Lincoln Electric LN-25 SVM179-B Service Manual
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Lincoln Electric LN-25 SVM179-B Service Manual

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LN-25
For use with machines having Code Numbers: 11387, 11388
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.
• 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
RETURN TO MAIN MENU
PRO WIRE FEEDER

SERVICE MANUAL

• World's Leader in Welding and Cutting Products •
11507, 11508
11620, 11621
11716, 11717
11746, 11747
Copyright © Lincoln Global Inc.
SVM179-B
April, 2011

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Summary of Contents for Lincoln Electric LN-25 SVM179-B

  • Page 1: Service Manual

    LN-25 For use with machines having Code Numbers: 11387, 11388 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.

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can 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.
  • Page 4 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-iv Installation .

  • Page 7: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – LN-25™ PRO (K2613-1, -2, -5, and -7) INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% 15-110 VDC (24-42 VAC with remote voltage control kit installed) RATED OUTPUT @ 104°F (40°C) DUTY CYCLE 60% rating 100% rating GEARING - WIRE FEED SPEED RANGE-WIRE SIzE GEARING WFS RANGE Extra torque...

  • Page 9: Safety Precautions

    Table A.1 Located below are copper cable sizes rec- ommended 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 Keep the increased for greater lengths primarily for the purpose of minimizing voltage drop in the cables.

  • Page 10: Cable Connections

    • 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.

  • Page 11: Procedure To Install Drive Rolls And Wire Guides

    Tools required: • 1/4" hex key wrench. 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.

  • Page 12: Pressure Arm Adjustment

    PRESSURE ARM ADJUSTMENT WARNING ELECTRIC SHOCK can kill. • 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"...

  • Page 13: Power Source To Ln-25™ Pro Cable Connection Diagrams

    Air Vantage 500 Ranger 10,000 Ranger 3 phase SAE 400 with CV adapter Engine Driven welder with Wire Feed Module 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.
  • Page 14 CV Power Source with Twist-Mate Connectors and Remote/Local Switch. (See Figure A.7) V350-Pro Place CV/CC switch in the feeder in the "CV" position. CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.8) Jumper CV-250 CV-300 CV-305 Place CV/CC switch in the feeder in the "CV"...
  • Page 15 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions and Graphic Symbol Definitions .

  • Page 16: Operation

    SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. 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 remain energized several sec- onds after the welding ceases..

  • Page 17: Recommended Processes

    “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...

  • Page 18: Case Front Controls

    K2613-1 & K2613-2 CASE FRONT CONTROLS (See Figure B.1) ITEM 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 1. ANALOG VOLTMETER The analog voltmeter shows the voltage between electrode and work.

  • Page 19: Cv Wire Feed Speed Operation

    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.
  • Page 20 TABLE B.2 - VV (CC) WIRE SPEED SETTING Desired In/Min OPERATION Arc Volts Used 700 642 700 650 LN-25™ PRO...

  • Page 21: Constant Current Vs Constant Voltage Wire Welding

    For these reasons, Lincoln Electric does NOT recom- mend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality requirements.
  • Page 22 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. 6. POLARITY LED (See Figure B.1) The Polarity LED...

  • Page 23: Internal Controls

    INTERNAL CONTROLS ITEM 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...

  • Page 24: Internal Controls Description

    B-10 INTERNAL CONTROLS DESCRIPTION (See Figure B.4) 2 STEP - TRIGGER INTERLOCK SWITCH The 2 Step - Trigger Interlock switch changes the function of the gun trigger. 2 Step trigger opera- tion turns welding on and off direct response to the trigger. Trigger Interlock operation allows welding to continue when the trig- ger is released for comfort on long...
  • Page 25 OPERATION B-11 B-11 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.

  • Page 26: Rear Controls

    B-12 REAR CONTROLS: ITEM Gas Purge Pushbutton Flow Meter Ball Flow Meter Valve Shielding Gas Inlet Electrode Lead Optional Water cooled gun connections OPERATION FIGURE B.5 DESCRIPTION LN-25™ PRO B-12...

  • Page 27: Gas Purge Pushbutton

    B-13 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 and for purging the lines..
  • Page 28 NOTES B-14 B-14 LN-25™ PRO...
  • Page 29 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Factory Installed Equipment .

  • Page 30: Factory Installed Equipment

    FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS WIRE TYPE ELECTRODE SIzE Steel Wires: .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) Cored Wires: .040-.045" (1.0-1.2mm) .052" (1.4mm) 1/16"...
  • Page 31 K2596-1 Aluminum Case K2596-2 Plastic Case K1796-xx AWG 1/0 Co-Axial Power Cable K2593-xx AWG #1 Coaxial Power Cable K1803-1 Work and Feeder Cables Package K1840-xx Weld Power Cable, Twist-Mate to K1842-xx Weld Power Cable, Lug to Lug K484 Jumper Plug Kit K2330-2 Timer Kit ACCESSORIES...
  • Page 32 K910-1 Ground Clamp K910-2 Ground Clamp K1500-1 Gun Receiver Bushing (for guns with K466-1 Lincoln gun connec- tors; Innershield and Subarc guns) 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) K1500-3 Gun Receiver Bushing (for guns...
  • Page 33 K1500-4 Gun Receiver Bushing (for gun with K466-3 Lincoln gun connec- tors; compatible with Miller® guns.) K1500-5 Gun Receiver Bushing (compatible with Oxo® guns.) K489-7 * Gun Receiver Bushing (for Lincoln Fast-Mate guns.) K435 Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2 in (51 mm) spindles.
  • Page 34 INSTALLATION OF THE K590-6 WATER COOLING KIT WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch before working on this equipment. • Do not touch electrically hot parts. • Only qualified personnel should install, use or service this equipment.
  • Page 35 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 36: Calibration Specification

    SAFETY PRECAUTIONS 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.
  • Page 37 Wire Feed Speed Validation (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. Tools required: •...
  • Page 38 MAINTENANCE FIGURE D.3. - MAJOR COMPONENT LOCATION 1. FRONT PANEL ASSEMBLY 2. CONTROL BOX ASSEMBLY 3. SPINDLE & MAST ASSEMBLY 4. WIRE DRIVE ASSEMBLY 5. CASE ASSEMBLY LN-25™ PRO...

  • Page 39: Control Board

    TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 40: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 — GENERAL DESCRIPTION ELECTRODE INPUT CONTACTOR CURRENT TRANSDUCER INPUT SOLENOID CONTROL BOARD 14 PIN AMPHENOL COLD FEED DIGITAL RUN IN DISPLAY BOARD 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.

  • Page 41: Input Power

    THEORY OF OPERATION FIGURE E.3 — INPUT POWER & TRIGGER CIRCUIT ELECTRODE INPUT CONTACTOR CURRENT TRANSDUCER INPUT SOLENOID CONTROL BOARD 14 PIN AMPHENOL COLD FEED DIGITAL RUN IN DISPLAY BOARD INPUT POWER 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.
  • Page 42 THEORY OF OPERATION FIGURE E.4 — FEEDBACK & CONTROL CIRCUITS ELECTRODE INPUT CONTACTOR CURRENT TRANSDUCER INPUT SOLENOID CONTROL BOARD 14 PIN AMPHENOL COLD FEED DIGITAL RUN IN DISPLAY BOARD FEEDBACK AND CONTROL CIR- CUITS The wire speed pot provides command signal to the control board indicating the desired wire speed.
  • Page 43 THEORY OF OPERATION FIGURE E.5 — OPTIONAL CIRCUITS & DIGITAL DISPLAY BOARD ELECTRODE INPUT CONTACTOR CURRENT TRANSDUCER INPUT SOLENOID CONTROL BOARD 14 PIN AMPHENOL COLD FEED DIGITAL RUN IN DISPLAY BOARD DIGITAL DISPLAY BOARD (control cable models only) When the wire feeder is not welding, the left display shows the wire feed speed.
  • Page 44 NOTES LN-25™ PRO...
  • Page 45 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 46: How To Use Troubleshooting Guide

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 47: Pc Board Troubleshooting Procedures

    - 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 prop- er failure analysis.
  • Page 48 (Across the arc models) 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. POSSIBLE AREAS OF...
  • Page 49 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.
  • Page 50 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. POSSIBLE AREAS OF...
  • Page 51 No shielding gas. 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. POSSIBLE AREAS OF...
  • Page 52 NOTES LN-25™ PRO...

  • Page 53: Test Description

    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.

  • Page 54: Case Removal

    TROUBLESHOOTING & REPAIR F-10 CASE REMOVAL PROCEDURE (CONTINUED) 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.

  • Page 55: Gas Solenoid Test

    TROUBLESHOOTING & REPAIR F-11 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.
  • Page 56 TROUBLESHOOTING & REPAIR F-12 GAS SOLENOID TEST (CONTINUED) CONTROL BOX CONTROL BOX COVER PROCEDURE 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. 3.

  • Page 57: Contactor Test

    TROUBLESHOOTING & REPAIR F-13 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.

  • Page 58: Control Box

    TROUBLESHOOTING & REPAIR F-14 CONTACTOR TEST (CONTINUED) CONTROL BOX 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.

  • Page 59: Drive Motor And Tach Feedback Test

    F-15 DRIVE MOTOR AND TACH FEEDBACK TEST 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.
  • Page 60 TROUBLESHOOTING & REPAIR F-16 DRIVE MOTOR AND TACH FEEDBACK TEST (CONTINUED) FIGURE F.4 – CONTROL BOX ASSEMBLY CASE CONTROL BOX ASSEMBLY 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.

  • Page 61: Motor Overload Test

    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.
  • Page 62 TROUBLESHOOTING & REPAIR F-18 MOTOR OVERLOAD TEST (CONTINUED) FIGURE F.5 – CONTROL BOX ASSEMBLY CASE CONTROL BOX ASSEMBLY 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.

  • Page 63: Contactor Removal And Replacement

    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.
  • Page 64 TROUBLESHOOTING & REPAIR F-20 CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) REMOVAL PROCEDURE 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.
  • Page 65 TROUBLESHOOTING & REPAIR F-21 CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.7 – BUSS BAR AND MOUNTING BLOCK BUSS BAR REPLACEMENT PROCEDURE 1. Loosely connect the buss bars to the new contactor. 2. Reconnect the coil leads. Slide the buss bar into the mounting block and start the 1/2-13 bolt.
  • Page 66 NOTES F-22 F-22 LN-25™ PRO...

  • Page 67: Front Panel Removal And Replacement

    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.
  • Page 68 TROUBLESHOOTING & REPAIR F-24 FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FRONT PANEL 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.

  • Page 69: Wire Drive Motor And Gear Box Removal And Replacement

    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.
  • Page 70 TROUBLESHOOTING & REPAIR F-26 WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.9 – BUSS BAR AND GAS HOSE REMOVAL Buss Bar Buss Bar 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.
  • Page 71 TROUBLESHOOTING & REPAIR F-27 WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.10 – WIRE DRIVE PANEL REMOVAL CONTROL BOX 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.
  • Page 72 NOTES F-28 F-28 LN-25™ PRO...

  • Page 73: Pc Board Removal And Replacement

    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.
  • Page 74 TROUBLESHOOTING & REPAIR F-30 PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.11 – CONTROL PC BOARD LOCATION 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.

  • Page 75: Gas Solenoid Removal And Replacement

    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.
  • Page 76 TROUBLESHOOTING & REPAIR F-32 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.12 – SOLENOID NUT AND HOSE CONTROL BOX CONTROL BOX COVER 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.

  • Page 77: Retest After Repair

    TROUBLESHOOTING & REPAIR F-33 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 charac- teristics. • If you repair or replace any electrical components. 1.
  • Page 78 NOTES F-34 F-34 LN-25™ PRO...
  • Page 79 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - Code 11387, 11388 (G5681) .

  • Page 80: Electrical Diagrams

    WiriNG DiaGram - lN-25 prO - CODEs 11387, 11388 (G5681) ANALOG DISPLAY CASE FRONT YELLOW WIRE FEED SPEED THERMAL CONTROL RHEOSTAT N.A. 10K2W 577A 575A 576A VOLTMETER TRIGGER CONNECTOR 667B 622A 500A BRIDGE RECTIFIER 667A TO WORK CLIP 667B N.D. 621A CONNECTS TO J17 ON HARNESS...
  • Page 81 WiriNG DiaGram - lN-25 prO - CODEs 11507, 11508 (G5681-1) ANALOG DISPLAY CASE FRONT YELLOW WIRE FEED SPEED THERMAL CONTROL RHEOSTAT N.A. 10K2W 577A 575A 576A VOLTMETER TRIGGER CONNECTOR 667B 622A 500A BRIDGE RECTIFIER 667A TO WORK CLIP 667B N.D. 621A CONNECTS TO J17 ON HARNESS...
  • Page 82 WiriNG DiaGram - lN-25 prO - CODEs 11620, 11621, 11716, 11717 (G5681-2) ANALOG DISPLAY CASE FRONT YELLOW WIRE FEED SPEED THERMAL CONTROL RHEOSTAT N.A. 10K2W 577A 575A 576A VOLTMETER TRIGGER CONNECTOR 667B 622A 500A WORK A 555A 622B BRIDGE RECTIFIER 667A WORK B 667B...
  • Page 83 WiriNG DiaGram - lN-25 prO - CODEs 11746, 11747 (G5681-3) YELLOW THERMAL N.A. WIRE FEED SPEED CONTROL WFS RANGE POTENTIOMETER SWITCH 10K2W N.B. 577A 575A 576A VOLTMETER 622B 555A TRIGGER CONNECTOR 667B 622A 500A WORK A BRIDGE RECTIFIER 667A WORK B 667B TO WORK CLIP 621A...
  • Page 84 sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11387, 11388 - (G5683) pG1 G5683 ENGINEERING CONTROLLED MANUFACTURER: TIMER P. C. BOARD CIRCUIT Timer Board Summary ADJUST KNOB CW= +5 CCW= 0V POSTFLOW POT. TIMER KIT (OPTIONAL) SCHEMATIC = M21342 ElECTriCal DiaGrams CHANGE DETAIL: REVISED LEADS GOING TO P17.
  • Page 85 sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11387, 11388 - (G5683) pG2 G5683 ENGINEERING CONTROLLED MANUFACTURER: TIMER P. C. BOARD CIRCUIT 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.
  • Page 86 sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11507, 11508 - (G5683-1) pG1 G5683-1 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: 667C 667A 1 of 2 621A WORK CLIP ca se front strain rel ief 14 PIN REMOTE LEADS ARE PRESENT BUT NOT USED IN THIS UNIT.
  • Page 87 sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11507, 11508 - (G5683-1) pG2 G5683-1 ENGINEERING CONTROLLED MANUFACTURER: TIMER P. C. BOARD CIRCUIT Timer Board Summary ADJUST KNOB CW= +5 CCW= 0V POSTFLOW POT. TIMER KIT (OPTIONAL) SCHEMATIC = M21342 ElECTriCal DiaGrams CHANGE DETAIL: MISC.
  • Page 88 G-10 sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11620, 11621, 11716, 11717 - (G5683-2) pG1 G5683-2 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: 667C 667A WORK 1 of 2 CLIP 621A ca se front strain rel ief Located on 667D Case front MOTOR FILTER P.C.
  • Page 89 G-11 sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11620, 11621, 11716, 11717 - (G5683-2) pG2 G5683-2 ENGINEERING CONTROLLED MANUFACTURER: TIMER P. C. BOARD CIRCUIT Timer Board Summary ADJUST KNOB CW= +5 CCW= 0V POSTFLOW POT. TIMER KIT (OPTIONAL) SCHEMATIC = M21342 ElECTriCal DiaGrams CHANGE DETAIL:...
  • Page 90 G-12 sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11746, 11747 - (G5683-3) pG1 G5683-3 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: 667C 667A WORK 1 of 2 CLIP 621A ca se front strain rel ief Located on 667D Case front MOTOR FILTER P.C. 667D BOARD SCHEMATIC= S27505...
  • Page 91 G-13 sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11746, 11747 - (G5683-3) pG2 G5683-3 ENGINEERING CONTROLLED MANUFACTURER: TIMER P. C. BOARD CIRCUIT Timer Board Summary ADJUST KNOB CW= +5 CCW= 0V POSTFLOW POT. TIMER KIT (OPTIONAL) SCHEMATIC = M21342 ElECTriCal DiaGrams CHANGE DETAIL: A.02, COMPLETELY REVISED...
  • Page 92 G-14 sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 1 TACHOMETER +15V 9 J4 0.063W 0.2A 0.063W BLUE 100pF 100V BLACK GAS ON/OFF 2.21K 0.1W +15V 6 J6 7 J6 8 J6 0.2A 0.2A 0.2A -15V...
  • Page 93 G-15 sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 2 ElECTriCal DiaGrams IM_PEAK IM_PEAK P0[0] CC_SENSE CC_SENSE P0[1] IM_AVE IM_AVE P0[2] 35V_SENSE 35V_SENSE P0[3] 13V_SENSE 13V_SENSE P0[4] WFS_POT WFS_POT P0[5] ARCV_SENSE ARCV_SENSE P0[6] BURNBACK BURNBACK P0[7]...
  • Page 94 G-16 sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 3 ElECTriCal DiaGrams MAX3221 0.1uF ROUT RS232_TX RS232_TX DOUT INVALID FORCEON 0.1uF FORCEOFF 3.32K 0.1W 0.1uF NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RS232_RX RS232_RX 0.1uF...
  • Page 95 G-17 sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 4 ElECTriCal DiaGrams +15V 0.2A -15V ELECTRODE R180 R175 R176 R177 221K 221K 221K 221K 0.2A R182 3.32K 33074ADT WORK R174 R173 R179 R178 221K 221K 221K...
  • Page 96 G-18 sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 5 600V 5.1K 5.1K 600V 600V 0.1uF 630V 220uF 2.67K 2.67K 400V DZ12 OVERVOLTAGE SHUTDOWN 113 - 126VDC 180uF 350V 82uF 3.3V ElECTriCal DiaGrams T1-10 58P6091 T1-9...
  • Page 97 G-19 sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 1 TACHOMETER +15V 9 J4 0.063W 0.2A 0.063W BLUE 100pF 100V BLACK GAS ON/OFF 2.21K 0.1W +15V 6 J6 7 J6 8 J6 0.2A 0.2A 0.2A...
  • Page 98 G-20 sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 2 ElECTriCal DiaGrams IM_PEAK IM_PEAK P0[0] CC_SENSE CC_SENSE P0[1] IM_AVE IM_AVE P0[2] 35V_SENSE 35V_SENSE P0[3] 13V_SENSE 13V_SENSE P0[4] WFS_POT WFS_POT P0[5] ARCV_SENSE ARCV_SENSE P0[6] BURNBACK P0[7]...
  • Page 99 G-21 sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 3 ElECTriCal DiaGrams MAX3221 0.1uF ROUT RS232_TX RS232_TX DOUT INVALID FORCEON 0.1uF FORCEOFF 3.32K 0.1W 0.1uF NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RS232_RX RS232_RX 0.1uF...
  • Page 100 G-22 sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 4 ElECTriCal DiaGrams +15V 0.2A -15V ELECTRODE R175 R176 R177 R180 221K 221K 221K 221K 0.2A R182 3.32K 33074ADT WORK R174 R173 R179 R178 221K 221K...
  • Page 101 G-23 sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 5 600V 600V 600V OVERVOLTAGE SHUTDOWN 126 - 146VDC 470uF 250V 350V 1.5K 0.1W ElECTriCal DiaGrams 58P6091 T1-9 0.0033uF 630V 600V 33.2 R130 600V DZ16 22.1K...
  • Page 102 G-24 sChEmaTiC - mOTOr FilTEr pC BOarD - CODE 11746, 11747 (s27505-1) PROPRIETARY & CONFIDENTIAL: SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE- ABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
  • Page 103 G-25 sChEmaTiC - K2330 TimEr KiT pC BOarD - all CODEs (m21341-1) GAS FLOW ENABLE 2.21K Power_Detect Postflow 100K 100K 0.1uF Preflow 100K 100K 0.1uF 100 MHz 100 MHz PLOTTING DELIMITER - DON’T DELETE ElECTriCal DiaGrams 1A/FR 400V P0[5] P0[4] P0[3] P0[2] 1A/FR...

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