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IM10078
March, 2011
RED-D-ARC
LN-25™ PRO EXTREME
RETURN TO MAIN MENU
For use with machines having Code Numbers: 11748
OPERATOR’S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends onYou
This welder 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.
1-800-245-3660
North America’s Largest Fleet of Welding Equipment
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
kill.
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.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
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 circum-
stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
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.
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 spe-
cific 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.
3.g. Never dip the electrode in water for cooling.
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.
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 prod-
ucts.
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.
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.
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
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.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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).
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.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
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.
6.j. Do not use a welding power source for pipe thawing.
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SAFETY
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 suiv-
antes:
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
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 lev-
age, 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.
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.
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.
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.
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.
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.
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 ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
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, pan-
talons sans revers, et chaussures montantes.
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.
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SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is compe-
tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
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SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-
lems of interference. Screening of the entire welding installation may be considered for special
1.
applications
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
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for selecting one of our QUALITY products. We want you to take
pride in operating this product ••• as much pride as we have in
bringing this product to you!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to
meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for
advice or information about their use of our products. We respond to our customers based on the best informa-
tion in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no
liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any responsibility for updating or correcting any such informa-
tion or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the
control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the
results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code (if available)______________________________________________________
Serial Number (if available)__________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TAbLE OF CONTENTS
Page
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Location................................................................................................................................A-2
High Frequency Protection...................................................................................................A-2
Weld cable Sizes, Electrode Lead........................................................................................A-2
Shielding Gas Connection....................................................................................................A-3
Wire Drive Configuration...............................................................................................A-3, A-4
Gun Receiver Bushing, Thumb Screw, Socket Head Cap Screw......................................A-4
Procedure to Install Drive Rolls and Wire Guides ..............................................................A-4
Loading Spools of Wire ........................................................................................................A-4
Pressure Arm Adjustment ....................................................................................................A-5
Gun Connections..................................................................................................................A-5
Power Source to RED-D-ARC LN-25™ PRO EXTREME Cable Connection Diagrams.........A-6 thru A-8
________________________________________________________________________________
Operation.........................................................................................................................Section b
Safety Precautions ...............................................................................................................B-1
Graphic Symbols that appear on this Machine or in this Manual .........................................B-1
Definition of Welding Terms .................................................................................................B-2
General Description..............................................................................................................B-2
Recommended Processes, Equipment Limitations, Recommended Power Sources..........B-2
Case Front Controls ...............................................................................................B-3 thru B-4
Constant Current Wire Welding............................................................................................B-4
Case Front Controls Description ..........................................................................................B-4
Internal Controls...................................................................................................................B-5
Internal Controls Decription..................................................................................................B-6
Rear Controls .......................................................................................................................B-7
________________________________________________________________________________
Accessories ....................................................................................................................Section C
Factory Installed Equipment.................................................................................................C-1
Drive Roll Kits used..............................................................................................................C-1
Accessories Used ..................................................................................................C-2 thru C-4
________________________________________________________________________________
Maintenance....................................................................................................................Section D
Safety Precautions...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Calibration Specification................................................................................................D-1,D-2
________________________________________________________________________________
Troubleshooting .............................................................................................................Section E
How to Use Troubleshooting Guide .....................................................................................E-1
Troubleshooting Guide .................................................................................................E-2, E-4
________________________________________________________________________________
Wiring Diagram & Dimension Prints .............................................................................Section F
________________________________________________________________________________
Parts Pages ................................................................................................................P-668 Series
_______________________________________________________________________________
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A-1
A-1
INSTALLATION
TEChNICAL SPECIFICATIONS – RED-D-ARC LN-25™ PRO EXTREME (K2613-6)
INPuT VOLTAGE and CuRRENT
INPuT VOLTAGE ± 10%
INPuT AMPERES
15-110 VDC
4A
RATED OuTPuT @ 104°F (40°C)
DuTY CYCLE
INPuT AMPERES
60% rating
450
GEARING - WIRE FEED SPEED RANGE-WIRE SIzE
GMAW
FCAW
GEARING
WIRE SIzES
WFS RANGE
WFS RANGE
WIRE SIzES
Standard Speed
K2613-6
.023 – 1/16"
(0.6 – 1.6mm)
50 – 700 ipm
(1.3 – 17.7m/min)
50 – 700 ipm
(1.3 – 17.7m/min)
.030 - 5/64
(0.8 - 2.0mm)
PhYSICAL DIMENSIONS
WIDTh
hEIGhT
DEPTh
WEIGhT
14.8 Inches
(376 mm)
Handle folded down
8.7 Inches
( 221 mm)
23.2 Inches
(589 mm)
38 lbs
(17 kg)
TEMPERATuRE RANGE
OPERATION:
STORAGE:
-40°F to 104°F (-40°C to 40°C)
-40°F to 122°F (-40°C to 50°C)
Thermal tests have been performed at ambient temperature. The duty cycle (duty factor) at 40°C has been deter-
mined by simulation.
Duty cycle is based upon the amount of welding performed in a 10 minute period.
174 HORSESHOE CIRCLE
GORDONSVILLE, VIRGINIA 22942
RED-D-ARC LN-25™ PRO EXTREME
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A-2
A-2
INSTALLATION
SAFETY PRECAuTIONS
The handle of the RED-D-ARC LN-25™ PRO
EXTREME is intended for moving the wire feeder
about the work place only.
WARNING
When suspending a wire feeder, insulate the
hanging device from the wire feeder enclosure.
ELECTRICꢀShOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box
hIGh FREQuENCY PROTECTION
before attempting to connect or
disconnect input power lines, out-
put cables or control cables.
CAuTION
• Only qualified personnel should
perform this installation.
• Do not touch metal portions of the RED-D-ARC
LN-25™ PRO EXTREME 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.
Locate the RED-D-ARC LN-25™ PRO EXTREME
away from radio controlled machinery. The normal
operation of the RED-D-ARC LN-25™ PRO
EXTREME 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 rec-
ommended for different currents and duty cycles.
Lengths stipulated are the distance from the welder to
work and back to the welder again. Cable sizes are
increased for greater lengths primarily for the purpose
of minimizing cable drop.
• Only use on power sources with open circuit
voltages less than 110 VDC.
------------------------------------------------------------------------
LOCATIONFor best wire feeding performance,
place the RED-D-ARC LN-25™ PRO EXTREME 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.
ELECTRODE LEAD
The electrode lead is a 4/0 cable.
Do not submerge the RED-D-ARC LN-25™ PRO
EXTREME .
The RED-D-ARC LN-25™ PRO EXTREME is rated
IP23 and is suitable for outdoor use.
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
DUTY
CYCLE
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
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
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
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
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
** 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).
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A-3
A-3
INSTALLATION
ShIELDING GAS CONNECTION
WIRE DRIVE CONFIGuRATION
(See Figure A.2)
WARNING
GuN buShING, ThuMb SCREW AND
SOCKET hEAD CAP SCREW
CYLINDER may explode if
damaged.
WARNING
• Keep cylinder upright and
chained to support.
ELECTRIC ShOCK can kill.
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
• 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.
• 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 sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• 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.)
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
Tools required:
• 1/4" hex key wrench.
Note: Some gun bushings do not require the use of
the thumb screw.
Install the shielding gas supply as follows:
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.
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 pre-
cision 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.
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.
10. Tighten the socket head cap screw 10 to 14 ft-lbs
(13.5 to 19.0 Nm).
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 out-
let.
4. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench. Note:
if connecting to 100% CO cylinder, insert regulator
2
adapter between regulator and cylinder valve. If
adapter is equipped with a plastic washer, be sure it is
seated for connection to the CO cylinder.
2
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.
11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.
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.
8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making a weld.
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A-4
A-4
INSTALLATION
7. Install a drive roll on each hub assembly secure
with the triangular lock.
FIGuRE A.2
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.
GUN RECEIVER BUSHING
OUTER WIRE GUIDE
WARNING
LOADING SPOOLS OF WIRE
• Keep hands, hair, clothing and tools
away from rotating equipment.
• Do not wear gloves when threading wire
or changing wire spool.
CONNECTOR BLOCK
• Only qualified personnel should install, use or
service this equipment.
SOCKET HEAD
CAP SCREW
------------------------------------------------------------------------
Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.
LOOSEN
TIGHTEN
PROCEDuRE TO INSTALL DRIVE ROLLS
AND WIRE GuIDES
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.
WARNING
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
1. Squeeze the release bar on the retaining collar and
remove it from the spindle.
2. Place the spindle adapter on the spindle, aligning
the spindle brake pin with the hole in the adapter.
• 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 sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
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.
• Only qualified personnel should perform mainte-
nance 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.
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.
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.
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A-5
A-5
INSTALLATION
GuN CONNECTION
PRESSuRE ARM and ADJuSTMENT
WARNING
WARNING
ELECTRIC ShOCK can kill.
ELECTRIC ShOCK can kill.
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
• Turn the input power OFF at the weld-
ing power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
• 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 sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance 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.
Many welding problems can be attributed to setting
the pressure arm too high and causing wire deforma-
tion. Set the pressure arm to minimum amount that
provides reliable feeding.
The RED-D-ARC LN-25™ PRO EXTREME comes
with a K1500-2 gun adapter installed. (See Figure
A.4)
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.
Set the pressure arm as follows:
(See Figure A.3)
Aluminum wires
Cored wires
Steel, Stainless wires between 3 and 5
between 1 and 2
between 1 and 3
Note: Not all gun bushings require the use of the
thumb screw.
FIGuRE A.3
FIGuRE A.4
6
F
Al
M
W
A
U
S
E
L
WIRES
I
L
S
WIRES
THUMB
SCREW
GUN
ALUMINUM WIRES
WIRES
Al
CORED
STEEL, STAINLESS WIRES
FCAW
GMAW
6
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A-6
A-6
INSTALLATION
POWER SOuRCE TO RED-D-ARC LN-25™ PRO
EXTREME CAbLE CONNECTION DIAGRAMS
ACROSS ThE ARC SET-uPS
CV Power Sources with Stud Connectors and
Remote/Local Switch (See Figure A.6)
FIGuRE A.6
Jumper
CV-400
CV-655
DC-400
DC-600
DC-655
V450-Pro
(Red-D-Arc LN-25™
PRO Extreme)
Electrode
Work clip
SAE 400 with CV adapter
Engine Driven welder with
Wire Feed Module
Work
Ranger 250 GXT
K#
Description
Place the power source Remote/Local switch in the
Local position.
K2613-6
(Red-D-Arc LN-25™
PRO Extreme)
Place CV/CC switch in the feeder in the "CV" position.
KP1695-XX
KP1696-XX
KP1697-XX
Drive Roll Kit
See magnum Literature
Welding Gun
CV power Source
Welding Cables
Jumper Plug Kit
K1803-XX
K484
CV Power Sources with Stud Connectors and no
Remote/Local Switch. (See Figure A.7)
FIGuRE A.7
Ranger 250, 250 LPG
Ranger 305G, 305D
Ranger 10,000
(Red-D-Arc LN-25™
PRO Extreme)
Electrode
Work
Ranger 3 Phase
Ranger 225, 225GXT
Commander 300
Work clip
Vantage 300, 400, 500
Air Vantage 500
Place CV/CC switch in the feeder in the "CV" position.
K#
Description
K2613-6
(Red-D-Arc LN-25™
PRO Extreme)
KP1695-XX
KP1696-XX
KP1697-XX
Drive Roll Kit
See Magnum Literature
Welding Gun
CC power Source
Welding Cables
K1803-XX
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A-7
A-7
INSTALLATION
CV Power Source with Twist-Mate Connectors and
Remote/Local Switch. (See Figure A.8)
FIGuRE A.8
(Red-D-Arc LN-25™
PRO Extreme)
V350-Pro
CV 305
Electrode
Work clip
Work
K#
Description
Place the power source Remote/Local switch in the
Local position.
K2613-6
(Red-D-Arc LN-25™
PRO Extreme)
Place CV/CC switch in the feeder in the “CV” position.
KP1695-XX
KP1696-XX
KP1697-XX
Drive Roll Kit
See Magnum Literature
Welding Gun
CV power Source
Welding Cables
K1841-XX
K852-95
Twist-Mate Cable Plug
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch. (See Figure A.9)
FIGuRE A.9
Jumper
CV-250
CV-300
(Red-D-Arc LN-25™
PRO Extreme)
Electrode
Work clip
Work
K#
Description
Place CV/CC switch in the feeder in the "CV" position.
K2613-6
(Red-D-Arc LN-25™
PRO Extreme)
KP1695-XX
KP1696-XX
KP1697-XX
Drive Roll Kit
See Magnum Literature
Welding Gun
CV power Source
Welding Cables
K1841-XX
K852-95
K484
Twist-Mate Cable plug
Jumper Plug kit
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b-1
b-1
OPERATION
GRAPhIC SYMbOLS ThAT APPEAR ON
ThIS MAChINE OR IN ThIS MANuAL
SAFETY PRECAuTIONS
READ AND uNDERSTAND ENTIRE SECTION
bEFORE OPERATING MAChINE.
INPuT POWER
ON
WARNING
• ELECTRIC ShOCK CAN KILL.
unless using COLD FEED fea-
ture, when feeding with gun trig-
ger, the electrode and drive
mechanism are always electri-
cally energized and could
remain energized several sec-
onds after the welding ceases..
• Do not touch electrically live part or electrode
with skin or wet 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.
OFF
WIRE FEEDER
POSITIVE OuTPuT
NEGATIVE OuTPuT
• Keep your head out of fumes.
• use ventilation or exhaust to
remove fumes from breathing
zone.
INPuT POWER
---------------------------------------------------------------------
• WELDING SPARKS can cause
fire or explosion.
DIRECT CuRRENT
• Keep flammable material away.
OPEN CIRCuIT
VOLTAGE
u
0
---------------------------------------------------------------------
ARCꢀRAYS can burn.
• Wear eye, ear and body protec-
tion.
u
INPuT VOLTAGE
OuTPuT VOLTAGE
INPuT CuRRENT
1
2
---------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
uNDER ARC WELDING SAFETY PRECAuTIONS
AND IN ThE FRONT OF ThIS OPERATING MAN-
uAL.
u
---------------------------------------------------------------------
I
1
I
OuTPuT CuRRENT
2
PROTECTIVE
GROuND
WARNING OR
CAuTION
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b-2
b-2
OPERATION
General Functional Description
DEFINITION OF WELDING TERMS
The RED-D-ARC LN-25™ PRO EXTREME has
adjustable WFS range for improving the knob sensitiv-
ity. The low range is great for critical welds with
Innershield wires, and the upper range is suitable for
general purpose welding. Selection of the WFS range
is by a rocker switch or through the set-up menu on
meters with digital displays.
WFS
• Wire Feed Speed
CC
• Constant Current
CV
• Constant Voltage
RECOMMENDED PROCESSES
• GMAW
• FCAW
GMAW
• Gas Metal Arc welding
PROCESS LIMITATIONS
SMAW
• Shielded Metal Arc welding
• GMAW-P procedures must be qualified by the cus-
tomer.
FCAW
• Flux Core Arc Welding
• Across-the-Arc models are not recommended for
stitch or spot welding.
GENERAL DESCRIPTION
General Physical Description
The RED-D-ARC LN-25™ PRO EXTREME is spe-
cially engineered to be the most rugged portable wire
feeder available.
EQuIPMENT LIMITATIONS
• The duty cycle of the wire feeder is 450A, 60%.
Duty cycle is based upon the amount of welding per-
formed in a 10 minute period.
• The maximum spool size is 45 lb. (24 Kg), 12”
(305mm) diameter.
This model includes a gas solenoid for the flexibility to
run most wire processes.
• Maximum FCAW gun length is 15 ft.
• Maximum GMAW gun length is 25 ft.
• K2330-1 Timer Kits do not work with the feeder. Use
K2330-2 kits.
• Push-pull guns do not work with the RED-D-ARC
LN-25™ PRO EXTREME .
The plastic case is molded from a high impact, flame
retardant plastic for durability and low weight.
The heart of the RED-D-ARC LN-25™ PRO
EXTREME 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 pow-
ers the patented drive rolls for smooth, steady feeding
without slippage.
• The digital displays do not show preset voltage
• Not compatible with K489-7 Euro connector (except
K2614-7,-8)
RECOMMENDED POWER SOuRCES
• Ranger 3 Phase
• Ranger 225
• Ranger 225 GXT
• Ranger 250
• Ranger 305
• SAE-400
• CV-305
• CV-400
• CV-655
• DC-400
• DC-600
• DC-655
With a 450 amp, 60% duty cycle rating, these feeders
are ready for heavy duty welding.
• Pipeliner 200G
• Classic 300
• Vantage 300
• Vantage 400
• Vantage 500
• Invertec V-350
• FlexTec 450
• Multi-Weld 350
• Ranger 10,000
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b-3
b-3
OPERATION
(See Customer Assistance Policy in the front of this
Instruction Manual)
Welding
The value in the left display will show actual wire
feed speed. The right display shows the arc voltage.
If the wire feeder is connected for electrode negative
welding, then the voltage display shows a minus
sign.
CASE FRONT CONTROLS (See Figure b.1)
FIGuRE b.1
150
WFS
1
WFS
5
150
2
2. WIRE FEED SPEED KNOb
Use the Wire Feed Speed Knob to adjust the rate of
wire feed speed.
3
4
Because the wire feeder is powered by the arc volt-
age, the full range of wire feed speed may not be
available at low voltages. While welding, the display
will show actual wire feed speed. If the actual WFS is
less than set WFS, then the arc voltage may be too
low for procedure.
The serviceability of a product or structure utilizing the
RED-D-ARC LN-25™ PRO EXTREME wire feeder is
and must be the sole responsibility of the builder/user.
Many variables beyond the control of The Lincoln
Electric Company affect the results obtained in using
the RED-D-ARC LN-25™ PRO EXTREME wire feed-
er. These variables include, but are not limited to,
welding procedure, plate chemistry and temperature,
weldment design, fabrication methods and service
requirements. The available range of the RED-D-
ARC LN-25™ PRO EXTREME wire feeder may not
be suitable for all applications, and the builder/user is
and must be solely responsible for welding settings.
ITEM
DESCRIPTION
1
2
3
4
5
Digital Display
Wire Feed Speed Knob
5-pin gun trigger connector
Work sense lead
Set-up Pushbutton
1. DIGITAL DISPLAY
Arc Voltage
15V
17V
Max WFS (Inches Per Minute)
Power-up
All of the LED’s will briefly illuminate during power-
up.
400ipm
450ipm
570ipm
650ipm
700ipm
21V
24V
27V
Idle
The left display shows the preset wire feed speed.
The right display shows OCV. The wire feed speed
LED is lit. If the wire feeder is connected for elec-
trode negative welding, then the voltage display
shows a minus sign.
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b-4
b-4
OPERATION
3. TRIGGER CONNECTOR
WIRE FEED SPEED uNITS
There is one circular connector for the gun trigger on
the front of the LN-25 PRO. Note – if the gun trigger
is already depressed when the feeder is powered up,
the feeder will not activate. Release and then press
the gun trigger to begin welding.
To change the wire feed speed units:
Rotate the WFS knob to the left to use “inches/minute”
for the wire feed speed units.
Rotate the WFS knob to the right to use
“meters/minute” for the wire feed speed units.
The 83% wire feed speed reduces the wire feed
speed to 83% of the original set value when activated.
For example, if the original wfs = 200 in/min, the feed-
er will regulate to 0.83 x 200 = 166 in/min.
Then rotate the WFS knob to the 12 o’clock position.
The 83% trigger requires a gun with a dual procedure
switch.
This feature is often useful when welding pipe, and a
“cooler” procedure is required on the bottom portion.
US
EUro
Pin
Function
Wiring
A
B
C
D
E
5-pin trigger
connector for
push-guns
only.
5 volt supply
Not used
Trigger
83%ꢀWFS switch
5 volt supply
C
B
Press the set-up button again to enter WFS calibration.
E
A
D
WFS CALIbRATION
Measurements for adjusting the WFS calibration must
be made before entering the set-up menu. If no
changes are being made to the calibration, then press
the set-up button to enter WFS Knob Range.
4. WORK SENSE LEAD
Always turn power off at the welding power source
before moving the work sense lead.
While in the set-up menu, adjust the calibration factor in
the following example:
The work sense lead attaches to the item being weld-
ed.
Actual WFS
Set WFS
405
400
= 1.01
= Caibration Factor
Example:
5. SET-uP PuShbuTTON
Press the set-up button when calibration factor is set.
before entering the set-up menu:
Calibration of Wire Feed Speed:
• Set the display to the desired wire feed speed
(example: 400 inches per minute)
• Measure the actual wire feed speed (example:
405 inches per minute)
• Place the WFS knob in the 12 o’clock position.
To enter the set-up menu, use paper clip to press the
small button located on the case front.
PUSHBUTTON
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b-5
b-5
OPERATION
INTERNAL CONTROLS
8
S
i
H
n
s
b
S
r
a
d
e
H
a
C
p
c
w
I
2
C
i
7
8
6
1
2
3
4
5
3
2
4
5
1
6
7
8
ITEM
DESCRIPTION
1
2
3
4
5
2 Step Trigger Interlock Switch
Pressure Arm
Optional Timer Kit
Spool Retainer
Spindle Brake
6
7
8
Gun Bushing, Thumb Screw and Socket Head Cap Screw
Drive Hubs
Cold Feed Pushbutton
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b-6
b-6
OPERATION
INTERNAL CONTROLS DESCRIPTION
(See Figure B.2)
2. PRESSuRE ARM and ADJuSTMENT
(SEE INSTALLATION SECTION)
1. 2 STEP - TRIGGER INTERLOCK
SWITCh
3. OPTIONAL TIMER KIT
The optional Timer Kit provides control of preflow
time, burnback, and postflow time.
The 2 Step - Trigger Interlock
switch changes the function of the
gun trigger. 2 Step trigger opera-
tion turns welding on and off in
direct response to the trigger.
Trigger Interlock operation allows
welding to continue when the trig-
ger is released for comfort on long
welds.
4. SPOOL RETAINER
To release the spool retainer, squeeze the metal bar
inwards. When securing the spool, verify the spool
retainer is fully seated in place in one of the three
grooves of the spindle.
5. SPOOL bRAKE
Place the toggle switch in the
DOWN position for 2 Step operation or in the UP posi-
tion for Trigger Interlock operation.
Adjust the spool brake to provide enough friction to
stop wire overrun. Excessive brake force may cause
motor thermal overloads or welding problems.
2 Step Trigger
6. GuN buShING, ThuMb SCREW AND
SOCKET hEAD CAP SCREW
(SEE INSTALLATION SECTION)
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.
7. DRIVE ROLLS AND WIRE GuIDES
(SEE INSTALLATION SECTION)
Trigger Interlock
8. COLD FEED PuShbuTTON
When cold feeding, the wire
drive will feed electrode but nei-
ther the power source nor the
gas solenoid will be energized.
Adjust the speed of cold feed-
ing by rotating the WFS knob.
Cold feeding, or "cold inching"
the electrode is useful for
threading the electrode through
Trigger Interlock operation provides for operator com-
fort 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 feed-
ing wire.
the gun.
CAuTION
If the arc goes out while welding with
trigger interlock operation, the elec-
trode 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.
------------------------------------------------------------------------
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b-7
b-7
OPERATION
FIGuRE b.4
REAR CONTROLS:
(See Figure B.4)
1. GAS PuRGE PuShbuTTON
The gas solenoid valve will energize but neither the
power source output nor the drive motor will be turned
on. The Gas Purge switch is useful for setting the
proper flow rate of shielding gas. Flow meters should
always be adjusted while the shielding gas is flowing.
1
2
3
ITEM
DESCRIPTION
1
2
3
Gas Purge Pushbutton
Shielding Gas Inlet
Electrode Lead
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C-1
C-1
ACCESSORIES
FACTORY INSTALLED EQuIPMENT
• K1500-2 Gun Receiver Bushing.
DRIVE ROLL KITS uSED
• See Parts Pages
K2330-2
Timer Kit
Includes: Panel and harness
for adjusting preflow, burnback
and postflow times.
K2596-2
Plastic Case
Includes: a complete engi-
neered plastic case.
K1796-xx
AWG 1/0 Coaxial Power Cable
Includes: 1/0 Coaxial weld
cable of length "xx". Ends of
the weld cable have lug con-
nections. Use for Pulse weld-
ing.
K2593-xx
K1803-1
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.
Work and Feeder Cables Package
Includes: Twist-Mate to Lug
2/0 cable 14' (1.2m) long with
Ground Clamp, and Twist-
Mate to Lug 2/0 Cable 9'
(2.7m) long.
K1840-xx
K1842-xx
Weld Power Cable, Twist-Mate to
Lug
Includes: Twist-Mate to Lug,
1/0 cable of length "xx".
IIncludes: 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).
Weld Power Cable, Lug to Lug
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C-2
C-2
ACCESSORIES
Includes: 14 pin circular
K484
Jumper Plug Kit
connector with jumper for
leads 2-4. For use in power
sources for turning the weld
terminals "ON" at all times.
K910-1
K910-2
K1500-1
Ground Clamp
Ground Clamp
Includes: One 300 Amp
Ground Clamp.
Includes: One 500 Amp
Ground Clamp.
Gun Receiver Bushing (for guns
with K466-1 Lincoln gun connec-
tors; Innershield and Subarc guns)
Includes: Gun receiver bush-
ing, set screw and hex key
wrench.
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 bush-
ing with hose nipple, set screw
and hex key wrench.
K1500-2
K1500-3
Gun Receiver Bushing (for guns
with K613-7 Lincoln gun connec-
tors; Magnum 550 guns and com-
patible with Tweco® #5)
Includes: Gun receiver bush-
ing with hose nipple, set screw
and hex key wrench.
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C-3
C-3
ACCESSORIES
Gun Receiver Bushing (for gun Includes: Gun receiver bush-
with K466-3 Lincoln gun connec- ing with hose nipple, set screw
K1500-4
tors; compatible with Miller® guns.)
and hex key wrench.
Includes: Gun receiver bushing
K1500-5
Gun Receiver Bushing (compatible with hose nipple, 4 guide tubes,
with Oxo® guns.) set screw and hex key wrench.
K435
Spindle Adapter, for mounting 14 Includes: Spindle Adapter made
lb. (6.4 kg) Innershield Coils on 2
in (51 mm) spindles.
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.
Includes: Deluxe Gas Regulator
for Mixed Gases, Adapter for
CO2 and 10' (3.0m) Hose.
K586-1
K283
Deluxe Adjustable Gas Regulator
Wire Feed Speed Meter
Includes: A wire feed speed
meter with digital display.
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D-1
D-1
MAINTENANCE
SAFETY PRECAuTIONS
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 sec-
onds after the gun trigger is released.
• Do not operate with covers, panels or guards
removed or open.
• Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
ROuTINE MAINTENANCE
• Check weld cables, control cables and gas hoses
for cuts.
• Clean and tighten all weld terminals.
PERIODIC MAINTENANCE
• Clean drive rolls and inner wire guide and replace if
worn.
• Blow out or vacuum the inside of the feeder.
• Inspect the motor brushes every 6 months. Replace
if shorter than 0.5” (12.7mm).
CALIbRATION SPECIFICATION
See the (OPERATION SECTION), set-up menu, for
calibration of amperage and wire feed speed.
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E-1
E-1
TROubLEShOOTING
hOW TO uSE TROubLEShOOTING GuIDE
WARNING
Service and Repair should only be performed by 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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Field Service Facility.
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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.
• Welding power source must be connected to system ground per the National Electrical
Code or any applicable local codes.
• Only qualified personnel should perform maintenance work.
CAuTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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E-2
E-2
TROubLEShOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAuSE
RECOMMENDED
COuRSE OF ACTION
Digital Display Models Error Codes
Motor overload, long term.
Err 81
1. Check that the electrode slides
easily through the gun and cable.
2. Remove tight bends from the gun
and cable.
3. Check that the spindle brake is
not too tight.
4. Verify a high quality electrode is
being used.
5. Wait for the error to reset and the
motor to cool (approximately 1
minute).
Err 82
Motor overload, short term.
1. Check that motor can turn freely
when idle arm is open.
2. Verify that the gears are free of
debris and dirt.
Output Problems
The feeder does power up - no dis- 1. The work sense lead is discon-
1. Connect the work sense lead to
the work in a location free of dirt,
rust and paint.
2. Turn ON the power source.
3. Reset the circuit breakers.
play, no cold feed.
nected or is a poor electrical con-
nection. (Across the arc models)
2. The power source is OFF.
3. The circuit breaker for the wire
feeder on power source have
tripped. (control cable models)
4. The control cable may be loose or
damaged. (control cable models)
4. Tighten, repair or replace the con-
trol cable.
(Across the Arc models)
The wire feeder power up but there
is no output when the trigger is 2. The contactor has failed.
pulled. The shielding gas is flowing
and the drive rolls turn.
1. The contactor coil connections are
loose.
1. Verify the contactor coil connec-
tions.
2. Replace the contactor.
No shielding gas.
1. The gas supply is OFF or empty.
2. The gas hose is cut or crushed.
1. Verify the gas supply is ON and
flowing.
2. Route the gas hose so it avoids
sharp corners and make sure
nothing is on top of it. Repair or
replace damaged hoses.
3. The flow meter valve is closed.
4. Dirt or debris is in the solenoid.
3. Open the flow meter valve.
4. Apply filtered shop at 80psi to the
solenoid to remove dirt.
5. There is a loose solenoid connec-
tion.
5. Remove the cover and check that
all connections are in good condi-
tion.
6. The solenoid has failed.
6. Replace solenoid.
CAuTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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E-3
E-3
TROubLEShOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAuSE
RECOMMENDED
COuRSE OF ACTION
Inconsistent wire feeding or wire not 1. The gun cable is kinked and/or 1. Keep the gun cable as straight as
feeding but drive rolls turning.
twisted.
possible. Avoid sharp corners or
bends in the cable.
2. Remove the gun from the wire
feeder and pull the jammed wire
out of the gun and cable.
2. The wire is jammed in the gun and
cable.
3. Blow dirt out of the liner with low
pressure (40psi or less). Replace
the liner if worn.
4. Use only clean electrode. Use
quality electrode, like L-50 or L-56
from Lincoln Electric.
5. Replace the contact tip.
6. Verify the proper parts are
installed.
7. Adjust the tension arm per the
Instruction Manual. Most elec-
trodes feed well at a tension arm
setting of "3".
8. Verify the spool of wire moves
with minimal effort.
9. Replace the drive rolls if worn or
filled with dirt.
1. Install the proper pinion gear in
the wire drive.
2. Inspect and replace the motor
brushes.
Wire feed speed consistently oper- 1. The wrong gear is installed in the
ates at the wrong value. The speed wire drive.
changes when the wire feed speed 2. The brushes on the motor are
knob is adjusted.
worn.
1. Verify all of the tachometer leads
are properly connected.
The wire feed speed stuck at 200- 1. The tachometer is connected
300 in/min and there is no change improperly.
2. Replace the motor and tachome-
ter assembly.
when the wire feed speed knob is 2. The tachometer has failed.
adjusted.
CAuTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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E-4
E-4
TROubLEShOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAuSE
RECOMMENDED
COuRSE OF ACTION
Output Problems
Variable or "hunting" arc.
1. Wrong size, worn and/or melted 1. Replace the contact tip.
contact tip.
2. Worn work cable or poor work 2. Verify all work and electrode con-
connection.
nections are tight and that the
cables are in good condition.
Clean/replace as necessary.
3. Adjust polarity to the recommend-
ed procedure.
3. Wrong polarity.
4. The gas nozzle is extended 4. Adjust the gas nozzle and shorten
beyond the contact tip or the wire the stickout to 3/8 to 1/2 inches.
stickout is too long.
5. Poor gas shielding on processes 5. Check gas flow and mixture.
requiring gas.
Remove or block sources of
drafts.
When the trigger is pulled, the wire
feeds slowly.
The Run-In switch is “ON”.
Use the set-up Push-button to turn
Run-in OFF.
Poor arc starts with sticking or
"blast-offs", weld porosity, narrow
and ropy looking bead.
1. Improper procedures or tech- 1. See "Gas Metal Arc Welding
niques. Guide" (GS-100).
CAuTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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F-1
F-1
DIAGRAMS
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F-2
F-2
DIMENSION PRINT
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NOTES
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NOTES
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l Do not touch electrically live parts or
electrode with skin or wet clothing.
l Insulate yourself from work and
ground.
l Keep flammable materials away.
l Wear eye, ear and body protection.
WARNING
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible
l Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
l Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAuCION
French
l Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
l Gardez à l’écart de tout matériel
inflammable.
l Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
l Isolez-vous du travail et de la terre.
German
l Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNuNG
Elektroden und dem Erdboden!
Portuguese
l Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
l Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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l Keep your head out of fumes.
l Use ventilation or exhaust to
remove fumes from breathing zone.
l Turn power off before servicing.
l Do not operate with panel open or
guards off.
WARNING
Spanish
l Los humos fuera de la zona de res-
piración.
l Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
l Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
l No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAuCION
French
l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux
tien.
l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
l Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
l Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
l Vermeiden Sie das Einatmen von
Schweibrauch!
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNuNG
Portuguese
l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer
serviço.
l Mantenha-se afastado das partes
moventes.
l Não opere com os paineis abertos
ou guardas removidas.
l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
l Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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 WEBꢀSITE: www.lincolnelectric.com
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