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Lincoln Electric LN-25 SVM179-B User Manual

Lincoln Electric LN-25 SVM179-B
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LN-25
PRO WIRE FEEDER
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April, 2011
For use with machines having Code Numbers: 
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
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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
World's Leader in Welding and Cutting Products
Copyright © Lincoln Global Inc.
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 PRE-
CAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
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Lincoln Electric LN-25 SVM179-B Specifications

General IconGeneral
Input Frequency50/60 Hz
ProcessesMIG, Flux-Cored
Wire Feed Speed Range50-700 ipm (1.3-17.7 m/min)
Drive Roll4-Roll
Wire Feed Motor TypePermanent Magnet
TypePortable Wire Feeder
Wire Size Range0.023-0.120 in (0.6-3.0 mm)

Summary

SAFETY

CALIFORNIA PROPOSITION 65 WARNINGS

Warnings specific to California regarding hazardous substances in engine exhaust.

FOR ENGINE powered equipment

Safety precautions for operating equipment powered by an engine.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

Information on potential hazards of EMF fields from welding operations.

ELECTRIC SHOCK CAN KILL.

FUMES AND GASES can be dangerous.

Hazards associated with welding fumes and gases and necessary ventilation.

ARC RAYS can burn.

Dangers of arc rays and protective measures for eyes and skin.

WELDING and CUTTING SPARKS can cause fire or explosion.

CYLINDER may explode if damaged.

Precautions for handling compressed gas cylinders to prevent explosions.

FOR ELECTRICALLY powered equipment.

Safety guidelines for operating electrically powered welding equipment.

INSTALLATION

Technical Specifications

Key technical details and parameters of the LN-25™ PRO wire feeder.

Safety Precautions

Crucial safety guidelines to follow during installation and operation.

Location

Guidance on optimal placement for the wire feeder.

High Frequency Protection

Measures to prevent interference with radio-controlled equipment.

Weld Cable Size

Recommendations for appropriate weld cable sizing based on current and duty cycle.

Cable Connections

Shielding Gas Connection

Instructions for connecting the shielding gas supply.

Wire Drive Configuration

Information on configuring the wire drive system.

Procedure To Install Drive Rolls and Wire Guides

Changing The Gun Receiver Bushing

Procedure for replacing the gun receiver bushing.

Pressure Arm Adjustment

Loading Spools of Wire

Instructions for loading wire spools onto the feeder.

Gun Connection

Steps for connecting the welding gun to the wire feeder.

ACROSS THE ARC SET-UPS

CV Power Sources with Stud Connectors and Remote/Local Switch

Diagrams for connecting to CV power sources with specific connector types.

CV Power Source with Twist-Mate Connectors and Remote/Local Switch

CV Power Source with Twist-Mate Connectors and no Remote/Local Switch

Diagrams for connecting to CV power sources without Remote/Local switch.

OPERATION

Safety Precautions and Graphic Symbol Definitions

Important safety rules and explanation of symbols used in the manual.

General Description

An overview of the LN-25™ PRO's design and capabilities.

Case Front Controls

Wire Feed Speed, CV Operation

How to set wire feed speed when using CV power sources.

Wire Feed Speed, CC Operation

TABLE B.2 - VV (CC) WIRE SPEED SETTING

A table providing wire speed settings based on arc voltage for CC operation.

CONSTANT CURRENT VS CONSTANT VOLTAGE WIRE WELDING

5-PIN GUN TRIGGER CONNECTOR

WORK SENSE LEAD

Importance and connection of the work sense lead for motor operation.

THERMAL LED, MOTOR OVERLOAD

Explanation of the thermal LED and automatic motor shutdown for overload protection.

POLARITY LED

Function of the polarity LED to indicate positive or negative polarity connection.

WIRE FEED SPEED RANGE SWITCH

How to use the speed range switch for precise low-speed settings.

INTERNAL CONTROLS

2 Step Trigger Interlock Switch

Functionality of the 2-step and trigger interlock switch for gun trigger operation.

CV/CC SWITCH

How the CV/CC switch determines wire feed speed control method.

COLD FEED PUSHBUTTON

Using the cold feed button for threading electrode without power or gas.

OPTIONAL PREFLOW, BURNBACK AND POSTFLOW TIMER KIT

Preflow Timer

Function and range of the preflow timer for gas purging and arc start.

Burnback Timer

Control of power source output after wire feed stops, prevents sticking.

Postflow Timer

Function and range of the postflow timer to protect the weld as it cools.

REAR CONTROLS:

Gas Purge Pushbutton

Function of the gas purge button for setting gas flow.

Flow Meter Ball

How the flow meter ball indicates shielding gas flow rate.

Flow Meter Valve

Valve used to adjust the shielding gas flow rate indicated by the meter.

Shielding Gas Inlet

Connection point for the shielding gas supply.

Electrode Lead

Connection for the electrode lead.

Optional Water cooled gun connections

Ports for connecting a water-cooled gun system.

GAS PURGE PUSHBUTTON

FLOW METER

How the flowmeter indicates and allows adjustment of shielding gas flow rate.

POWER-UP SEQUENCE

Steps and indicators to observe during the machine's power-up sequence.

ACCESSORIES

FACTORY INSTALLED EQUIPMENT

Equipment pre-installed on the wire feeder.

DRIVE ROLL KITS

Different kits for drive rolls and wire guides for various wire types.

Aluminum Case

Plastic Case

Accessory for a plastic case with pre-assembled components.

AWG 1/0 Co-Axial Power Cable

Power cable accessory for pulse welding.

AWG #1 Coaxial Power Cable

Power cable accessory for pulse or STT™ welding.

Work and Feeder Cables Package

Package including ground clamp and cables.

Weld Power Cable, Twist-Mate to Lug

Power cable with specific connector types.

Weld Power Cable, Lug to Lug

Power cable with lug connectors.

Jumper Plug Kit

Kit for connecting power sources to turn weld terminals ON.

Timer Kit

Kit providing adjustable preflow, postflow, and burnback.

Ground Clamp

Gun Receiver Bushing

Various bushings for connecting different welding guns.

Gun Receiver Bushing

Spindle Adapter

Adapters for mounting different sizes of wire spools.

Water Connection Kit

Kit for water-cooled gun models.

Deluxe Adjustable Gas Regulator

Gas regulator accessory with adapters.

INSTALLATION OF THE K590-6 WATER COOLING KIT

MAINTENANCE

SAFETY PRECAUTIONS

Safety guidelines specifically for maintenance procedures.

ROUTINE MAINTENANCE

Regular maintenance tasks for cables and terminals.

PERIODIC MAINTENANCE

Periodic tasks like cleaning drive rolls and vacuuming the feeder.

CALIBRATION SPECIFICATION

Information on calibration status for voltmeter and flow meter.

Voltmeter Validation, Across the Arc Analog Meter Models

Procedure to verify the accuracy of the analog voltmeter.

Flow Meter Validation

Procedure to verify the accuracy of the gas flow meter.

Wire Feed Speed Validation

MAJOR COMPONENT LOCATION

Theory of Operation

General Description

An overview of the LN-25™ PRO's design and capabilities.

Input Power

How the unit receives and processes input power.

Trigger Circuit

Explanation of the gun trigger's function and operation modes.

Feedback and Control Circuits

How the feeder monitors and controls motor speed and wire feed.

Optional Circuits & Digital Display Board

Description of optional features like timer kits and digital displays.

Troubleshooting and Repair

How to Use Troubleshooting Guide

Instructions on how to effectively use the troubleshooting guide.

PC Board Troubleshooting Procedures

Steps for diagnosing and troubleshooting issues related to PC boards.

Troubleshooting Guide

A table listing problems, possible causes, and recommended actions.

PC board can be damaged by static electricity

OUTPUT PROBLEMS

Inconsistent wire feeding or wire not feeding but the drive rolls are turning.

Steps to resolve inconsistent or failed wire feeding issues.

Wire feed speed consistently operates at the wrong value.

Troubleshooting steps when wire speed is incorrect or unresponsive.

This wire feeds but cannot be controlled with the wire speed pot.

Diagnosing issues where wire speed cannot be adjusted.

Variable or “hunting” arc.

When the trigger is pulled, the wire feeds slowly.

Troubleshooting slow wire feeding when the trigger is activated.

No shielding gas.

CASE REMOVAL PROCEDURE

GAS SOLENOID TEST

CONTACTOR TEST

DRIVE MOTOR AND TACH FEEDBACK TEST

MOTOR OVERLOAD TEST

CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE

FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE

WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT PROCEDURE

PC BOARD REMOVAL AND REPLACEMENT PROCEDURE

GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE

RETEST AFTER REPAIR

OPERATION VERIFICATION

Checks for verifying correct operation of key components after repair.

ELECTRICAL DIAGRAMS

WIRING DIAGRAM - LN-25 PRO - CODES 11387, 11388 (G5681)

Wiring diagram for specific model codes.

WIRING DIAGRAM - LN-25 PRO - CODES 11507, 11508 (G5681-1)

Wiring diagram for specific model codes.

WIRING DIAGRAM - LN-25 PRO - CODES 11746, 11747 (G5681-3)

Wiring diagram for specific model codes.

SCHEMATIC - LN-25 PRO - COMPLETE MACHINE CODES 11387, 11388 - (G5683) PG1

SCHEMATIC - LN-25 PRO - COMPLETE MACHINE CODES 11507, 11508 - (G5683-1) PG1

SCHEMATIC - LN-25 PRO - COMPLETE MACHINE CODES 11620, 11621, 11716, 11717 - (G5683-2) PG1

SCHEMATIC - LN-25 PRO - COMPLETE MACHINE CODES 11746, 11747 - (G5683-3) PG1

SCHEMATIC - LN-25 PRO CONTROL PC BOARD - CODES 11387, 11388, 11507, 11508 (G4745-1) PG 1

SCHEMATIC - LN-25 PRO CONTROL PC BOARD - CODES 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) PG 1

SCHEMATIC - MOTOR FILTER PC BOARD - CODE 11746, 11747 (S27505-1)

SCHEMATIC - K2330 TIMER KIT PC BOARD - ALL CODES (M21341-1)

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