:
DRS
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
Return to Section TOC
G-20
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 2
CC_SENSE
Return to Master TOC
Return to Section TOC
35V_SENSE
WFS_POT
BURNBACK
SCLK
SPIBUS
PWM_MOTR
SPI_MOSI
SPI_SCLK
PWM_SOL
IM_AVE
13V_SENSE
ARCV_SENSE
DATA
TACH_IN
PWM_CONT
POLARITY_SENSE
POLARITY_SENSE
TRIGGER
BRAKE
XRES
Return to Master TOC
IM_PEAK
CC_SENSE
IM_AVE
35V_SENSE
13V_SENSE
WFS_POT
ARCV_SENSE
BURNBACK
DATA
SCLK
TACH_IN
PWM_MOTR
PWM_CONT
PWM_SOL
IM_PEAK
MISO
CS1
CS2
CS3
SS
Return to Section TOC
G-20
ElECTriCal DiaGrams
TRIGGER
BRAKE
MISO
XRES
74 P0[0]
3 P0[1]
77 P0[2]
99 P0[3]
79 P0[4]
97 P0[5]
81 P0[6]
95 P0[7]
44 P1[0]
30 P1[1]
45 P1[2]
29 P1[3]
46 P1[4]
28 P1[5]
47 P1[6]
24 P1[7]
68 P2[0]
7 P2[1]
69 P2[2]
6 P2[3]
70 P2[4]
5 P2[5]
72 P2[6]
4 P2[7]
56 P3[0]
19 P3[1]
57 P3[2]
18 P3[3]
58 P3[4]
17 P3[5]
59 P3[6]
16 P3[7]
62 XRES
1 NC1
2 NC2
12 NC12
13 NC13
25 NC25
26 NC26
27 NC27
31 NC31
33 NC33
35 NC35
48 NC48
49 NC49
50 NC50
X3
P4[0] 63 CUR_SENSE
P4[1] 11 GAS_PURGE
P4[2] 64 TRIG_INLK_2_STEP
P4[3] 10 CV_CC
P4[4] 66 COLD_FEED
P4[5] 9
LED
P4[6] 67
P4[7] 8
THERMAL_LED
52
P5[0]
LED[1]
P5[1] 23
STATUS_LED
P5[2] 53
P5[3] 22
P5[4] 54
P5[5] 21
P5[6] 55
P5[7] 20
P6[0] 86 RXD
P6[1] 87 TXD
P6[2] 88
P6[3] 89
P6[4] 90 OUT_2_4
P6[5] 91
P6[6] 92
P6[7] 93
P7[0] 43 CONFIG[0]
P7[1] 42 CONFIG[1]
P7[2] 41 DUAL_P_TRIGGER
P7[3] 40 CONFIG[3]
P7[4] 39
P7[5] 38
P7[6] 37
P7[7] 36
NC51 51
NC60 60
NC61 61
NC71 71
NC73 73
NC75 75
NC76 76
NC78 78
NC80 80
NC94 94
NC96 96
NC98 98
NC100 100
CUR_SENSE
GAS_PURGE
TRIG_INLK_2_STEP
CV_CC
COLD_FEED
LED
GAS_ON_OFF
GAS_FLOW
RXD
TXD
OUT_2_4
CONFIG[0]
CONFIG[1]
DUAL_P_TRIGGER
CONFIG[3]
CY8C29866
Return to Master TOC
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GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SEE PAGE 1
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
PSOC
EARTH GROUND CONNECTION
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 02 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
MATERIAL
A
10-23-2009 PROJECT
NUMBER: CRM40617 G 4783-1C0
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: APM
9/2/2010
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: APM
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED: DRS
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
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Return to Section TOC
G-21
G-21
ElECTriCal DiaGrams
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 3
RXD
RS232_TX
RXD
RS232_TX
+5V
R19
200
R37
3.32K
0.1W
MAX3221
9 ROUT
13 DOUT
10 INVALID X2
12 FORCEON
16 FORCEOFF
RIN 8
DIN 11
C2- 6
C2+ 5
V- 7
V+ 3
C1- 4
C1+ 2
EN 1
0.1uF 50V
C25
0.1uF
C29
R36
200
TXD
RS232_RX
RS232_RX
TXD
50V
C27
0.1uF
50V
C26
0.1uF
50V
GND
Return to Master TOC
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GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SEE PAGE 1
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
RS232
EARTH GROUND CONNECTION
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 03 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
PROJECT
MATERIAL
4783-1C0
A
G
10-23-2009 NUMBER: CRM40617
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: APM
9/3/2010
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: APM
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED: DRS
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
Return to Master TOC
G-22
ElECTriCal DiaGrams
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 4
+15V
D50
0.2A
30V
3
2
+5V
1
-15V
ELECTRODE
R180
221K
R175
221K
3
R176
221K
2
X6
R177
221K
1
33074ADT
3
1
D51
0.2A
70V
2
R182
3.32K
3
D18
0.2A
30V
2
1
GND
POLARITY_SENSE
R184
2.21K
R181
Return to Section TOC
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G-22
221K
C70
0.1uF
50V
GND
WORK
R174
221K
R173
221K
R179
221K
GND
R178
221K
+15V
-15V
D14
0.2A
30V
1
3
6
5
GND
X6
7
33074ADT
R183
3.32K
3
R171
2
1
D52
0.2A
70V
2
METER_COMP
R170
20K
0.1W
475
R172
10K
C71 0.1W
0.1uF
50V
9
10
X6
+15V
8
3
33074ADT
D19
0.2A
30V
2
1
-15V
Return to Master TOC
Return to Section TOC
GND
Return to Master TOC
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GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SEE PAGE 1
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
ARC VOLTS READ
EARTH GROUND CONNECTION
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 04 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
PROJECT
MATERIAL
4783-1C0
A
G
10-23-2009 NUMBER: CRM40617
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: APM
9/3/2010
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: APM
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED: DRS
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 5
D28
3A
600V
R114
2K
R115
IN
C2
82uF
35V
2K
15VDC_SUPPLY
OUT
X5
78M15
GND
R119
R120
1
1
1
1
1
1
R199
1
1
R202
1
R197
1
3.32K
0.063W
R131
C61
0.0047uF
50V
R200
C60
100pF
100V
D40
1A
400V
R152
332
3.01K
0.1W
DZ11
15V
3W
1
R117
R116
C4
0.001F
35V
D33
1A
600V
C6
82uF
35V
DZ18
3.3V
0.5W
R127
D41
1A
400V
3.01K
0.1W
332
R151
R198
3
2
C59
150pF
100V
R121
1K
0.063W
R195
C7
220uF
25V
D29
0.2A
30V
8
4
2
1
3
R196
DZ5
17V
5W
VREF
RT/CT
VFB
COMP
2843BD1
CS
X10
D27
3A
40V
100
GND
4
R192
7 VCC
6 OUT
5 GND
3
2K
R126
Q8
20A
600V
DZ16
22.1K
18V
0.063W
0.5W
R128
2.21K 0.063W
R129
100K 0.063W
R122
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C19
0.1uF
630V
D39
1A
400V
5VSPI_SUPPLY
100
C5
220uF
25V
2
33.2
R130
D47
3A
600V
5VSPI_SUPPLY
L1
10uH
1.02A
1
T1-9
C12
0.0033uF
630V
D43
1A
600V
T1
R193
3K
10W
R194
D48
15A
600V
GND
T1 10
9
58P6091
R138
10 0.5W
R137
10 0.5W
R136
10 0.5W
R135
10 0.5W
D46
3A
600V
15VDC_SUPPLY
C3
220uF
25V
624
R11
624
Return to Section TOC
G-23
ElECTriCal DiaGrams
R143
10 0.5W
R142
10 0.5W
R141
10 0.5W
R140
10 0.5W
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G-23
2K
C56
0.1uF
50V
GND
IN
X9
79M15
D38
1A
400V
R220
100
LED1
IN
C10
82uF
35V
DZ10
15V
3W
X12
7805
GND
OUT
NEG15V_SUPPLY
5.0VDC_SUPPLY
C9
82uF
35V
1A
600V
T1-5
5
GND
OUT
15V_ISO
15V_ISO
D34
6 T1
58P6091
C62
0.1uF
50V
C74
82uF
35V
DZ19
18V
0.5W
ISO
R169
10 0.5W
R168
10 0.5W
R165
10 0.5W
R164
10 0.5W
1
MOTOR_SUPPLY
MOTOR_SUPPLY
5.1K
5W
R14
R12
3.92K
1W
R147
301
0.1W
T1-7
8 T1
58P6091
1A/FR
400V
D35
D35-C
8
IN
C64
1uF
35V
X11
1
78L05A
OUT
GND
2 3 6 7
5V_ISO2
C11
1uF
35V
COM_ISO2
5V_ISO2
COM_ISO2
+5V
1
1
1
1
1
1
1
1
1
1
R111
C18
82uF
35V
C69
0.0047uF
50V
R211
DZ9
3.3V
3W
C67
100pF
100V
3.32K
0.063W
R149
R209
1K
2
667
667
D37
30A
600V
R148
1K
0.063W
R210
3
D44
0.2A
30V
C68
150pF
100V
R207
DZ8
30V
3W
8
4
2
1
3
DZ17
18V
0.5W
R208
C13
1uF
63V
1.5K
0.1W
X13
C17
0.012F
50V
7
R205
OVERVOLTAGE
SHUTDOWN
126 - 146VDC
C20
470uF
350V
VREF
RT/CT
VFB
COMP
2843BD1
CS
7 VCC
6 OUT
5 GND
B1
35VDC_SUPPLY
B2
R206
Q15
25A
250V
R150
15K
D56
0.5A
30V
28K 0.1W
R161
2.67K 0.1W
R160
35VDC_SUPPLY
GND
R203
15K
D45
8A
1000V
T2
6
TX06101B
3
TX06101B
C8
0.0015uF
2000V
Q10
47A
600V
R227
15
R222
15
GND
DZ6
56V
3W
DZ7
30V
3W
R45
VS8 8
OUT7 7
X14
OUT6 6
MIC4452YM GND5 5
R201
15K
R47
1 VS1
2 IN
4 GND4
DZ12
43V
1W
4
1
GND
R204
301
R167
10 0.5W
R166
10 0.5W
R163
10 0.5W
R162
10 0.5W
2.67K
T2
R41
2.2
5W
C16
0.0033uF
630V
D42
1A
400V
100K 0.063W
R159
R52
R224
3K
10W
2.67K
R139
R23
R18
R53
3K
10W
15K
R46
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R223
D36
15A
600V
15V_ISO_COM
4.75K
0.063W
VM_LIM
GND
R112
33.2K
0.063W
GENERAL INFORMATION
Q6
0.5A
40V
R113
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GND
39.2K
0.1W
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
C57
0.022uF
50V
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SEE PAGE 1
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
GND
POWER SUPPLY
EARTH GROUND CONNECTION
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PAGE 05 OF 05
EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DOCUMENT
DOCUMENT
SCHEMATIC, CONTROL PCB
SUBJECT:
REVISION:
NUMBER:
APPROVAL
MATERIAL
A
10-23-2009 PROJECT
NUMBER: CRM40617 G 4783-1C0
DISPOSITION: NA DATE:
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: APM
9/3/2010
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: APM
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
--------APPROVED: DRS
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Return to Master TOC
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G-24
G-24
ElECTriCal DiaGrams
sChEmaTiC - mOTOr FilTEr pC BOarD - CODE 11746, 11747 (s27505-1)
D1
40A
1600V
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1 J61
L1
470uH
11.4A
J61 3
C1
470uF
350V
C2
470uF
350V
2 J61
J61 4
GND
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
LABELS
R-
_
C-
_
D-
_
LAST NO. USED
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
Return to Master TOC
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EARTH GROUND CONNECTION
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
SINCE COMPONENTS OR CIRCUITRY ON A
DESIGN INFORMATION
PAGE 01 OF 01
EQUIPMENT TYPE:
LN-25 PRO
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: WDW
10-30-2008
DOCUMENT
DOCUMENT
ABILITY OF A COMPLETE BOARD, THIS
SCHEMATIC,
MOTOR
FILTER
PCB
SUBJECT:
REVISION:
NUMBER:
DIAGRAM MAY NOT SHOW THE EXACT
ENGINEER: APM
REFERENCE:
APPROVAL
PROJECT
COMPONENTS OR CIRCUITRY OF CONTROLS
--------- MATERIAL
S 27505-1B0 A.01
APPROVED:
------DISPOSITION: NA DATE:
NUMBER: 5021492
HAVING A COMMON CODE NUMBER.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
sChEmaTiC - K2330 TimEr KiT pC BOarD - all CODEs (m21341-1)
+15V
+5V
8
GAS FLOW ENABLE
R11
2.21K
R13
R17
CW
R15
100K
10K
C11
0.1uF
50V
100K
+5V
D10
1A/FR
400V
C12
0.1uF
50V
R14
Postflow
4.75K
COM
Power_Detect
COM
D11
1A/FR
400V
+5V
D1
1A/FR
400V
C3
0.1uF
50V
100K
R5
R1
10K
D2
1A/FR
400V
+5V
COM
L3
180
100 MHz
C7
0.1uF
50V
C8
4.7uF
35V
D5
1A/FR
400V
J60
L2
180
100 MHz
CW
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L1
180
100 MHz
COM
PLOTTING DELIMITER - DON’T DELETE
X1
7805
GND
OUT
C5
82uF
35V
C6
22uF
63V
1
COM
COM
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
COM
R- 19
LABELS
LAST NO. USED
Q- 1
C- 12
X- 2
D- 11
L- 3
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
PROPRIETARY & CONFIDENTIAL:
C2
0.1uF
50V
IN
5
B/B VIPER
10K
J60
C9
0.1uF
50V
+5V
COM
COM
J60
+15V
6
J60
8
Vdd
X2
CY8C27143
Vss
4
C4
0.1uF
50V
+5V
4
d
7
GAS ON/OFF
J60
D3
1A/FR
400V
D4
1A/FR
400V
J60
+5V
Power_Detect
+15V
J60
100 ms
D6
1A/FR
400V
COM
R7
1K
COM
R19
13.7K
100 ms
+15V
COM
R6
100K
D7
1A/FR
400V
COM
R16
1K
R2
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CW
C1
0.1uF
50V
2
COM
COM
100 ms
b
R10
100
33.2K
4.75K
3
+15V
Preflow
GAS_ON_OFF
Q1
195mA
60V
COM
R3
Return to Master TOC
+5V
2K
100 ms
1 P0[5]
P0[4] 7
2 P0[3]
X2 P0[2] 6
3 P1[1]
P1[0] 5
CY8C27143
C10
0.022uF
50V
12.1K
2K
R18
D8
1A/FR
400V
R8
J60
R9
5V
D9
1A/FR
400V
Return to Section TOC
G-25
ElECTriCal DiaGrams
R12
Return to Master TOC
Return to Section TOC
G-25
SINCE COMPONENTS OR CIRCUITRY ON A
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY OF CONTROLS
HAVING A COMMON CODE NUMBER.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
DESIGN INFORMATION
DRAWN BY:
MFN
ENGINEER:
MFN
APPROVED:
REFERENCE:
M20337
DO NOT
SCALE THIS
DRAWING
PAGE 01 OF 01
EQUIPMENT TYPE:
LN-25 PRO & LF-72
DOCUMENT
DOCUMENT
SCHEMATIC, TIMER PCB
SUBJECT:
REVISION:
NUMBER:
MATERIAL
APPROVAL
PROJECT
3/27/2007 NUMBER: 5021492-A M 21341-1B0 A.01
DISPOSITION: NA DATE:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
Source Exif Data:
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