lN25 Manual Tecnico

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NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.
LN-25 ™ PORTABLE CV/CC

SEMIAUTOMATIC WIRE FEEDER
For use with machines having Code Numbers:
9218 9810 10557
9219 9811 10558
9220 9812 11144

View Safety Info
9383 10556 11145
SERVICE MANUAL
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View Safety Info
SVM114-C | Issue Date 08, Jul

© Lincoln Global, Inc. All Rights Reserved.
i SAFETY i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the

powered equipment. radiator pressure cap when the engine is
hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated.
2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________
welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi-
before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment.
effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler 2.d.3. Do not place your body between the electrode and
by pushing on the throttle control rods while work cables. If the electrode cable is on your right
the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar ‘95
ii SAFETY ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5. b. The operation of welding fume control equipment is affected
damaged insulation.
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling.
welding procedure and application involved.
Worker exposure level should be checked upon installation
3.h. Never simultaneously touch electrically “hot” parts of

and periodically thereafter to be certain it is within applicable
electrode holders connected to two welders because voltage
OSHA PEL and ACGIH TLV limits.
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.
3.i. When working above floor level, use a safety belt to protect
The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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.

Aug ‘06
iii SAFETY iii
WELDING and CUTTING CYLINDER may explode

SPARKS can if damaged.

cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 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 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
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 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate circuits. Electrical Code, all local codes and the manufacturer’s
This can create fire hazards or overheat lifting chains or recommendations.
cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturer’s recommendations.
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.

Jan ‘07
iv SAFETY iv
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un
antes: 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
1. Protegez-vous contre la secousse électrique: 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
a. Les circuits à l’électrode et à la piéce sont sous tension éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains. câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met- 9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse. produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc- 10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement. d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir. du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
de la tension à vide des deux machines. le code “Code for safety in welding and cutting” CSA Standard
f. Si on utilise la machine à souder comme une source de W 117.2-1974.
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

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
contre les chutes dans le cas ou on recoit un choc. Ne jamais
TRANSFORMATEUR ET À
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
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 1. Relier à la terre le chassis du poste conformement au code de
qu’un verre blanc afin de se protéger les yeux du rayon- l’électricité et aux recommendations du fabricant. Le dispositif
nement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. 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
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
4. Garder tous les couvercles et dispositifs de sûreté à leur place.

talons sans revers, et chaussures montantes.
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.
Mar ‘93
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual (below code 10500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-175
Parts Manual (above code 10500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-333
LN-25™
Section A TABLE OF CONTENTS Section A
- INSTALLATION SECTION -
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Power Source Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
DC-250™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
DC-400™ and CV-400™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
DC-600™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
SAM-400™, -650™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
SA-200™, -250™ or SAE-300™, -400™ . . . . . . . . . . . . . . . . . . . . . A-4
Invertec, CV300™ and other newer Lincoln Power Sources . . . . . . A-4
Gun Cable Connection to Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Weld Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Electrode Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Work Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Wire Feed Drive Roll and Guide Tube Kits . . . . . . . . . . . . . . . . . . . . . . . . A-5

LN-25™
A-2 INSTALLATION A-2
TECHNICAL SPECIFICATIONS – LN-25™

Return to Section TOC
VOLT
OPERATING AGE
ARC VOLTAGE
Constant Voltage (CV)

or 15-40 VDC (110VDC Maximum OCV)
Constant Current (CC)
RRATED
AT ED C UR REN T
CURRENT
Rated current without contactor 500 Amps 60% Duty Cycle
Rated current with contactor 300 Amps 60% Duty Cycle
W IRE SPEED
WIRE F EED RANGE
SPE ED
50 – 700 Inches Per Minute (IPM)
WIRE ELECTRODE
RECOMMENDED D I A ME T E R S
WIRE SIZES
.023” to ⁄16”
1
SOLID STEEL WIRE
.045” to ⁄64”
5
CORED WIRE
.035” to 1⁄16” ALUMINUM WIRE
PHPHYSICAL
Y SI CAL D I ME N S I O N S
DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT

(Handle Down) w/o Options
14 Inches 7.4 Inches 21 Inches 28 lbs

(354 mm) (187 mm) (531 mm) (13 kg)
TEMPERATURE RANGE
OPERATION: - 40o C to +40o C (- 40o F to +104o F)
STORAGE: - 40o C to +70o C (- 40o F to +158o F)
ENVIRONMENTAL RAT ING

IP23 (IEC529)
LN-25™
SAFETY PRECAUTIONS
WARNING
WARNING
ELECTRIC SHOCK can kill.
Unless an optional output control or contactor is used
• Do not operate with covers
with the LN-25™, the electrode circuit (including
removed.
welding wire, wire drive and welding gun) is
electrically hot when the welding power source is on. • Turn off power source before
The gun trigger controls wire feed only. installing or servicing.
Disconnect or shut off welding power source before • Do not touch electrically
making connections or installations to the LN-25™. hot parts.
Welding gun should be stored in the insulated • Turn the input power to the
gun holder, located near the rear on the top of the welding power source off at the
LN-25™ case, to avoid accidental arcing. The LN- fuse box before working in the
25™ should be positioned upright on a horizontal terminal strip.
surface.
• Only qualified personnel should
WARNING install, use or service this
equipment.
• Do not touch metal portions

of the LN-25™ lead clip when DC-250™
welding power source is on.
a. Connect a jumper from 2 to 4 on the power source
terminal strip so the output will be energized when
POWER SOURCE CONNECTION the DC-250™ is turned on.
The LN-25™ can be used with any DC welding power b. Connect electrode cable to the “Innershield/
source. A constant voltage power source is GMAW” output terminal of polarity required by
recommended; however, the LN-25™ can also be electrode. Connect work lead to other
used with a constant current power source as long as “Innershield/GMAW” output terminal.
the open circuit voltage is less than 110V DC.

c. Place “Set to CV Electrode Cable Polarity” switch

at appropriate position.
CAUTION
d. Place power source toggle switch in “Output
Do not use LN-25™ models below Code 9200 with Control at DC-250™” position, unless a Remote
any TIG or Square Wave welding power sources. Do Control is connected to 75, 76 and 77 on the DC-
not use LN-25™ models equipped with internal 250™ terminal strip.
contactors with non- Lincoln TIG or Square Wave e. Place mode switch in “Innershield GMAW (CV)”
welding power sources. Damage to the LN-25™ position. Set CV arc control to “2” (or “NORMAL”
circuit can occur as a result of the high output on some machines). Initially set the output control
inductance typically associated with these power on “7”.
sources. TIG high frequency power should never be
applied to the LN-25™.
DC-400™ AND CV-400™
If not using an LN-25™ Remote Output Control option
a. Connect a jumper from 2 to 4 on the power
(See Remote Output Control Options and Cable
source ter minal strip so the output will be
Assemblies Section), the power source output must

energized when the power source is turned on.

be electrically “hot” at all times when the power source
is turned on. NOTE: DC-400™ machines above Code 9200 have
an output toggle switch to perform this function.
See the power source instruction manual for proper
power source connections and setting required. b. Connect the electrode cable to the output
ter minal of polarity required by electrode.
Connect work lead to other output terminal.
LN-25™
c. Place “Set to Same Polarity As Electrode Cable “POSITIVE”. For electrode positive welding,
Connection” switch at appropriate position. interchange the above lead connections so the
LN-25™ electrode lead is then connected to the
d. Place power source toggle switch in “Output positive power source terminal.
Control at DC(CV) -400™” position, unless a
remote control is connected to 75, 76 and 77 on b. Place both switches on the CV Adapter to the CV
the power source terminal strip or to the MS type INNERSHIELD position and make appropriate
connector. power source settings per the CV Adapter instruc-
tions provided for the power source being used.
e. If power source has a mode switch, set switch to
Constant Voltage Innershield. Initially set the c. The output voltage is set with the voltage control
output control on “6”. on the CV Adapter.
DC-600™ NOTE: Refer to the Instruction Manual provided with

the machine for details on connection and operation
a. Connect a jumper from 2 to 4 on the power source of the LN-25™ with the power source.
terminal strip so the output will be energized when
the DC-600™ is turned on. (For DC-600™ below INVERTEC, CV300™ AND OTHER
Code 8200, also jumper N to S.) NEWER LINCOLN POWER SOURCES

b. Connect the electrode cable to the output terminal Refer to the instruction manual provided with the
of polarity required by electrode. Connect work power source for details on connection and operation
lead to other output terminal. of the LN-25™ with these newer machines.
c. Place “Set to Same Polarity As Electrode Cable
Connection” switch at appropriate position. GUN CABLE CONNECTION TO
d. Place power source toggle switch in “Output FEEDER
Control at DC-600™” position, unless a remote
control is connected to 75, 76 and 77 on the DC- Lay the cable out straight. Insert the connector on the
600™ terminal strip. welding conductor cable into the brass conductor block
on the front of the wire drive unit. Make sure it is all the
e. Set mode switch to Constant Voltage Innershield. way in and tighten the hand wheel clamp. Keep this
Initially set output control on “4”. connection clean and bright. Connect the control cable
polarized amphenol plug into the mating 5-cavity
SAM-400™, –650™ receptacle on the front panel of the wire feeder case.
a. Connect a jumper from 2 to C4 on the power FOR GMA GUN AND CABLES:
source ter minal strip so the output will be
energized when the SAM power source is on. Requires installation of K430-1 or K430-2 Gas
Solenoid Kit (factory installed on K446 and K449
b. Connect work lead to WORK stud. Connect models).
electrode to AUTO EQUIPMENT stud. Connect
SAM-650™ “Tap” lead to the Innershield stud See K430-1 or K430-2 Gas Solenoid Kit Section (in
desired. Accessories Section) for gas solenoid operation and
gas supply connection.
c. Set ELECTRODE POLARITY switch to constant
voltage polarity required by electrode.
d. Set toggle switch to “Constant Voltage” and set

the Constant Voltage Control on welder and the
portable field control on #5 for initial start.
SA-200™, –250™ OR SAE-300™, –400™

(WITH CV ADAPTER)
a. For electrode negative welding, connect the
electrode lead from the LN-25™ to the output
terminal on the CV Adapter, and the work lead to
the power source output ter minal labeled
LN-25™
Install the barbed fitting and union nut to the 5⁄8-18 WIRE FEED DRIVE ROLL AND
female inert gas fitting on the front panel of the LN-

25™ case. Connect the 3⁄16" I.D. gas hose from the gun
GUIDE TUBE KITS
cable to the barbed fitting.
WARNING
When the gun is to be removed, this fitting can be
easily detached by loosening the union nut.
Turn off power source before installing or changing
drive roll and/or guide tubes.
WELD CABLE CONNECTION
The size of the electrode cable and work cable must
be sufficient for the maximum weld current and total NOTE: The maximum wire sizes the LN-25™ will
cable length to be used. Refer to table A.1. satisfactorily feed are 5⁄64" cored and 1⁄16" solid electrodes.
TABLE A.1 The electrode sizes that can be fed with each roll and
guide tube are stencilled(1) on each part. Check the kit
Total Cable Length for proper components. See the instructions, included
Weld Current
with the drive roll kit, to install these parts on new

60% Duty Cycle 50'-100' 100'-150' 150'-200' 200'-250'

machines or replace them on used machines. Refer
200Amps 2 AWG 2 AWG 1 AWG 1/0 to table A.2.
300Amps 1 AWG 1 AWG 1/0 2/0
400Amps 2/0 2/0 3/0 3/0
TABLE A.2
500Amps 2/0 3/0 3/0 4/0
ELECTRODE CABLE CONNECTION Kit Instructions
Steel Wire Sizes:

On units without an internal contactor route the .068-5⁄64 Cored KP653-3⁄32 L9932
electrode cable through the oval hole in the LN-25™ 1
⁄16 (.062) Cored or Solid -1⁄16
rear panel, then along the case floor behind the reel Steel
(Can also be used for .052)
support and around the door side of the wire drive. .045 and .052 Solid Steel -.052
Connect the electrode cable to the LN-25™ using the .045 and .052 Cored -.052C
1⁄2" bolt on the front of the wire drive. .035 Solid Steel -.035S
.035 Cored -.035C
On units with an internal contactor connect the .030 Solid Steel -.030S
.025 Solid Steel -.025S
electrode cable to the LN-25™ electrode input cable
with the nut and bolt provided. Tape the bolted

Aluminum Wire Sizes:

connection. 1
⁄16 KP654-1⁄16A L9932
3
⁄64 -3⁄64A
.035 -.035A
ELECTRODE CABLE CONNECTION
(FOR LATER CODE NUMBERS ABOVE 10500)
Drive rolls for only cored electrode sizes are stencilled with a
(1)
Route the electrode cable through the oval hole “C” suffix to the wire sizes.
in the lower por tion of the LN-25™ rear panel.
Drive rolls for only solid electrode sizes are stencilled with an “S”
Connect the electrode cable to the LN-25™ input suffix to the wire sizes.
stud using the the 1/2” nut provided.
Drive rolls for aluminum wire sizes are stencilled with an “A” suffix
Secure the cable with the strain relief clamp to the wire sizes.
provided. All units are supplied with an optional
pigtail for customers that prefer to make a taped
and bolted connection externally.
WORK CABLE CONNECTION

Connect a work lead of sufficient size between the

proper output stud on the power source and the
work. Be sure the connection to the work makes
t i g h t m e t a l - t o - m e t a l e l e c t r i c a l c o n t a c t . Poor
work lead connections can result in poor welding
performance.
LN-25™
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-6
LN-25™
NOTES
A-6
Section B TABLE OF CONTENTS Section B
- OPERATION SECTION -
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . B-2
Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
LN-25™ Instruments and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Loading Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Mounting 22 to 30 lb Readi-Reel Coils . . . . . . . . . . . . . . . . . . . . B-5
Mounting 10 to 30 lb Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Mounting 13 or 14 lb Innershield Coils . . . . . . . . . . . . . . . . . . . . B-5
Loading Wire Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Idle Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Presetting Wire Feed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Setting Constant Wire Feed Speed (CV Mode) . . . . . . . . . . . . . B-7

Setting Arc Sensing Wire Feed Speed (CC Mode) . . . . . . . . . . . B-7
Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Procedure at End of Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Open Arc Welding with a Constant Current Power Source . . . . . . . . . . . B-9
Automatic Protection Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Overvoltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Motor Overload Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
LN-25™
B-2 OPERATION B-2
SAFETY PRECAUTIONS GENERAL DESCRIPTION

The LN-25™ is a lightweight portable semiautomatic

READ AND UNDERSTAND ENTIRE SECTION
wire feeder designed for “across-the-arc” operation
BEFORE OPERATING MACHINE without a control cable on most any DC welding power
source. Simply connect the LN-25™ to the electrode
cable, clip it to Work and it is ready to weld, using up
to 30 lb. coils or spools.
WARNING The wire drive, controls and wire reel are fully
enclosed in a rugged molded plastic case providing a
compact and versatile welding package ideally suited
• Do not touch electrically live to “on-the-go” field welding applications in virtually any
part or electrode with skin or environment.
wet clothing.
• Insulate yourself from work

RECOMMENDED PROCESSES
and ground.
• Always wear dry insulating

AND EQUIPMENT
gloves.
When combined with the drive roll kits and
FUMES AND GASSES can accessories available for use with the LN-25™, a
be dangerous. versatile portable welding system can be provided to
meet the specific needs of Innershield, submerged arc
• Keep your head out of or gas metal arc welding applications within the wire
fumes. feed capabilities of the LN-25™.
• Use ventilation or exhaust to The LN-25™ provides constant wire feed speed for
remove fumes from breath- use with constant voltage (CV) power sources, and
ing zone. arc-sensing wire feed speed for use with constant
current (CC) (formerly variable voltage) power
WELDING SPARKS can sources. Wire speed is presettable on a dual-range
cause fire or explosion. calibrated dial.
• Keep flammable material

The power sources recommended for use with the LN-
away.
25™ include the DC-250™, -400™, -600™, CV-400™
and R3S type transformer machines, and the SAM-
ARC RAYS can burn. 400™, -650™ engine welders, as well as the SA-
200™, -250™ or SAE-300™, -400™ with CV Adapter
• Wear eye, ear and body pro- and Pulse Power 500™ with K460-1 LN-25™ Kit.
tection.
WELDING CAPABILITY
The LN-25™ will handle up to 500 Amp 60% duty
cycle welding currents. However, when equipped with
a K443-1,-2, or-3 (depending on code number)
Contactor, the LN-25™ will handle up to 300 Amp
60% duty cycle.
LN-25™
B-3 OPERATION B-3
LN-25™ INSTRUMENTS AND

NOTE:
CONTROLS 1. The Voltmeter will read zero if the LN-25™ work

clip lead is not connected to work, even if the
Refer to Figure B.1 for control locations. electrode is electrically “hot” to work.
FIGURE B.1 – CONTROL LOCATIONS. 2. The Voltmeter will read below zero if the LN-25™
polarity switch is not set to the same polarity as
REMOTE WIRE SPEED the electrode.
ARC VOLTAGE DIAL RANGE
CONTROL SWITCH 3. The Voltmeter will read power source open circuit
(OPTIONAL)
voltage when the gun trigger is open, even if the
WIRE
LN-25™ is equipped with the internal contactor.
SPEED
DIAL “ELECTRODE POLARITY” SWITCH
The polarity switch is located on the front panel of the

LN-25™ case.
VOLT
GAS POST/ METER

PRE FLOW
TIMERS Set the switch to the same polarity as the electrode
(OPTIONAL)
lead connection to the power source. If the switch is
not set for the correct polarity, the wire feeder will not
ELECTRODE
POLARITY operate.
WORK CLIP
SWITCH
LEAD
GAS WIRE FEED MODE SWITCH
FITTING GUN
(OPTIONAL) CONNECTION The CV-VV (CC) Wire Feed Mode switch is located
GUN
BLOCK
inside the LN-25™ case. The toggle switch extends
TRIGGER from beneath the control box just above the wire drive.
AMPHENOL
CONNECTOR
The forward “CV” position provides constant wire feed
speed mode for use with constant voltage (CV)
welding power sources.
The backward “VV (CC)” position provides arc-sensing

wire feed speed mode for use with constant current

(formerly variable voltage) welding power sources.
OPTIONAL
GAS INPUT WIRE SPEED DIAL AND RANGE SWITCH
FITTING
The Wire Speed control dial on the front panel of the

LN-25™ has two calibrated dial ranges selected by
GAS PURGE the HI-LO Dial Range switch.
BUTTON
When switched to the LO range position, the constant

wire feed speed (CV Wire Feed Mode) is set on the
inside (white) dial range calibrated for 50 to 350 in/min.
ELECTRODE When switched to the HI range position, the constant

CABLE wire feed speed (CV Wire Feed Mode) is set on the
outside (black) dial range calibrated for 50 to
VOLTMETER 700 in/min.
The volts marks around the HI range calibrated dial

(Factory installed on model Codes above 9218)
indicate the minimum arc volts required to obtain the
The 40V DC analog voltmeter is mounted to the front indicated HI range wire feed speeds. For example; if
control panel of the LN-25™ and is connected to read wire speed is set to 400 in/min., a welding procedure
the arc voltage between the LN-25™ electrode cable arc voltage of at least 17V would be required to obtain
connection and the work clip lead. the 400 in/min. wire feed speed.
LN-25™
B-4 OPERATION B-4
WORK CLIP LEAD AWG Maximum Length

#14 25 Ft (7.6m)
WARNING #12 50 Ft (15.2m)
#10 100 Ft (30.5m)
ELECTRIC SHOCK can kill. #6 200 Ft (61m)
• Do not touch metal portions
REMOTE ARC VOLTAGE CONTROL (OPTIONAL)
of the LN-25™ lead clip when
welding power source is on.
This rheostat control allows you to control the power
source output arc voltage level. Refer to K444, K444-1
and K444-2 Remote Voltage Kits in the Accessories
section.
WARNING
GAS FITTING (OPTIONAL)
IMPORTANT SAFETY NOTE: To avoid possible Provides gas output connection to the welding gun for
electrical shock, do not touch the metal portions of the GMAW process. Refer to K430-1 or 2 Gas
the LN-25™ work lead clip if the power source output Solenoid Kit in the Accessories Section.
is on. The clip will be electrically “HOT” to work if the
input electrode cable to the LN-25™ is electrically GAS POST PRE-FLOW TIMERS (OPTIONAL)
“HOT” even if the gun trigger is off and even if an
internal contactor is used. Care should be taken to Allows for variable adjustment of gas pre-flow & post-
only handle the LN-25™ work clip by its non-metal flow at the start and end of the weld. Refer to K434-1
insulated portions and/or the welding power source Gas Flow Timer Kit in Accessories Section.
should be turned off before handling the work clip.
The 15 ft work clip lead attached to the front panel of

the LN-25™ case must be connected directly to the
work using the spring clip on the end of the lead.
If not connected, the LN-25™ will not operate even

if a K431-1 or K624-1 (42V) Remote Output Control
option (refer to Accessories Section) is used.
However, the electrode will still be electrically “HOT”

when the clip lead is dis connected, if K431-1 or
K624-1 (42V) Remote Output Control Option, or
Internal Contactor (K443-1, 2 or3), is not used.
NOTE: The clip lead also serves as a work sensing

lead for the LN-25™ Voltmeter (if installed). If the clip
lead is extended by the user beyond the standard 15
ft. (4.6m) length, the voltmeter reading will be lower
than the actual arc volts due to the LN-25™ motor
control current flowing through the resistance of the
extended lead. To minimize this voltmeter error, the
following minimum lead size is recommended for the
maximum extended lengths shown:
LN-25™
B-5 OPERATION B-5
SEQUENCE OF OPERATION g. To remove Readi-Reel® from Adapter, depress re-

taining spring tab with thumb while pulling the

LOADING ELECTRODE Readi-Reel® cage from the molded adapter with
both hands. It is not necessary to remove adapter
WARNING from spindle.
ELECTRIC SHOCK can kill. h. Load wire into wire drive per Loading Wire Drive
Section.
• Unless an optional output
control or internal contactor is MOUNTING 10 TO 30 LB SPOOLS
used with the LN-25™, the
electrode circuit is electrically For 12" Diameter Spools:
“Hot” when the power source
is on. a. Remove the locking collar and the Readi-Reel ®
adapter shipped on the 2" diameter spindle
• Turn off the power source (adapter is not required).
while mounting electrode
coils. b. Place the spool on the spindle so the brake
holding pin enters one of the holes in the back
side of the spool. Be sure the wire comes off the

MOUNTING 22 TO 30 LB READI-REEL® COILS spool in a clockwise direction when dereeled from
the bottom of the coil.
The early models of the LN-25™ were factory
equipped with a K363-P Readi-Reel® Adapter which c. Replace and tighten the locking collar.
is required to load Lincoln 22 to 30 lb Readi-Reel® d. See Loading Wire Drive section for loading
coils. Later models require the optional K363-P instructions.
adapter kit.
For 8" Diameter Spools (Requires optional K468
a. Make certain that the threaded locking collar is
Spindle Adapter for 8" Spools):
tight and securely locks the adapter on the
spindle (See Figure B.2). a. Remove the locking collar and the Readi-Reel ®
adapter shipped on the 2" diameter spindle
b. Rotate the spindle and adapter so the retaining
(adapter is not required).
spring is at the 12 o’clock position.
b. Slide S18221 Spindle Adapter onto the 2" spindle
c. Position the Readi-Reel® so that it will rotate in a
so the brake holding pin enters the adapter pin
clockwise direction when feeding (wire is to be

hole.
dereeled from bottom of the coil).
c. Place the spool on the spindle so the adapter tab
d. Set one of the Readi-Reel® inside cage wires on
enters one of the holes in the back side of the
the slot in the retaining spring tab.
spool. Be sure the wire comes off the spool in a
e. Lower the Readi-Reel ® to depress the retaining clockwise direction when dereeled from the
spring and align the other inside cage wires with bottom of the coil.
the grooves in the molded adapter.
d. Replace and tighten the Locking Collar.
f. Slide cage all the way onto the adapter until the
e. Load wire into wire drive per Loading Wire Drive
retaining spring “pops up” fully.
Section.
MOUNTING 13 OR 14 LB INNERSHIELD COILS

WARNING (Requires Optional K435 Spindle Adapter for 14 lb
Check to be sure the retaining spring has fully Coils.)
returned to the locking position and has securely
a. Remove the locking collar and the Readi-Reel ®

locked the Readi-Reel® cage in place. Retaining spring adapter shipped on the 2" diameter spindle
must rest on the cage, not the welding electrode. (adapter is not required).
b. Mount K435 Spindle Adapter and Innershield coil

per the Instructions (S18256) included with the
K435.
LN-25™
B-6 OPERATION B-6
FIGURE B.2 – READI-REEL® INSTALLATION.

2" O.D. MOLDED ADAPTER

SPINDLE
RETAINING
SPRING
THREAD LOCKING
COLLAR
BRAKE HOLDING PIN
(MUST ENGAGE HOLE
IN ADAPTER RIB)
GROOVES
READI-REEL
INSIDE CAGE
WIRES
LOADING WIRE DRIVE f. Inch the electrode through the gun.
a. Turn the reel or spool until the free end of the g. Adjust the brake tension with the thumbscrew on
electrode is accessible. the spindle hub until the reel turns freely, but with
little or no overrun when wire feeding is stopped.
b. While tightly holding the electrode, cut off the bent Do not over tighten.
end and straighten the first six inches. Cut off the
first inch. (If the electrode is not properly
straightened, it may not feed or may not go into CAUTION
the outgoing guide tube causing a “birdnest”.)

Keep gun in LN-25™ gun holder when not feeding wire
c. Insert the free end through the incoming guide to prevent accidental arcing.
tube to the drive roll.
d. Turn on the welding power source.
IDLE ROLL PRESSURE SETTING
WARNING The idle roll pressure is set at the factory backed out
two turns from full pressure. This is an approximate
Unless an optional output control or internal contactor setting. For small wire sizes and aluminum wire, the
is used with the LN-25™, the electrode circuit is optimum idle roll pressure varies with type of wire,
electrically “hot” when the power source is on. surface condition, lubrication and hardness. The op-
timum idle roll setting can be determined as follows:
e. Press the gun trigger and push the electrode until 1. Press end of gun against a solid object that is
it just enters the drive roll. electrically isolated from the welder output. Press
the gun trigger for several seconds.
WARNING 2. If the wire “birdnests,” jams or breaks at the drive

roll, the idle roll pressure is too great. Back the
When inching with gun trigger, the electrode and drive pressure setting out 1⁄2 turn, run new wire through
mechanism are always “hot” to work and ground. Use gun, and repeat above steps.
the “cold” inch switch on models with internal contactor.
3. If the only result is drive roll slippage, shut off the
power source, then loosen the gun cable clamping
LN-25™
B-7 OPERATION B-7
screw in the gearbox conductor block and pull the FIGURE B.3 – CC WIRE SPEED SETTING.
gun cable forward about six inches. There should

be a slight waviness in the exposed wire. If there DESIRED IN/MIN ARC VOLTS USED
is no waviness, the pressure is too low. Increase 700 35
the pressure setting 1⁄4 turn, lock the gun cable in
650
place and repeat the above steps. 31
600
PRESETTING WIRE FEED SPEED 550
29
27
The LN-25™ permits accurate presetting of the 500
25
desired wire feed speed, before welding, in both CV 450
and CC wire feed modes. 23
400
21
SETTING CONSTANT WIRE FEED SPEED (CV 350
MODE) 19
300
17
a. Set Wire Feed Mode switch to CV position. 250
15
b. Set Dial Range switch to LO position for wire feed 200
speeds up to 350 in/min., or HI position for wire 150

feed speeds over 350 in/min.
100
c. Set Wire Feed dial to the desired wire feed speed 50
on the selected calibrated dial range. 50 100 150 200 250 300 350 400 450 500 550 600 650 700
CC Wire Speed Setting

The wire speed will remain constant at the value set, (Hl or LO Range)
independent of arc voltage changes, as long as the
arc voltage does not drop below the value per the b. Referring to the graph located above the Mode
chart below for the max. wire feed speed shown: switch (also shown in Figure B.3):
1. Select the horizontal line representing the DE-
Maximum Speed Minimum Arc Volts SIRED IN/MIN. for the welding procedure. (See
example arrow line for 375 in/min.)
350 IPM 15V
400 IPM 17V 2. Select the diagonal line representing the ARC
500 IPM 21V VOLTS to be used for the welding procedure.
600 IPM 24V (See example arrow line for 29 volts.)

700 IPM 27V 3. Determine the vertical line representing the CC
WIRE SPEED SETTING where the above two
SETTING ARC SENSING WIRE FEED SPEED lines cross. (See example arrow line for 450.)
(CC MODE)
c. Set the Wire Speed dial to the value determined
When using a constant current (formerly variable in Step (3) above (450 for example used). Use HI
voltage) power source, welding performance is im- Dial Range if value to be set is over 350.
proved using arc sensing wire feed speed (CC [VV]
The wire will feed at the DESIRED IN/MIN speed
mode). In this wire feed mode the wire speed
when the welding power source is set to the arc
increases if arc voltage increases, and decreases if
voltage to be used for the weld procedure (375 in/min.
arc voltage decreases, but remains constant at any
at 29V for example used).
specific voltage level.
A chart representation of the CC wire speed setting
The LN-25™ permits accurate CC mode presetting of graph is shown in Figure B.4, giving the Wire Speed
the desired wire feed speed, for the desired arc dial setting required for the DESIRED IN/MIN and
voltage to be used, by setting the Wire Speed dial in
ARC VOLTS used for the welding procedures:

the following manner before welding:
a. Set Wire Feed Mode switch to CC position.
LN-25™
B-8 OPERATION B-8
FIGURE B.4 – VV (CC) WIRE SPEED SETTING. MAKING A WELD

Arc Volts Used SETUP

Desired
In/Min 16 18 20 22 24 26 28 30 32 34 a. Connect work cable to metal to be welded. Work
cable must make good electrical contact to the
50 109 97 88 80 73 67 63 58 55 51 work. The work must also be grounded as stated
60 131 117 105 95 88 81 75 70 66 62
70 153 136 123 111 102 94 88 82 77 72 in “Arc Welding Safety Precautions.”
80 175 156 140 127 117 108 100 93 88 82
90 197 175 158 143 131 121 113 105 98 93 b. Check that the LN-25™ is properly connected to
the power source for the polarity and process to
100 219 194 175 159 146 135 125 117 109 103 be used, and appropriate power source settings
110 241 214 193 175 160 148 138 128 120 113
120 263 233 210 191 175 162 150 140 131 124
are made for the procedure to be used. (Refer to
130 284 253 228 207 190 175 163 152 142 134 power source operating and connection
140 306 272 245 223 204 188 175 163 153 144 instructions.)
150 328 292 263 239 219 202 188 175 164 154 NOTE: If the K431-1 Remote Output Control Kit or
160 350 311 280 255 233 215 200 187 175 165
K624-1 42V Remote Control Module is installed but
170 372 331 298 270 248 229 213 198 186 175
180 394 350 315 286 263 242 225 210 197 185 the LN-25™ is to be used without the Remote Control
190 416 369 333 302 277 256 238 222 208 196 Cable Assembly, then the Remote Board harness plug
must be removed from the 16-pin receptacle on the
200 438 389 350 318 292 269 250 233 219 206
210 459 408 368 334 306 283 263 245 230 216
Control Board and the jumper plug (T13498-21)
220 481 428 385 350 321 296 275 257 241 226 reinstalled.
230 503 447 403 366 335 310 288 268 252 237
240 525 467 420 382 350 323 300 280 263 247 c. Place the LN-25™ conveniently near the work
area in a location to minimize exposure to weld
250 547 486 438 398 365 337 313 292 273 257 spatter and to avoid sharp bends in the gun cable.
260 569 506 455 414 379 350 325 303 284 268
270 591 525 473 430 394 365 338 315 295 278
d. Connect the LN-25™ Clip Lead to work and set
280 613 544 490 445 408 377 350 327 306 288
290 634 564 508 461 423 390 363 338 317 299 Polarity Switch to same polarity as electrode.
300 656 583 525 477 438 404 375 350 328 309 e. Set WIRE FEED MODE switch to CV or VV (CC),
310 678 603 543 493 452 417 388 362 339 319 as appropriate for the power source, then set the
320 700 622 560 509 467 431 400 373 350 329 proper DIAL RANGE and WIRE SPEED dial set-
330 642 578 525 481 444 413 385 361 340
340 661 595 541 496 458 425 397 372 350
ting for the proper wire feed speed per the welding
procedure:
350 681 613 557 510 471 438 408 383 360
360 700 630 572 526 484 450 420 394 370 For CV: Set dial to the calibrated IN/MIN desired.
380 666 604 554 512 472 444 416 392 (Refer to Setting Constant Wire Feed Speed
400 700 636 584 538 500 466 438 412 Section.)
420 668 612 566 526 490 460 432
For CC: Set dial to value determined from the CC
440 700 642 592 550 514 482 452 Wire Speed Graph for the DESIRED IN/ MIN
460 670 620 576 536 504 472
480 700 646 600 560 526 494
and ARC VOLTS to be used. (Refer to Setting
500 674 626 584 546 514 Arc Sensing Wire Feed Speed Section.)
520 700 650 606 568 536 NOTE: If procedure permits a range of acceptable
540 676 630 590 556 arc voltage, use the middle of the range to
560 700 654 612 576 determine proper WIRE SPEED setting.
580 676 634 598
600 700 656 618 f. If using the optional Gas Flow Timer, set the de-
620 678 638
sired PREFLOW TIME and POSTFLOW TIME.
640 700 658
660 680
g. Be sure the proper contact tip for the wire size
680 700 being used is in the gun, and the gun is safe
700 from work contact. (Use the LN-25™ insulated
gun holder.)
VV(CC) Speed Setting = Desired IPM X 35
Arc Volts
LN-25™
B-9 OPERATION B-9
h. Turn on the welding power source, as well as the c. Lower welding helmet, close gun trigger, and
shielding gas supply (if used). begin welding. Hold the gun so the contact tip to
work distance gives the correct electrical stickout
as required for the procedure being used.
WARNING NOTE: If the arc voltage is not within the proper

procedure range adjust the power source output
Unless an optional output control or internal contactor control. (The CC mode WIRE SPEED setting should
is used, the electrode is electrically “hot” when the not be changed from the preset procedure value for
power source is on. The gun trigger controls wire the proper arc voltage.)
feed only.
d. To stop welding, release the gun trigger and
then pull the gun away from the work. Store the
gun in the LN-25™ insulated gun holder when
WARNING not welding.
CYLINDER may explode if PROCEDURE AT END OF COIL

damaged.
When the wire on the reel is used up, the following
• Keep cylinder upright and
procedure is to be followed for removing the old wire
chained to support.
from the gun cable and loading a new reel.
• Keep cylinder away from
a. Shut off power source if a Remote Output Control
areas where it may be dam-
Option or internal contactor is not used.
aged.
b. Cut the end of the electrode off at the gun end.
• Never lift welder with cylinder
Do not break it off by hand since this puts a slight
attached
bend in the wire and makes it difficult or
• Never allow welding elec- impossible to pull it back through the nozzle.
trode to touch cylinder.
c. U n c o u p l e t h e g u n c o n d u c t o r c a b l e f r o m
• Keep cylinder away from the LN-25™.
welding or other live electrical
d. Lay the cable out straight.
circuits.
e. Using pliers to grip the wire, pull it out of the

cable from the connector end. Do not pull it from
the gun end.
WELDING
f. Put the conductor cable back on wire drive unit
after the electrode has been removed.
WARNING
g. Load a new coil of wire and feed it through the
cable as described in Loading Electrode Section.
ARC RAYS can burn.
• Do not touch metal portions OPEN ARC WELDING WITH A

of the LN-25™ lead Clip
when welding power source CONSTANT CURRENT (formerly
is on. variable voltage) POWER
SOURCE
Although a constant voltage (CV) power source
a. Cut the electrode within approximately 3⁄8" of the

end of the contact tip for solid wire and within is recommended for Innershield ® and gas metal
approximately 3⁄4" of the extension guide for cored arc (GMAW) open arc welding, satisfactory general
wire. pur pose welding may be obtained using the
LN-25™ with a constant current (CC) power
b. Position electrode over joint. End of electrode source for non-critical commercial quality mild
should be slightly off the work. steel welding applications.
LN-25™
B-10 OPERATION B-10
Arc shorting is more difficult to avoid when using

CAUTION a CC power source, and requires a more refined

operator technique than when using a CV power
source. Improved performance can be obtained on
Do not use LN-25™ models below Code 9200 with CC power source applications within the following
any TIG or Square Wave welding power sources. Do guidelines:
not use LN-25™ models equipped with internal
contactors with non-Lincoln TIG or Square Wave 1. Flatter slope power sources with higher arc force
welding power sources. Damage to the LN-25™ (short circuit current) will improve performance
circuit can occur as a result of the high output over steep slope machines. The steeper the slope,
inductance typically associated with these power the more critical it is to hold proper electrode
sources. TIG high frequency power should never be stickout to maintain arc stability. Welding
applied to the LN-25™. techniques, such as weaving, will be more difficult
to control. Use the highest output current tap or
setting capable of providing the voltage
While welding with a continuously fed electrode, weld adjustment required for the procedure.
current variations are continuously taking place. There
2. Use spray or non-shorting small ball type transfer
are many causes for these variations, but
processes at higher procedure voltage levels.

predominantly they occur due to changes in electrical
Generally, open arc processes with procedure
stickout (operator hand movements, nozzle tip contact
voltage levels over 22 volts perform satisfactorily.
variations, etc.) and the dynamic metal transfer
Arc stability at procedure voltage levels below 22
characteristics of the process or procedure being
volts may be more difficult to control, with the
used (short arc, globular transfer, etc.).
general exception of fine (.023–.035) solid steel
When using a CV power source, these current electrodes with Argon-rich shielding gas or NR-152
variations have essentially no effect on the welding and NR-211 Innershield®.
arc stability since CV power sources can provide a
wide range of weld current levels with virtually no
change in average arc voltage. These “flat slope” CV
CIRCUIT PROTECTION AND
power sources, therefore, provide the arc power AUTOMATIC SHUTDOWN
required to produce the best welding characteristics
and ease of operation for most open arc, constant The LN-25™ control provides automatic electronic
wire feed speed, welding processes. protection circuits which shut down the LN-25™ under
various fault conditions.
CC (formerly VV) power sources, on the other hand,

permit the arc voltage to decrease with increases in OVERVOLTAGE SHUTDOWN

welding current. The output characteristics of these
power sources can range from a “drooping slope,” If the power source open circuit voltage exceeds about
which provide minor arc voltage changes with weld 110-120 volts, the LN-25™ will not operate until the
current variations, to “steep slope” which provide power source voltage drops below about 102-110
broad voltage changes with only minor current volts.
variations. The steeper the slope the more difficult it
becomes to maintain arc voltage stability with a MOTOR OVERLOAD SHUTDOWN
constant wire speed open arc process.
If excessive motor overload occurs (due to prolonged
To aid in stabilizing the arc voltage when welding on excessive feeding force, jammed drive rolls or shorted
CC power sources the LN-25™ is provided with a CC motor leads), the LN-25™ will shut down within a few
wire feed mode. This arc voltage sensing feed mode seconds after the overload occurs.
decreases (or increases) the wire speed when the arc
voltage decreases (or increases). However, if the CONTROL PC BOARD (Codes above 9900).
electrode shorts to the work, the arc voltage will
essentially drop to zero and the short circuit current

supplied by the CC power source may not provide The Control P.C. Board has electronic protection for trig-
enough power to re-establish the arc (especially with ger circuit faults to the electrode circuit.
steeper slope machines). Under this condition the LN-
25™ feeder will stop, as if the trigger was released, The shutdown will reset automatically when the gun
and not restart until the short has been opened. trigger is released, but will reoccur if the situation is
not remedied.
LN-25™
Section C TABLE OF CONTENTS Section C
- ACCESSORIES SECTION -
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
LN-25™ Option Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Gas Solenoid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K434-1 Gas Flow Timer Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
LN-25™ Contactor Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Remote Output Control Options and Control Cable Assemblies . . . . . . . C-4
K431-1 Remote Output Control Kit . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K433 Power Source Remote Box . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K432 Remote Control Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . C-4
K439 Remote Extension Cable Assembly . . . . . . . . . . . . . . . . . . . . . C-5
K624-1 42V Remote Output Control Module . . . . . . . . . . . . . . . . . . C-5
K625, K626, K627 Remote Control Cable Assembly . . . . . . . . . . . . C-5
K444, K444-1 or K444-2 Remote Voltage Control Kit . . . . . . . . . . . . C-5
K363P Readi-Reel® Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Gun Cable Connector Requirements To Permit Proper Connection
To LN-25™ Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
LN-25™
C-2 ACCESSORIES C-2
How to use Table C.1.
Determine which Kit No. is to be used. Locate that Kit No. in the left hand vertical column.
Scan horizontally to determine which LN-25™ model is required and what additional kits may be required.
TABLE C.1
LN-25™ OPTION CHART

O = CANNOT BE USED WITH X = REQUIRED ➀ = REQUIRES ONE OF THESE + = INCLUDED WITH
SEE TEXT
LN-25™ MODELS LN-25™ KITS

KIT NO.
LN-25™
LN-25™
LN-25™
K431-1
K443-1
K444-1
K444-2
K460-1
K624-1
K432
K433
K444
K461
K625
K626
K627
K428
K446
K449
Solenoid
K430-1,2 Kit X + +
Remote Output
K431-1 Control Module ➀ ➀ O X X O O O O O O
Remote
K432 Control Cable X X
115VAC
K433 Power Source X X
Remote Box
Gas Flow
K434-1 Timer Kit ➀ ➀ ➀ ➀ ➀
50 Ft.
K439 Ext. Cable X
K443-1 Contactor Kit + O O O
Contactor Kit
K443-2 Codes 10500,10558 + O O O
K443-3 Contactor Kit + O O O

Codes 11144 & Above
Remote for Power
K444 Source w/Terminal Strip ➀ ➀ ➀ O O O
Remote for Power

K444-1 Source w/6 Pin Amphenol ➀ ➀ ➀ O O O
Remote for Power

K444-2 Source w/14 Pin Amphenol ➀ ➀ ➀ O O O
42VAC Remote
K-624-1 Output Control Module ➀ ➀ O O O O O O O ➀ ➀ ➀
500 Amp Cable /w Stud-

K625 Type Output Terminals X
350 Amp Cable /w Stud-

K626 Type Output Terminals X
400 Amp Cable /w Twist-

K627 Mate™ Type Terminals X
Pulse Power™
K460-1 Adapter Kit ➀ ➀ O O O O O O X O
Pulse Power™
K461 Control Cable X
IMPORTANT SAFETY NOTE: This wire feeder provides “COLD” electrode when gun trigger is released if equipped with K431-1, K432 or
K433 remote output control system, or K443-2 internal contactor kit. This feature and the use of a DC Constant Voltage welder provide
an added margin of safety when welding must be performed under electrically hazardous conditions such as: • Damp locations • While
wearing wet clothing • On metal structures, or, • In cramped positions (sitting, kneeling or lying) if there is a high risk of unavoidable or
accidental contact with the workpiece or ground.
LN-25™
C-3 ACCESSORIES C-3
OPTIONAL ACCESSORIES
WARNING WARNING
ELECTRIC SHOCK can kill. CYLINDER may explode if
damaged.
removed. • Keep cylinder upright and
chained to support.
• Turn off power source before
installing or servicing. • Keep cylinder away from
areas where it may be dam-
• Do not touch electrically hot aged.
parts.
• Never lift welder with cylinder
• Turn the input power to the attached.
welding power source off at
the fuse box before working in • Never allow welding electrode
the terminal strip. to touch cylinder.
• Only qualified personnel • Keep cylinder away from weld-
should install, use or service ing or other live electrical cir-

this equipment. cuits.
GAS SOLENOID KIT (K430-2 FOR CODES

See GMA Gun Cable Gas Connection.
ABOVE 10500 OR K430-1 FOR CODES BELOW 10500)
Installation instructions are included with the kit.
(Factory Installed on K446 and K449 Models)
K434-1 GAS FLOW TIMER KIT
The kit permits the LN-25™ to be used for Gas
Metal Arc Welding (GMAW) processes with a GMA (Requires either a K431-1 Remote Output Control Kit,
gun cable. K624-1 42V Remote Output Control Kit, or internal
contactor K443-1 or K443-2 installed in LN-25™).
The kit can be used with or without a Remote Output
Control option installed in the LN-25™ and provides The K434-1 Gas Flow Timer Kit is used with the
flow of shielding gas: LN-25™ Gas Solenoid when the LN-25™ is
equipped with any of the Remote Output Control
1. With wire feed, when the gun trigger is closed. Options or internal contactor.
2. Without wire feed, when the kit’s Purge button This kit provides the following gas flow
(located beneath the gas inlet fitting) is pressed. timer functions:
NOTE: Always shut off the valve at the gas cylinder 1. Preflow Control - Provides flow of shielding
before making any gas connections to the LN-25™. gas to the work before the arc is established.
The solenoid valve is energized immediately
User must provide a supply of shielding gas, a pres- when the gun trigger is closed, but the time
sure regulator, a flow control valve and a hose from delay before the wire feeder and welding output
the flow valve to the gas inlet fitting of the LN-25™. are energized is adjustable between at least
Install by connecting a supply hose from the gas flow
0 to 1 second.
valve outlet to the 5⁄8-18 female inert gas fitting on the
back panel of the LN-25™ case. The LN-25™ can be 2. Postflow Control - Provides flow of shielding gas
used with any shielding gas recommended in the to the work after welding is stopped. Delay of the
electrode’s product literature at a maximum pressure shut off of the solenoid valve after the gun trigger
of 60 psi (4.1 bar). This may include gases such as is released is adjustable between at least 0.5 to
Argon, Helium, Nitrogen and blended gases such as 5 seconds.
Ar-He, Ar-N2, Ar-O2, Ar-CO2, CO2, Ar-CO2-O2.
Installation instructions are included with this kit.

WARNING
See American National Standard Z-49.1, “Safety in
Welding and Cutting” published by the American
Welding Society.
LN-25™
C-4 ACCESSORIES C-4
LN-25™ CONTACTOR KIT NOTE: If the K431-1 Remote Output Control Kit is
(K443-1 FOR CODES

BELOW 10500, K443-2 FOR CODES 10500 TO 10558 OR K433-3
installed but the LN-25™ is to be used without the
FOR CODES ABOVE 11144)
K432 Remote Control Cable Assembly, then the Re-
(Factory installed in K449 Model.) mote Board harness plug must be removed from the
12-pin receptacle on the Control Board and the jumper
The internal contactor provides “cold” electrode until plug (T13498-21) reinstalled.
the gun trigger is pressed, and a fixed burnback time
delay to prevent electrode from sticking in the weld K433 POWER SOURCE REMOTE BOX
crater when the trigger is released. The contactor is
rated for use up to 300 amps. A cold inch switch (Requires K431-1 Remote Output Control Kit installed
allows the wire to be loaded into the system without in LN-25™ using K432 Remote Control Cable.)
being electrically “hot”.
The Remote Box is designed to mount and connect
Installation Instructions are included with the kit. to Lincoln Idealarc® semiautomatic power sources per
the Installation Instructions and power source
connection diagrams included with the kit.
CAUTION
The Remote Box provides the proper welding power
These kits can only be used with LN-25™’s above source control interface and isolated 24V AC input
Code 9200 or with LN-25™’s equipped with a G1757- supply for the LN-25™ equipped with the K431-1
3 (or higher part number) Control PC board. To prevent Remote Output Control Kit.
possible damage to the LN-25™ with internal
contactor, do not connect to non-Lincoln TIG or Remote Box requires 115V AC, 50/60 Hz input and a
Square Wave power sources. TIG high frequency welding power source using a contact closure output
power should never be applied to the LN-25™. pilot circuit, as available on appropriate Lincoln weld-
ing power sources.
NOTE: The K443-1, K443-2 or K433-3 cannot be used
with K431-1 or K624-1 Remote Output Control Kit. If K432 REMOTE CONTROL CABLE
remote voltage control is desired along with the ASSEMBLY
internal contactor, obtain a K444, K444-1 or K444-2
Remote Voltage Control Kit. (Requires K431-1 Remote Output Control Kit installed
in LN-25™ and K433 Remote Box mounted to power
REMOTE OUTPUT CONTROL source with 115V AC auxiliary power.)
OPTIONS AND CONTROL CABLE
The K432 control cable assemblies include an elec-

ASSEMBLIES trode cable, rated for up to 500 amps 60% duty cycle,
and a 6-conductor control cable with pin connectors
Remote Output Control Options are available to pro- on both ends. Available in 25, 50, 75 and 100 ft.
vide the LN-25™ with the following additional features: lengths.
1. “Cold” electrode until the gun trigger is pressed, The cable assembly end with the socket pin connector
and a fixed burnback time delay to prevent elec- connects to the LN-25™ per the Instructions included
trode from sticking in the weld crater when the with the K431-1 kit.
gun trigger is released.
The cable assembly end with the male pin connector
2. Remote (10K ohm rheostat) control of power connects to the K433 and power source per the In-
source output arc voltage level. structions included with the K433 kit.
K431-1 REMOTE OUTPUT CONTROL KIT K363P READI-REEL® ADAPTER KIT
Adapts Lincoln Redi-Reel® coils of electrode 30 lb.

(For use with K432 Remote Control Cable and K433
(14kg) and 22 lb. (10kg) to a 2” (51mm) spindle.

Power Source Remote Box.)
Durable molded plastic one piece construction.
The Kit includes a Remote PC board and control Designed for easy loading: adapter remains on spindle
cable receptacle which mount and connect inside the for quick changeover.
LN-25™ control box per the Installation Instructions
(M17584) included with the kit.
LN-25™
C-5 ACCESSORIES C-5
K439 REMOTE EXTENSION CABLE

CABLE 60% DUTY POWER SOURCE

ASSEMBLY TYPE RATING ELECTRODE
CONNECTION
The 50 ft. Extension cable assemblies are used to ex-
tend the K432 Remote Control Cable Assembly when K625 500 Amps Stud Terminal
longer cable lengths are required. K626 350 Amps Stud Terminal
K627 400 Amps Twist-Mate™
Multiple K439 Extensions may be used, however, to
prevent excessive weld cable voltage drops, the 500
amp max. rating of the K432 should be reduced by at
least 50 amps for each K439 Extension used. For
example, if three K439 Extensions are used (150 ft The cable assembly end with the socket pin connector
total extension), the maximum welding current used connects to the LN-25™ per the Instructions included
should be less than 350 amps. with the K624-1 Kit.
The K439 Extension cable end with the male pin con- The cable assembly end with the male pin connector
nector connects to the K433 Remote Box and power connects to the power source per the Instructions
source per the Instructions included with the K433 kit. included with the K624-1 kit.
The K439 Extension cable end with the socket pin K444, K444-1 OR K444-2 REMOTE
connector connects to the mating K432 cable end (or VOLTAGE CONTROL KIT
next K439 Extension cable end). The electrode cables
are connected using the bolt and nut provided with (Not required if using K431-1 or K624-1 Remote
the K439 Extension. Properly insulate the bolted con- Output Control Kit.
nection with electrical tape.
The Remote Voltage Control Kit provides remote (10K
ohm rheostat) control of power source output arc
voltage level.
K624-1 42V REMOTE OUTPUT
CONTROL MODULE K444 connects to power sources with control terminal
strip connections for lead numbers 75, 76 and 77.
( Fo r u s e w i t h K 6 2 5 , K 6 2 6 , K 6 2 7 R e m o t e
Control Cable) K444-1 connects to power sources with a 6-pin control
receptacle.
The Module includes a 42V Remote PC board and

control cable receptacle which mount and connect NOTE: To use a K444-1 with power sources with only
inside the LN-25™ control box per the Installation a 14-pin control receptacle, a K864 Adapter is required
Instructions included with the kit. to connect to K444-1 and if using a power source
without an output control switch, a K484 Jumper Plug
NOTE: If the K624-1 42V Remote Output Control will also be required to jumper the output pilot circuit
Module is installed but the LN-25™ is to be used (2-4).
without the K625, K626 or K627 Remote Control
Cable Assembly, then the Remote Board harness plug K444-2 connects to power sources with a 14-pin
must be removed from the 16-pin receptacle on the control receptacle and provides a 2-4 jumper to
Control Board and the jumper plug (T13498-21) activate power source output.
reinstalled.
Installation Instructions are included with the kit.
K577-1 REAR HANDLE KIT

K625, K626, K627 REMOTE CONTROL (For LN-25™ model codes above 9383)
CABLE ASSEMBLY
The fold-down handle mounts to the rear of the LN25

(Requires K624-1 Remote Output Control Module case per the Installation Instructions (M16567)
installed in LN-25™.) shipped with the kit.
The K625, K626, K627 control cable assemblies This handle provides a means to also carry the LN25
include an electrode cable and a 8-conductor control in the vertical position, especially convenient for
cable: passing the unit through a manhole.
LN-25™
C-6 ACCESSORIES C-6
The following Figures C.1 and C.2 should serve as a guide to determine if a particular gun or switch
can be connected to the LN-25™.

FIGURE C.1
GUN CABLE CONNECTOR REQUIREMENTS

TO PERMIT PROPER CONNECTION TO
LN-25™ WIRE FEEDER.
.749D.
.747
.62D. .03 x 45o
STYLE "A" .06R.
1.25 MAX.
"A" DIA. HOLE
.295
.290
.252
CONNECTOR MUST
.260
BE INSULATED
1.00
IN THIS AREA
2.00 1.25
LN-25 Connector for 1/16 (.062) through 5/64 Wire
.180
.160
STYLE "B" .03 x 45o
"A" DIA. HOLE
LN-25 Cable Connector for .023 through .052 Wire .495 MAX.
(For all other dimensions, see above) DIA.
FIGURE C.2 – SWITCH REQUIREMENTS.
NOTE: Connector part with .749/.747 diameter should

be made from brass if it is to be part of the welding SWITCH REQUIREMENTS
current carrying circuit. 1
⁄2 Amp AC 24 Volts – Inductive
1
⁄2 Amp DC 24 Volts – Inductive
“A Dia. Hole”
To be Concentric to .749/.747 TO GUN SWITCH
Wire Size Dia. Within .008 F.I.M.
.068 thru 5⁄64 .125 (1⁄8 Drill)
⁄16 (.062)
1
.078 (5⁄64 Drill)
.045 & .052 .062 (1⁄16 Drill)
.023 thru .035 .055 (#54 Drill)
CONNECT LEADS TO
Drive Roll & Guide Tube Wire Sizes Used PINS "A" AND "C"
Kit No.
T-13355-3⁄32 5
⁄64, .072 & .068
T-13355- ⁄16
1 (1)
⁄16, .062
1
S12024-1 (L.E. PART NO.)

T-13355-.052C .045, .052 Cored AMPHENOL AN3057-10 (OR EQUIV.)
T-13355-.052 .045, .052 Solid S12020-6 (L.E. PART NO.)
T-15010.-.035S .023 thru .035 Solid AMPHENOL MS-3106A-18-11P (OR EQUIV.)
(1)
Can also be used for .052" wire
LN-25™
Section D TABLE OF CONTENTS Section D
- MAINTENANCE SECTION -
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Drive Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Wire Reel Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Wire Drive Motor and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Gun and Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Circuit Protection and Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . D-2
Control PC Board Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Automatic Protection Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Adjusting Speed Sensor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Calibration of LN-25™ Wire Speed Dial . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
LN-25™
D-2 MAINTENANCE D-2
SAFETY PRECAUTIONS CONTROL BOX

Every six months open and inspect the control sec-

WARNING tion. The accumulated dirt should be gently blown off
all of the electrical components. Be sure the air that
ELECTRIC SHOCK can kill. is being used is dry. Check that lead plugs are secure
in their receptacles.
removed.
WIRE DRIVE MOTOR AND GEARBOX
• Turn off power source before
installing or servicing. Every year examine the gearbox. Paint the gear teeth
with molydisulfide filled grease. Do not use a graphite
• Do not touch electrically hot grease.
parts.
Check the motor brushes. Replace if they are worn
• Turn the input power to the
down to 1⁄4 ’’ or less. When ordering feed motor
welding power source off at
b r u s h e s, g i ve a l l i n fo r m a t i o n f r o m t h e motor
the fuse box before working in
nameplate.
the terminal strip.
• Only qualified personnel GUN AND CABLE MAINTENANCE
should install, use or service
this equipment. See IM manual provided with the gun and cable as -
sembly.
ROUTINE MAINTENANCE CIRCUIT PROTECTION AND

AUTOMATIC SHUTDOWN
DRIVE ROLLS AND GUIDE TUBES
CONTROL PC BOARD FUSE
After feeding every coil of wire, inspect the drive roll
section. Clean it as necessary. Do not use a solvent On G1757-6 (or higher part no.) PC boards the 1⁄8 amp
for cleaning the idle roll because it may wash the lu - fuse was replaced with electronic protection for trigger
bricant out of the bearing. The drive roll, idle roll and circuit faults to electrode circuit.
guide tubes are stamped with the wire sizes they will
feed. If a wire size other than that stamped on the rolls On G1757-2 through -5 part no. PC boards, the 1⁄8 amp
is to be used, the rolls and guide tubes must be fuse interrupts the 500A lead to the trigger switch. On
changed. G1757- 1 PC boards a 5 amp fuse was used to
interrupt the 667 lead. The LN-25™ will not operate if
The drive rolls for .035 through .052 cored electrode the fuse is blown.
and 1⁄16 through 5⁄64 electrode have a double set of teeth
so they can be reversed for additional life. Drive rolls AUTOMATIC PROTECTION SHUTDOWN
for .023 through .052 solid electrode and aluminum
sizes have no teeth but use two grooves so they also (See Automatic Protection Shutdown Section.)
can be reversed for additional life.
See Wire Feed Drive Roll and Guide Tube Kits Sec - ADJUSTING SPEED
tion for roll changing instructions. SENSOR MODULE
WIRE REEL SPINDLE The LN-25™ Speed Sensor Module is a three lead
Hall Effect switch device encased in an externally

No routine maintenance required. Do not lubricate threaded housing which is screwed into a mounting
spindle. plate on the motor side of the wire drive gearbox.
LN-25™
D-3 MAINTENANCE D-3
Proper positioning of this module is critical to proper

operation of the LN-25™ wire feed speed control. If WARNING

the device is not screwed in far enough, the LN-25™
motor speed could be unstable or run at full speed Electrode will be electrically “hot”. Do not allow fed
with no control. If screwed in too far, it will rub a wire to contact any metal common with welding work.
moving part inside the gearbox.
The module is properly mounted to the gearbox

as shipped from the factory. If the device is ever An alternate means to measure wire feed speed
removed or replaced, proper mounting technique is as is as follows:
follows: a. Cut wire off at the end of the gun tip.
1. Be sure all power to the LN-25™ is shut off at the b. Press trigger to feed wire for exactly 30 seconds.
power source.
c. Cut fed wire off at the end of the gun tip and
2. Check that the module mounting plate is screwed accurately measure its length.
securely to the side of the gearbox. Refer to Drive
d. Multiply the measured length by 2 to obtain
Motor and Gearbox Replacement Procedure
the wire speed (IN/MIN).

and access to the Hall Effect Module in the
Troubleshooting and Repair Section. e. Repeat above steps to assure repeatable
accuracy.
3. Gently screw the module into the mounting plate
until it just touches and stops against the rotating 4. Carefully slip speed knob onto potentiometer
part inside the gearbox. shaft so it points precisely to the wire speed
measured in step 3, then secure the knob set
4. Back the module out 1⁄2 turn, then snug the module screw without disturbing the position. Recheck by
lock nut without rotating the module position. Do repeating step 3.
not over tighten lock nut.
CALIBRATION OF LN-25™ WIRE

SPEED DIAL
Calibration of the LN-25™ Wire Speed dial is achieved
by proper mounting of the dial knob to the speed
potentiometer shaft. Whenever the knob is removed,

the dial is recalibrated as follows:
NOTE: Knob set screw does not seat on shaft flat.
1. Be sure the Wire Speed potentiometer mounting

nut is securely tightened, then rotate the
potentiometer shaft so its flat faces about to the
100 mark on the LO range calibrated dial.
2. Set DIAL RANGE switch to LO and WIRE FEED

MODE switch to CV position.
3. Press gun trigger to feed wire and measure

the wire feed speed (IN/MIN) using a Portable
Digital Wire Feed Speed Meter (Lincoln K283).
Take at least two readings to assure repeat-
able accuracy.
LN-25™
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-4
LN-25™
NOTES
D-4
Section E TABLE OF CONTENTS Section E
- THEORY OF OPERATION SECTION -
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Control Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Welding Current Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Feedback and Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Trigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Optional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Gas Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Protective Devices & Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Overvoltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Motor Overload Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Control PC Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
FIGURE E.1 THEORY OF OPERATION BLOCK DIAGRAM
OPTIONAL
CONTACTOR
CONDUCTOR GUN CABLE

BLOCK
M GUN
COLD O TRIGGER
INCH OPTIONAL T HALL CONNECTOR
SWITCH CONTACTOR O EFFECT
BOARD R MODULE
ELECTRODE
INPUT CABLE
P
O S
L W
A I ARMATURE VOLTAGE
R T VOLT
TO WORK I C METER
CONTROL RPM FEEDBACK
SENSING LEAD T H
Y BOARD
RANGE
WIRE FEED SWITCH
MODE SWITCH
WIRE SPEED
CONTROL
SOLENOID GAS
PC BOARD SOLENOID
EARLY MODELS ONLY - LATER MODELS HAVE CIRCUITRY

INCLUDED ON CONTROL BOARD
LN-25™
E-2 THEORY OF OPERATION E-2
GENERAL DESCRIPTION voltage. It is designed for maximum versatility in

a variety of field applications. It can be used with

The LN-25™ is a portable semiautomatic wire most constant voltage or constant current DC
feeder designed to operate from a DC arc power sources without the need of a control
cable.
FIGURE E.2 – INPUT POWER CIRCUIT.
OPTIONAL
CONTACTOR
CONDUCTOR GUN CABLE

BLOCK
M GUN
COLD O TRIGGER
BOARD R MODULE
ELECTRODE
INPUT CABLE
P
O S
L W
R T VOLT
TO WORK I C METER
SENSING LEAD T H
Y BOARD
RANGE
WIRE FEED SWITCH
MODE SWITCH
WIRE SPEED
CONTROL
SOLENOID GAS
PC BOARD SOLENOID

CONTROL CIRCUIT WELDING CURRENT CIRCUIT

OPERATION The electrode voltage is also applied to the
conductor block through a heavy current
INPUT POWER CIRCUIT carrying cable. The welding gun cable is
connected to the conductor block. This
The DC arc voltage from the power source is combination of welding cable, optional contactor,
applied to the LN-25™ through the electrode conductor block and gun cable constitute the
cable and work sensing lead. This DC voltage is welding current path to the electrode wire. See
connected to the polarity switch, which allows Figure E.2.
the wire feeder to be used in either electrode
positive or electrode negative polarity. The
voltage is then coupled to the voltmeter and

control board. A wire feed mode switch is
included to give the user the capability of using
a constant voltage or, in some processes, a
constant current power source. See Figure E.2.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
LN-25™
FIGURE E.3 – CONTROL CIRCUITS.

OPTIONAL
CONTACTOR
CONDUCTOR GUN CABLE

BLOCK
M GUN
COLD O TRIGGER
BOARD R MODULE
ELECTRODE
INPUT CABLE
P
O S
L W
R T VOLT
TO WORK I C METER
SENSING LEAD T H
Y BOARD
RANGE
WIRE FEED SWITCH
MODE SWITCH
WIRE SPEED
CONTROL
SOLENOID GAS
PC BOARD SOLENOID

FEEDBACK AND CONTROL is desirable to compensate for the varying arc

CIRCUITS voltages associated with the constant current
process. To accomplish this, the control board
The combination of the range switch and wire monitors the command voltage, the feedback
speed control provides a command voltage for signal from the hall effect module and the arc
the control board. The hall effect module voltage. These three factors are monitored and
transforms the motor RPM to a digital voltage compared, and then the appropriate armature
frequency that is “fed back” to the control board. voltage is applied to the wire feed motor.
When operating in the constant voltage (CV)
mode, the control board monitors the “feedback TRIGGER CIRCUIT
signal”, compares it to the command voltage and
delivers the appropriate armature voltage to the When the gun trigger is closed, the control board
wire feed motor. In this manner, a constant wire is “signaled” to apply armature voltage to the
feed speed is maintained. See Figure E.3. When drive motor and to activate any auxiliary circuits
the LN-25™ is connected to a constant current that may be incorporated within the LN-25™.
(CC) power source, a variable wire feed speed See Figure E.3.
LN-25™
FIGURE E.4 – OPTIONAL CIRCUITS.

OPTIONAL
CONTACTOR
CONDUCTOR GUN CABLE

BLOCK
M GUN
COLD O TRIGGER
BOARD R MODULE
ELECTRODE
INPUT CABLE
P
O S
L W
R T VOLT
TO WORK I C METER RPM FEEDBACK
CONTROL
SENSING LEAD T H
Y BOARD
RANGE
WIRE FEED SWITCH
MODE SWITCH
WIRE SPEED
CONTROL
SOLENOID GAS
PC BOARD SOLENOID

OPTIONAL CIRCUITS
CONTACTOR GAS SOLENOID
Early Models Only (Below 10500)

The contactor, contactor PC board, and cold inch
switch are commonly incorporated in the LN-25™. This The gas solenoid feature permits the LN-25™ to be
feature enables the user to have an electrically “COLD” used for gas metal arc welding (GMAW) processes.
gun even though the power sources output terminals When the gun trigger circuit is activated, the control
are electrically “HOT”. Upon receiving a command board signals the solenoid PC board to activate the
from the control board, the contactor PC board sends gas solenoid, which allows shielding gas to flow
a current signal to activate the contactor. The signal through the gun to the arc.
closes the welding current path from the cable to the
conductor block, making the gun electrically “HOT”. Later Models Only (Above 10500)
The cold inch switch allows the user to feed wire
without closing the contactor. In this manner, the The solenoid PC board circuitry has been added to
electrode wire can be fed through the gun with the gun the Control board and the solenoid PC board has been
tip electrically “COLD”. See Figure E.4. eliminated.
LATER MODELS
Codes above 11144 have the Contactor circuitry

added to the Control Board and the Contactor PC
Board has been eliminated. Older codes that have
been upgraded to the newew PControl Board may
have had the Contactor PC Board removed
LN-25™
PROTECTIVE DEVICES AND

CIRCUITS
OVERVOLTAGE SHUTDOWN
If the power source open circuit voltage exceeds

about 110-120 volts, the LN-25™ will not operate until
the power source voltage drops below about 102-112
volts.
MOTOR OVERLOAD SHUTDOWN
If excessive motor overload occurs (due to prolonged

excessive feeding force, jammed drive rolls or shorted
motor leads) the LN-25™ will shut down within a few
seconds after the overload occurs. The shutdown will

reset automatically when the gun trigger is released,
but will reoccur if the overload situation is not remedied
CONTROL PC BOARD FUSES
On G1757-2 thru -5 part no. PC boards, the 1/8 amp

fuse interrupts the 500A lead to the trigger switch.
On G1757-1 PC boards, a 5 amp fuse was used to
interrupt the 667 lead. The LN-25™ will not operate
if either fuse is blown.
On G1757-6 (or higher) part no. PC boards, the 1/8

amp fuse was replaced with electronic protection for
trigger circuit faults to electrode circuit.
LN-25™
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-6
LN-25™
NOTES
E-6
Section F TABLE OF CONTENTS Section F
- TROUBLESHOOTING AND REPAIR SECTION -
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Test Procedures
Gas Solenoid Valve and Solenoid PC Board Test . . . . . . . . . . . . . . . F-7
Gas Solenoid Valve and Control PC Board Test . . . . . . . . . . . . . . . . F-13
Hall Effect Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19
Wire Drive Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23
Contactor & Contactor PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . F-25
Component Replacement Procedures
Contactor PC Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . F-31
Control PC Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-35
Contactor Replacement (codes below 10500) . . . . . . . . . . . . . . . . . F-39
Contactor Replacement (codes above 10500) . . . . . . . . . . . . . . . . . F-41

Gas Solenoid Valve and/or Solenoid
PC Board (If Present) Replacement . . . . . . . . . . . . . . . . . . . . . . . . F-43
Drive Motor And Gearbox Replacement and
Access to Hall Effect Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-47
Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-51
WARNING
• Never work on the inside of the machine without removing the

input power. You can receive a life threatening electrical shock if
you fail to do this. Only qualified technicians should perform
installation, maintenance, and troubleshooting work on the
machine.
LN-25™
F-2 TROUBLESHOOTING AND REPAIR F-2
HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
This Troubleshooting Guide is provided to Step 3. RECOMMENDED
help you locate and repair possible machine COURSE OF ACTION
malfunctions. Simply follow the three-step The last column labeled “Recommended
procedure listed below. Course of Action” lists the most likely com-
ponents that may have failed in your
Step 1. LOCATE PROBLEM (SYMPTOM). machine. It also specifies the appropriate
test procedure to verify that the subject com-
Look under the column labeled “PROBLEM

(SYMPTOMS)”. This column describes pos- ponent is either good or bad. If there are a
sible symptoms that the machine may exhib- number of possible components, check the
it. Find the listing that best describes the components in the order listed to eliminate
symptom that the machine is exhibiting. one possibility at a time until you locate the
Symptoms are grouped into the following cause of your problem.
categories: output problems, function prob-
lems, wire feeding problems, and welding All of the referenced test procedures referred
problems. to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Step 2. PERFORM EXTERNAL TESTS. Refer to the Troubleshooting and Repair
The second column labeled “POSSIBLE Table of Contents to locate each specific
AREAS OF MISADJUSTMENT(S)” lists the Test Procedure. All of the specified test
obvious external possibilities that may con- points, components, terminal strips, etc. can
tribute to the machine symptom. Perform be found on the referenced electrical wiring
these tests/checks in the order listed. In diagrams and schematics. Refer to the
general, these tests can be conducted with- Electrical Diagrams Section Table of
out removing the case wrap-around cover. Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
LN-25™
PC BOARD TROUBLESHOOTING PROCEDURES

- Remove the PC board from the static-shielding bag

WARNING and place it directly into the equipment. Don’t set the
ELECTRIC SHOCK PC board on or near paper, plastic or cloth which
can kill. could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
• Have an electrician install and ing bag.
service this equipment. Turn the
input power OFF at the fuse box - If the PC board uses protective shorting jumpers,
before working on equipment. Do don’t remove them until installation is complete.
not touch electrically hot parts.
- 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-
CAUTION er failure analysis.
Sometimes machine failures appear to be due to PC 4. Test the machine to determine if the failure
board failures. These problems can sometimes be symptom has been corrected by the
traced to poor electrical connections. To avoid prob- replacement PC board.

lems when troubleshooting and replacing PC boards,
please use the following procedure: NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component NOTE: Allow the machine to heat up so that all
causing the failure symptom. electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected. 5. Remove the replacement PC board and
substitute it with the original PC board to
3. If the problem persists, replace the suspect PC recreate the original problem.
board using standard practices to avoid static
a. If the original problem does not reappear by
electrical damage and electrical shock. Read
substituting the original board, then the PC
the warning inside the static resistant bag and
board was not the problem. Continue to look
perform the following procedures:
for bad connections in the control wiring
PC board can be damaged by static electricity. harness, junction blocks, and terminal strips.
- Remove your body’s static b. If the original problem is recreated by the

charge before opening the static- substitution of the original board, then the PC
shielding bag. Wear an anti-static board was the problem. Reinstall the
wrist strap. For safety, use a 1 Meg replacement PC board and test the machine.
ohm resistive cord connected to a 6. Always indicate that this procedure was
grounded part of the equipment followed when warranty repor ts are to be
ATTENTION frame. submitted.
Static-Sensitive - If you don’t have a wrist strap, NOTE: Following this procedure and writing on the
Devices touch an un-painted, grounded, warranty report, “INSTALLED AND SWITCHED PC
Handle only at part of the equipment frame. Keep BOARDS TO VERIFY PROBLEM,” will help avoid
Static-Safe touching the frame to prevent denial of legitimate PC board warranty claims.
Workstations static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must

be either conductive, anti-static or static-dissipative.
LN-25™
Troubleshooting Guide –
See Wiring Diagrams for location of specified Observe Safety Guidelines

components. See Wiring Diagrams for troubleshooting of specific circuits. detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FEEDING PROBLEMS
NOTE: Many options and possible option combinations are available for the LN-25™. In many cases, it is
best to disconnect the options and test the LN-25™ in its “basic” form. In this manner, many possible faulty
circuits can be isolated and/or eliminated from the troubleshooting procedure.
Major physical or electrical damage 1. Contact Lincoln Electric

is evident when the box cover is Ser vice Depar tment 1-888-
removed. 935-3877.
When gun trigger is pulled, there is 1. Check to see if the drive rolls 1. With the gun trigger circuit
no wire feed. are tur ning when the gun activated and the mode switch
trigger is pulled. If the drive in the CV position, check for
NOTE:On codes above 10100, the rolls are turning, then check for the presence of 2 to 23 VDC at
motor leads (541 & 539) are a mechanical restriction in the leads 539 to 541. This is the
in Control Board Connector wire feed path. nor mal range for ar mature
J4, pins 13 & 14. voltage, which is dependent on
2. If the drive rolls do not turn, the wire speed setting.
then check to ensure the power
source is on and an open 2. If the normal armature voltage
circuit voltage (OCV) is present is present at leads 539 to 541,
at the weld terminals. then the motor or motor
brushes may be faulty. Check
3. Make sure the LN-25™ work or replace.
clip is connected to the work
piece or work terminal. 3. If the correct armature voltage
is missing, then remove any
4. Ensure the LN-25™ polarity option plugs that may be
switch matches the electrode connected to J3 on the control

polarity. board. Install the jumper plug
5. Check if the jumper plug on the into the J3 receptacle. If the
control board or contactor problem is solved, then the
board (if used) is loose or option board may be faulty.
missing. 4. Check the wire speed control,
6. Make certain the power source range switch and associated
open circuit voltage is above 15 wiring to the control board.
VDC but not more than 110 5. If the correct armature voltage
VDC. is still not present at leads 539
7. Check if the gun trigger is to 541, then the control board
faulty. Repair or replace. may be faulty. Replace.
8. On “older” control boards,

check the 1/8 amp fuse. If
“blown”, the gun may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LN-25™


FEEDING PROBLEMS (Continued)

The wire feeds for a short period of 1. The drive motor may be 1. Check the motor ar mature
time but then stops feeding. When overloaded. Check the wire current through either of the
the gun trigger is released and feeding path for mechanical armature leads (539 or 541). A
then retriggered, the wire resumes restrictions. typical value is 4 amps DC.
feeding but soon stops again.
2. While welding make certain the 2. If 5 amps or less is indicated
power source arc voltage is and the ar mature voltage is
staying above 15 VDC. The being disabled by the control
feeder will not function properly board, then the control board
on less than 15 VDC. may be faulty. Replace.
3. If more than 5 amps is

indicated, then the motor is
drawing too much ar mature
current. Check and or replace
the motor brushes.
4. The motor or gearbox may be

faulty. Replace.
The wire stops or stubs while 1. If the LN-25™ is connected to 1. Monitor the motor ar mature
welding. a constant current power voltage (leads 539 to 541).
source, the arc voltage may be Normal range is 2 to 23 VDC.
NOTE:On codes above 10100, the “dipping” below the 15 VDC If the ar mature voltage is
motor leads (541 & 539) are threshold that is essential for proper, then check or replace
in Control Board Connector proper LN-25™ operation. the motor brushes.
J4, pins 13 & 14.
2. Try connecting the LN-25™ to 2. If the motor armature voltage is

a constant voltage power not correct, then the control

source or a flatter slope output. board may be faulty. Replace.
3. Make sure the wire feed mode
switch (S3) is in the correct
position for the power source
being used, and proper speed
setting is used for the
procedure.
4. Check for mechanical

restrictions in the wire feed
path.
CAUTION
Call 1-888-935-3877.
LN-25™


FUNCTION PROBLEMS (Continued)

The wire feed motor runs at a 1. Make sure the mode switch 1. Perform the Hall Effect
constant speed with no control. (S3) is in the CV mode. Module Test.
NOTE:Loss of tach feedback may 2. Make sure the wire speed 2. Perform the Wire Drive Motor
result in MAX speed or a control and the wire speed Test.
motor voltage of approx. range switch (S2) are set
correctly. 3. The control board may be
14VDC depending on the
faulty. Replace.
Control Board being used.
The gas solenoid valve will not 1. Make sure the LN-25™ is 1a.Perform the Solenoid PC
function. equipped with a gas solenoid Board and Gas Solenoid
valve and properly connected. Valve Test
2. Make sure the gas supply is NOTE:Test is code specific.
adequate and the gas hoses Codes above 10100 may
are not loose or kinked. or may not have a
Solenoid PC Board.
NOTE:Control Boards L12253-[ ]
or higher do not use a Gas 2. If a K434-1 gas flow timer kit is
Solenoid PC Board. installed in the unit, disconnect
and plug in the timer jumper
plug. If the gas solenoid
functions, then replace the
K434-1 kit.
3. The contactor board or remote

control board (if used) may be
faulty.
4. The control board may be

faulty. Replace.
The contactor does not function. 1. Make cer tain the LN-25™ is 1. Perform the Contactor Test.
equipped with a contactor and
properly connected. NOTE:Test is code specific.
Codes above 10100 may
2. Check the connections to the or may not have a
contactor PC board. Contactor PC Board.
NOTE:Control Boards L12253-[ ] 2. The Contactor PC board or the

or higher do not use a Control Board may be faulty.
Contactor PC Board. Replace.
CAUTION
Call 1-888-935-3877.
LN-25™
GAS SOLENOID VALVE AND SOLENOID PC BOARD TEST

(FOR CODES BELOW 10500 ONLY)
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.
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the gas solenoid valve or the solenoid PC board are functional.
MATERIALS NEEDED
Phillips Head Screwdriver

12 VDC Supply
Volt/Ohmmeter
DC Voltage Source (25 to 100 VDC)
LN-25™

(continued)
FIGURE F.1 – CONTROL BOX COVER REMOVAL.
CONTROL BOX
COVER
SCREW
35
ED
US
S
LT 31
VO
C 29
AR
27
IN
IN/M 25
D
SIRE
23
DE 21
19
700
17
650
15
600
550
500
450
700
400 650
600
350
550
500 ED:
300
ING
SPE
450 E
250 400 TT WIR IRED
SE E DES TS
350 MOD for VOL
200 D E) CC line
ARC
EE
lines
300 NG l for
RA
250 SP W TING horis
onta
line whe
re
SPE
ED
150
E LO SET ct line E
WIR(HI
onal
200 PRE Sele
of 1. IN/M
IN. diag cal
CC
WIR
er
150 ct verti prop TS.)
100 is dial.
100 CC Sele D.
2. USE e
rmin
line t
fron and i
set
at
29
VOL
50 50 ED Detes. cal on CC weld

SPE 3. cros verti IN
E TED , to while IN/M
WIRIBRA PH This TING ch
375
M-15242
GRA 4. SET swit TS

CAL for
PER Set VOL
5. ARC ple
exam
ED
SPE E E (See
E TED WIRD WIRCC
WIRIBRA IN
FEE E E FOR
CALIN IN/M IABL RCE
MOR
VAR ED SOU
SPEER
POW
E
WIR
CV
NT FORRCE
STA
CON ED SOU
SPEER
POW
CASE DOOR
H
INCT1308
6 99
COLD
SCREW
WIRE REEL RETAINING

COLLAR
TEST PROCEDURE
GAS SOLENOID VALVE

1. Open the case door. Remove the wire reel by
removing the retaining collar. See Figure F.1.
2. Remove the screws holding the control box

cover in place and remove the control box
cover. See Figure F.1.
LN-25™

(continued)
FIGURE F.2 – SOLENOID LEADS.
SOLENOID LEADS
SOLENOID LEADS
3. Locate and remove the two solenoid leads from 6. If the solenoid does not activate and allow gas
the solenoid valve (For codes 9812 and below, to flow, then the solenoid is faulty. Replace.
remove the two leads from the Solenoid PC
Board). See Figure F.2. 7. The nor mal solenoid resistance is
approximately 20 to 27 ohms.
4. Make sure the gas supply for the solenoid is
hooked up, and then apply 12 VDC to the gas
solenoid.
5. If the solenoid activates and allows gas flow,

then the solenoid valve is good.
NOTE: There should not be any gas flow until the

solenoid is activated.
LN-25™

(continued)
FIGURE F.3 – APPLIED VOLTAGE POLARITY.
ELECTRODE CABLE
POLARITY
SWITCH
WORK
SENSING LEAD
SOLENOID PC BOARD
1. Apply at least 25 VDC but no more than 100
VDC to the LN-25™ from the electrode cable to
the work sensing lead. Make sure the polarity
switch is set to match the polarity of the
electrode cable. For example, if the electrode
cable is positive and the work sensing lead is
negative, set the polarity switch to positive. See
Figure F.3.
LN-25™
GAS SOLENOID VALVE AND SOLENOID PC BOARD TEST (continued)

FIGURE F.4 – PC BOARD FOR K430-1 GAS SOLENOID KIT.
512
624A 621
621 J11
PC BOARD FOR K430 GAS SOLENOID KIT.
M15202
M15202
606
624A 512 621
2. Check for the presence of the DC voltage 6. If the above voltage checks are not correct, the
applied from lead 624A(+) to lead 621(-). See control board, contactor board (if used), remote
Figure F.4 control board (if used) and/or wiring harness
may be faulty. Refer to the wiring diagrams in
3. Check for the presence of 12 VDC from lead the Electrical Diagrams Section.
512(+) to lead 621(-).
The appropriate jumper plugs may be used to
4. Check for the presence of 10 VDC from lead isolate and check suspect contactor or remote
606(+) to lead 621(-). When the LN-25™ trigger

control boards.
circuit is activated, the voltage should drop to
about 1 VDC.
5. If the above voltage readings are good and the

solenoid valve is functional, the Solenoid PC
Board may be faulty.
LN-25™
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12
LN-25™
NOTES
F-12
GAS SOLENOID VALVE AND CONTROL PC BOARD TEST

(FOR CODES ABOVE 10500 ONLY)
WARNING
manual.
bleshooting assistance before you proceed,. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the gas solenoid valve or the control PC board valve actuation
circuitry is functional.
MATERIALS NEEDED

12 VDC Supply
Volt/Ohmmeter
NOTE: LN-25™ units with the L12253-[ ] Control Board do not use a Contactor PC
Board. Codes above 10100 may have been upgraded to use this Control
Board and must be tested accordingly.
LN-25™

(FOR CODES ABOVE 10500 ONLY) (continued)
FIGURE F.5 – CONTROL BOX COVER REMOVAL.
CONTROL BOX
COVER
SCREW
35
ED
US
S
LT 31
VO
C 29
AR
27
IN
IN/M 25
D
SIRE
23
DE 21
19
700
17
650
15
600
550
500
450
700
400 650
600
350
550
500 ED:
300
ING
SPE
450 E
250 400 TT WIR IRED
SE E DES TS
350 MOD for VOL
200 D E) CC line
ARC
EE
lines
300 NG l for
RA
SP W onta e
line ED
250 TING horis wher SPE
150
E LO SET ct line E
WIR(HI
nal
200 PRE Sele
of 1 IN/M
IN diago al
CC
WIR
er )
150 ct vertic prop TS
100 is dial
100 CC Sele D
2 USE e
rmin
line
front and i
set
at
29
VOL
50 50 ED Detes al on weld
SPE 3 cros vertic CC IN
E TED to while IN/M
WIRIBRA PH This TING h
375
M-15242
GRA 4 SET switc TS

CAL for
PER Set VOL
5 ARC ple
exam
ED
SPE E E (See
E TED WIRD WIRCC
WIRIBRA IN
FEE E E FOR
CALIN IN/M IABL RCE
MOR
VAR ED SOU
SPEER
POW
SCREWS
E
WIR
CV
NT FORRCE
STA
CON ED SOU
SPEER
POW
INCH
T1308
6-99
COLD
SCREW
WIRE REEL RETAINING

COLLAR
TEST PROCEDURE
GAS SOLENOID VALVE


cover. See Figure F.5
LN-25™

FIGURE F.6. – SOLENOID LEADS.
SOLENOID LEADS
3. Locate and remove the two solenoid leads #690 6. If the solenoid does not activate and allow gas
and #691 from the solenoid valve. See Figure to flow, then the solenoid is faulty. Replace.
F.6.
7. The nor mal solenoid resistance is
4. Make sure the gas supply for the solenoid is approximately 20 to 27 ohms.
hooked up, and then apply 12 VDC to the gas
solenoid.
5. If the solenoid activates and allows gas flow,

then the solenoid valve is good.
NOTE: There should not be any gas flow until the

solenoid is activated.
LN-25™

FIGURE F.7. – APPLIED VOLTAGE POLARITY.
ELECTRODE
CABLE
POLARITY
SWITCH
WORK SENSING LEAD

CONTROL PC BOARD SOLENOID CIRCUITRY

TEST
1. Apply at least 25 VDC but no more than 100
VDC to the LN-25™ from the electrode cable to
the work sensing lead. Make sure the polarity
switch is set to match the polarity of the
electrode cable. For example, if the electrode
cable is positive and the work sensing lead is
negative, set the polarity switch to positive. See
Figure F.7.
LN-25™

FIGURE F.8. – CONTROL PC BOARD.
G3425
667 555 691

621
J1 J3 J4 J2
500 512 690
2. Check for the presence of the DC voltage

applied from plug J1 pin 1 (667+) to plug J1 pin
3 621(-). See Figure F.8.or F.8.a. NOTE: Machines with Codes above 10100 that
have been upgraged to the L12253-[ ]
3. Check for the presence of 5 to 6 VDC from lead Control boardhave thesme connection
690(+) to lead 691(-) at solenoid valve. points ad shown in Figure F.8 for the
The LN-25™ trigger circuit must be activated supply and solenoid voltages
or the purge button must be pressed.
4. If the above voltage reading is not correct at the

solenoid valve, check for 5 to 6VDC at plug J2
pin 3 lead 690(+) & pin 6 lead 691 (-). See
Figure F.8.
5. If the above voltage check is not correct, the

control board may be faulty. Refer to the wiring
diagrams in the Electrical Diagrams Section.
The appropriate jumper plugs may be used to

isolate and check suspect contactor or remote
control boards
LN-25™
LN-25™
NOTES
F-18
HALL EFFECT MODULE TEST

WARNING
manual.
TEST DESCRIPTION
This test will determine if the hall effect module is functioning correctly.
MATERIALS NEEDED

Volt/Ohmmeter
LN-25™
HALL EFFECT MODULE TEST (continued)

FIGURE F.9 – CONTROL PC BOARD (CODES 10148 THRU 10500).
G2196
539
541 555
J1 J3 J4 J2
500 512
FIGURE F.10 – CONTROL PC BOARD (CODES 9812 AND BELOW).
539 541
G1757
G1757
500 555 512
TEST PROCEDURE 3. Locate the three hall effet ̀ leads 500, 512 and
555 incorporated in plug J4 o ̀ the Control

1. Open the case door. Remove the wire ree ̀ by Board for ̀ codes 9812 and below, the leads
removing the retaining collar. See Figure F.5. connect directly to the Control Board). o ̀ ot ̀
2. Remove the screws holding the control box disconnect the leads from the board. ee ̀
Figure F.9, or F.10. See Figure F.11 for codes
cover in place and remoe ̀ the control box
above ......
LN-25™
HALL EFFECT MODULE TEST (continued)

FIGURE F.11 CONTROL PC BOARD (CODES ABOVE 10500)
G3425
555
J1 J4
J3 J2
500 512
4. Apply at least 25 VDC but no more than 100 represents the correct feedback voltage from
VDC to the LN-25™ from the electrode cable to the hall effect device to the control board.
the work sensing lead. Observe polarity and set
polarity switch. 7. f the oe ote re ot orret the
h effet ee m ee to e te ee
5. Check for the presence of 12 VDC from lead the Maintenance Section or ree ee the
512(+) to lead 500(-). If the 12 VDC is not Drive Motor and Gearbox Replacement and
present or low, the control board may be faulty. Access to Hall Effect Module procedure.
See Figure F.11or F.11.a.
NOTE:Machines with L12253-[ ] PC Boards react
6.Activate the LN-25™ trigger circuit, make sure the differently to loss of feedback. Instead of
drive motor is running and check for the running full speed, the motor voltage is
presence of approximately 6.0 VDC from lead held to approximately 14VDC.
555(+) to lead 500(-). The value of 6.0 VDC
FIGURE F.11.a CONTROL PC BOARD (CODES ABOVE 10500)

C36
R108 R36
Q1
CONTROL
R76
R77
R79
R78
R83
R81
R80
R82
D19
D20
R65
R62
R27
R21
R17
R18
R20
C34
R67
R4
C6
D8
T1
Q7 X6
R75
D7 L12253-4
Q2
DZ10 R84 DZ1 C30

D55
D43
D22
X5
C44
R66
C31
R86
R94
C35
R69
R33
R24
R64
C19
R15
R60
X1
C5
D21
D29
C40
D52
R113
C32
R55
R90
R70
C22
R85
DZ13
DZ14
D47
D53
D56
C33
R100
R105
R102
R103
C41
T2
R101
R104
D9
R99
R98
D34
D6
R61
C27
R32
R23
R14
R63
DZ12
R59
R68
DZ17
R19
R72
C21
C4
C3
C2
D35
D28
D42
C42
DZ15
D49
DZ16
DZ4
R91
R115
R114
C10
R88
R89
R121
C17
C45 D1
Q8
DZ11
R13
C14
R71
D12
D13
D51
D40
D41
R22
R74
R48
C8
R9
D25
DZ18
C43
D46 Q10
D3
R112 R106
R119
R2
Q3
DZ3
D54 R92 C18

R120
X4
R110
X7
C47
D24
C12
R11
C7
R7
R109
D11
D36
R96
C37
R12
C13
D17
D18
C15
C16
R16
X3 X2
R6
R35
C38
R107
R97
C24
R95
C20
C1
D10
R3
D26
D15
D16
R34
Q9
D38
D27
D39
R116
R117
R118
R56
R38
R73
R31
C48
C9
R54
R46
R47
DZ2
R49
R5
D2
R45
R52
R53
C26
Q4
R37
D48
R58
R41
D37
C23
R25
R26
R10
C11
R50
R51
D14
D32
R1
R28
R44
R30
Q6 Q5
R43
R29
D4
D5
C39
667 555
621
TP1
J14 691
R57
D44
C29
D33
R111
C46
J4 J2
J1 J3
500 512 Contactor 690
LN-25™
LN-25™
NOTES
F-22
WIRE DRIVE MOTOR TEST

WARNING
manual.
TEST DESCRIPTION
The following procedure will determine if the wire drive motor is functional.
MATERIALS NEEDED

Voltage Source (variable 2 to 23 VDC)
Volt/Ohmmeter
LN-25™
FIGURE F.12 – HALL EFFECT MODULE AND DRIVE MOTOR LEADS IN-LINE CONNECTORS.
DRIVE MOTOR
LEAD IN-LINE
CONNECTOR
HALL EFFECT MODULE

LEAD IN-LINE
CONNECTOR
TEST PROCEDURE
1. Open the case door. Remove the wire reel by 4. Apply a variable DC voltage to the drive motor
removing the retaining collar. See Figure F.5. from lead 541(black)(+) to lead 539(white)(-).
2. Remove the screws holding the control box 5. When the supply voltage is varied from 2 to 23
cover in place and remove the control box VDC, the drive motor speed (RPM) should vary
cover. See Figure F.5. accordingly. If the motor does not run or vary
in speed, the motor, gearbox or motor brushes
3. For codes 10148 and above, separate the in- may be faulty. Check or replace.
line connector (containing the drive motor
leads) located behind the mylar insulation. Be 6. Check the resistance between each of the
sure to identify the correct in-line connector. motor leads [541(black) and 539(white)] and the
There is also an in-line connector for the hall motor case. The resistance should be very high
effect module behind the mylar insulation. See (at least 500,000 ohms). If the resistance is low,
Figure F.12. the motor is grounded to the motor case and
should be replaced.
For codes 9812 and below, remove the two
motor leads 539(white) and 541(black) from the
control PC board. See Figure F.10.
LN-25™
CONTACTOR & CONTACTOR PC BOARD TEST

WARNING
manual.
TEST DESCRIPTION
The following test will determine if the contactor is functional.
MATERIALS NEEDED

12 VDC Supply
Volt/Ohmmeter
NOTE: LN-25™ units with the L12253-[ ] Control Board do not use a Contactor PC
Board. Codes above 10100 may have been upgraded to use this Control
Board and must be tested accordingly.
LN-25™
CONTACTOR & CONTACTOR PC BOARD TEST (continued)

FIGURE F.13. – CONTACTOR LEAD IN-LINE CONNECTORS.
IN-LINE
CONNECTORS
CONTACTOR TEST PROCEDURE

1. Open the case door. Remove the wire reel by 3.Separate the two in-line connectors located behind
removing the retaining collar. See Figure F.5. the reel stand assembly. See Figure F.13. For
codes 9812 and below, remove the two
2. Remove the screws holding the control box contactor coil leads from the contactor PC
cover in place and remove the control box board. See Figure F.14.
LN-25™

FIGURE F.14 – CONTACTOR PC BOARDS

CODES 9812 AND BELOW CODES BELOW 10500
S20963
J6 J7
J6
#667
#621
J7 J9
CONTACTOR CONTACTOR
COIL LEADS COIL LEADS
4. Apply 12 VDC to the contactor coil leads. 7.If the resistance is “high” or “open” between the two
large terminal studs when the contactor is
CAUTION activated, the contactor is faulty. Replace.
Do not leave the 12 VDC applied to the contactor 8. If the contactor activates and the resistance
coil for a prolonged period of time (15 seconds between the terminals is low when the 12 VDC
maximum). Damage to contactor may result. is applied, the contactor is good.
5. If the contactor does not activate when the 12
NOTE: When the contactor is not activated, the
VDC is applied, the contactor is faulty. Replace.
resistance between the terminals should be very high
6. If the contactor activates when the 12 VDC is (infinite). If the resistance is always low, the contacts
applied, check the resistance between the two are “stuck” and the contactor is faulty. Replace.
large ter minal studs with the contactor
activated. The resistance should be very low (0
to 1 ohm).
LN-25™

FIGURE F.15. CONTROL BOARD

667 555 691

621
J1 J3 J4 J2
500 512 690

CONTACTOR PC BOARD TEST

1. Check to be sure plug J9, on contactor board 5. With the trigger activated, and a normally
and plug J3, on the control board are present operating contactor connected, the voltage
and secure. See Figures F.14 and F.15. measured at the contactor leads J9 pins 13 &
14 is approximately 1.0 VDC. See Figure F.14.
2. If optional gas timer pc board is installed, See the Wiring Diagram. If the 1.0 VDC is not
remove plug J6 from contactor board and install present when the trigger is activated, the
jumper plug. See Wiring Diagram. contactor board may be faulty.
3. Apply at least 25VDC but no more than 6. Be sure to reconnect all plugs previously
100VDC to the LN-25™ from the electrode removed.
cable to the work sensing lead. Observe
polarity and set polarity switch.
4. Check for the applied voltage at plug J9 pins 1 Note: If the original Control Board has been
& 2 (lead 667+ and 621-). See Figure F.14. replaced with L12253-[ ], See Figure F.16 and
follow instructions for that Control Board
LN-25™

FIGURE F.16 CONTROL BOARD (L12253-[ ])
C36
R108 R36
Q1
CONTROL
R76
R77
R79
R78
R83
R81
R80
R82
D19
D20
R65
R62
R27
R21
R17
R18
R20
R67
C34
R4
C6
D8
T1
Q7 X6
R75
D7 L12253-4
Q2
DZ10 R84 DZ1 C30
D55
D43
D22
X5
C44
R66
C31
R86
R94
C35
R69
R33
R24
R64
C19
R15
R60
X1
C5
D21
D29
C40
D52
R113
C32
R55
R90
R70
C22
R85
DZ13
DZ14
D47
D53
D56
C33
R100
R105
R102
R103
C41
T2
R101
R104
D9
R99
R98
D34
D6
R61
C27
R32
R23
R14
R63
R59
DZ12
R68
DZ17
R19
R72
C21
C4
C3
C2
D35
D28
D42
C42
DZ15
D49
DZ16
DZ4
R91
R115
R114
C10
R88
R89
R121
C17
C45 D1
Q8
DZ11
R13
C14
R71
D12
D13
D51
D40
D41
R22
R74
R48
C8
R9
D25
DZ18
C43
D46 Q10
D3
R112 R106
R119
R2
Q3
DZ3
D54 R92 C18

R120
X4
R110
X7
C47
D24
C12
R11
C7
R7
R109
D11
D36
R96
C37
R12
C13
D17
D18
C15
C16
R16
X3 X2
R6
R35
C38
R107
R97
C24
R95
C20
C1
D10
R3
D26
D15
D16
R34
Q9
D38
D27
D39
R116
R117
R118
R56
R38
R73
R31
C48
C9
R54
R46
R47
DZ2
R49
R5
D2
R45
R52
R53
C26
Q4
R37
D48
R58
R41
D37
C23
R25
R26
R10
C11
R50
R51
D14
D32
R1
R28
R44
R30
Q6 Q5
R43
R29
D4
D5
C39
667 555
621
TP1
J14 691
R57
D44
C29
D33
R111
C46
J4 J2
J1 J3
500 512 Contactor 690
1. Check to be sure that plug P14 is connected to the

Control Board and is secure.
2. Apply at least 25vdc but no more than 100vdc to the

LN-25™ from the Electrode cable to the Work
Sensing Lead. Observe the polarity and set the
Polarity Switch accordingly.
3. Check for the applied voltage at Plug J1 pins 1 and

3 (leads 667+ and 621-). See Figure F.16.
4. With the Trigger closed and a normally operating

contactor connectedthe voltag measured at Pins 1
and 9 of J14 should be approximately 1.0VDC. If

not, the Control Board may be defective.
LN-25™
LN-25™
NOTES
F-30
CONTACTOR PC BOARD REPLACEMENT

WARNING
manual.
TOOLS REQUIRED

LN-25™
CONTACTOR PC BOARD REPLACEMENT (continued)

FIGURE F.17. – CONTACTOR PC BOARD (CODES 10148 AND ABOVE).

J6 J7
J9
REPAIR PROCEDURE
1. Observe the static electricity precautions 3.Remove the screws holding the control box cover
detailed in PC Board Troubleshooting in place and remove the control box cover. See
Procedures at the beginning of this section. Figure F.5.
2. Open the case door. Remove the wire reel by 4. For codes 10148 and above, remove plug J9
removing the retaining collar. See Figure F.5. and plug J7 from the contactor PC board. See
Figure F.17.
LN-25™

FIGURE F.18. – CONTROL PC BOARD PLUG LOCATIONS (CODES 9812 AND BELOW).
G1757
J1
J2
J3
J4
5. For codes 9812 and below, remove the codes 9812 and below, remove plug J3 from the
contactor coil leads and plug J7 from the control PC board. See Figure F.18.
contactor PC board. See Figure F.17. Also for
LN-25™

FIGURE F.19. - CONTACTOR PC BOARD REPLACEMENT.
CONTACTOR PC
BOARD ASSEMBLY
SCREW
6. Remove the four screws from the front panel 9.For codes 9812 and below, install the contactor coil
holding the contactor PC board assembly in leads and plug J7 onto the contactor PC board.
place. Carefully remove the contactor PC board See Figure F.18. Also for codes 9812 and
assembly. See Figure F.19. below, install plug J3 onto the control PC board.
See Figure F18.
7. Place the new contactor PC board assembly in
position behind the front panel. Secure the 10. Install the control box cover and secure by
contactor PC board assembly by installing the installing the screws previously removed.
four screws into the front panel.
11. Install the wire reel and retaining collar and

8. For codes 10148 and above, install plug J9 and close the case door.
plug J7 onto the contactor PC board. See
Figure F.17.
LN-25™
CONTROL PC BOARD REPLACEMENT

WARNING
manual.
TOOLS REQUIRED

LN-25™
CONTROL PC BOARD REPLACEMENT (continued)

FIGURE F.20. – CONTROL PC BOARD PLUG LOCATIONS (CODES 10148 AND ABOVE).
G2196
J1 J3 J4 J2
REPAIR PROCEDURE
1. Obser ve the static electricity precautions 5. For codes 9812 and below, remove the four
detailed in PC Board Troubleshooting plugs J1, J2, J3 and J4. Also, tag and remove
Procedures at the beginning of this section. the five individual leads (three hall effect leads
500, 512 and 555 and two drive motor leads
2. Open the case door. Remove the wire reel by 539 and 541) connected to the control PC
removing the retaining collar. See Figure F.5. board. See Figure F.21.
3. Remove the screws holding the control box NOTE:For Codes above 10148 with newer Control
cover in place and remove the control box Board (L12253-[ ]) and a contactor, remove
cover. See Figure F.5. plug J14. See Figure F.22.
4. For codes 10148 and above, remove the four 6. On older codes, the control PC board is larger.
plugs J1, J2, J3 and J4. See Figure F.20. It may be necessary to remove the Contactor
PC Board or the Remote Control PC Board if
installed.
FIGURE F.21. – CONTROL PC BOARD (CODES 9812 AND BELOW).

539 541
G1757
G1757
500 555 512

LN-25™
D51 R113 D55

D52
DZ12
D47
D48
R107 R110
R97
C34
C40
DZ10
C24
C45
X7
R95
C32
DZ17
C20 R55
D44
R90
C29 R96
R108
R70
X5
R109 DZ16 C22
R37
R34
C37 C43
DZ15 D53
TP1 DZ18
C47 D49 R85
R101 R66
R104 C31
R84
R36
R86
D54
621
R99
R112
J1
R98 R94
R100
C39
C38 Q8 R105
Q7
C42
R102
R92
R106
R103
667
R75
DZ11 D20
T2
R76
DZ1
J3
R77
R91
Q4 R79
C1 Q3
R6
R78
R83
DZ2 DZ3 R81
C30
R5 R80
D2 R82
R2
R35 D3 C41
D1
T1
R1
R58 R56
R41 D38
D7
C44
X3
R38
LN-25™
C18
D37 D27
D9
C33
D46
D14 R73
J4 C23 C9
C15 C35 C36
R25 D39
R26 R31 C10
500
X6
R116 DZ4
R10 C48 R88 D56
C11 R117
X2
R89
R50 R118 DZ13
R120
Q10
555
D43
R51 R115
512
Q9 DZ14
R114 D22
R119
D32 D21
C16 D34
R28 C26 R16 R61 R69 Q2 Q1
C46
R57
R111
D33
D4 D35 D29 R65

R22
R44 D26 C5 D19
C7 R74
R30 C27 R33 R62
R3 C8
D24
R121
D10 D25
R7 R32
R24 R27
Q6
D15 C12 D40 R23

R64 R21
R14
D16 R11 D41 R4
C4
TROUBLESHOOTING AND REPAIR
R9 C6
D5 R63
R54 D11 R48 D8
R59
R46
J14
R43
Contactor
R17
X1
R29 D28 R18

R20
C17
X4 C3
R67
R49
R47
R68
Q5
C2
690
C19
FIGURE F.22. - PLUG LOCATIONS FOR L12253-[ ] CONTROL BOARD
D42 R15
D12 R60
D36 R19
691
R45 D13 R72

D17
R52 R13 D6
CONTROL
R12
L12253-4
J2
C14
C13 C21
R71
R53 D18
F-37
CONTROL PC BOARD REPLACEMENT (continued)

FIGURE F.24. – CONTROL BOARD REPLACEMENT.
CONTROL
PC BOARD
SCREW
7. Remove the screws holding the control PC 10. For codes 9812 and below, install the four
board to the inside of the case. Carefully Molex type plugs J1, J2, J3 and J4. Also,
remove the control board. See Figure F.24. connect the five individual leads to the control
PC board. If necessary, refer to the wiring
8. Place the new control PC board in position diagrams in the Electrical Diagrams Section.
inside the case. Secure the control PC board See Figure F.21.
by installing the screws from the outside of the
case. 11. Re-install the Contactor PC Board or Remote
Control PC Board if previously removed
9. For codes 10148 and above, install the four

Molex type plugs J1, J2, J3 and J4 onto the 11. Install the control box cover and secure by
control PC board. See Figure F.20. installing the screws previously removed.
NOTE:For Codes above 10148 with a newer 12. Install the wire reel and retaining collar and
Control Board (L12253-[ ]) and a contactor, close the case door.
install plug J14. See Figure F.22.
LN-25™
CONTACTOR REPLACEMENT
(FOR CODES BELOW 10500)
WARNING
manual.
TOOLS REQUIRED

5/16" Nut Driver
11/16" Wrench
LN-25™
CONTACTOR REPLACEMENT (continued)

FIGURE F.25 - CONTACTOR REPLACEMENT.

11/16" BRASS
NUTS
IN-LINE
CONNECTORS
VOLTAGE SENSING
REEL STAND LEAD 67
ASSEMBLY
WELDING CABLES
CONTACTOR
BAFFLE
5/16" SCREW
REPAIR PROCEDURE 8. Carefully remove the contactor from the LN-

25™.

removing the retaining collar. See Figure F.5. 9. Install a new contactor in the LN-25™.
2. Remove the screws holding the control box 10. Connect the contactor coil lead in-line
cover in place and remove the control box connectors behind the reel stand assembly.
cover. See Figure F.5. See Figure F.25. For codes 9812 and below,
install the contactor coil leads onto the
3. Remove the baffle from in front of the contactor. contactor PC board. See Figure F.19.
See Figure F.25.
11. Install the welding cables and voltage sensing
4. Remove the 5/16" screw holding the contactor lead #67 to the contactor and secure with the
in place. two 11/16" brass nuts. See Figure F.25.
5. Remove the two 11/16" brass nuts holding NOTE: Be sure brass nuts are tight. 11 ft-lb
voltage sensing lead #67 and the welding torque is recommended.
cables to the contactor.
12. Install the 5/16" screw to secure the contactor
6. Disconnect the contactor coil leads by in place.
separating the two in-line connectors behind

the reel stand assembly. For codes 9812 and 13. Install the baffle in front of the contactor.
below, remove the two contactor coil leads from
14. Install the control box cover and secure by
the contactor PC board. See Figure F.25.
installing the three screws. See Figure F.5.
7. Cut or remove any cable ties or harness tape
as necessary.
close the case door. See Figure F.5.
LN-25™
CONTACTOR REPLACEMENT
(FOR CODES ABOVE 10500)
WARNING
manual.
TOOLS REQUIRED

5/16" Nut Driver
11/16" Wrench
3/4” Wrench
5/8” Wrench
LN-25™
CONTACTOR REPLACEMENT (continued)

FIGURE F.26.
11/16" BRASS ELECTRODE

NUTS CABLE
IN-LINE
CONNECTORS
VOLTAGE SENSING
LEAD #67
ELECTRODE
LEAD
POLARITY WELDING CABLES
SWITCH
CONTACTOR
WORK SENSING LEAD
REPAIR PROCEDURE 9. Carefully remove the contactor assembly from

the LN-25™.
removing the retaining collar. See Figure F.5. 10. Install a new contactor in the LN-25™.
2. Remove the screws holding the control box 11. Connect the contactor coil lead in-line
cover in place and remove the control box connectors behind the reel stand assembly.
3. Remove the two fiber baffles from the area in 12. Place contactor assembly in position.
front of the contactor. See Figure F.25.
13. Install the 5/16" screw to secure the contactor
4. With a 3/4” wrench, remove the electrode to the spindle assembly.
lead. See Figure F.26.
14. Install the welding cables and voltage sensing
5. Using the 11/16” wrench, remove the two lead #67 to the contactor and secure with the
brass nuts from the contactor terminals. two 11/16" brass nuts. See Figure F.26. Be
Remove the heavy leads and lead #67 from sure brass nuts are tight. 11 ft-lb torque is
the terminals. Note location of lead #67. See recommended.
Figure F.26.
15. Install the baffles in front of the contactor.
6. Remove the 5/16” screw holding the contactor
16. Install the control box cover and secure by
bracket to the spindle bracket.
installing the screws previously removed.
7. Disconnect the contactor coil leads by

separating the two in-line connectors behind
close the case door.
the reel stand assembly.
18. Install the two 5/8” screws previously removed
8. Cut or remove any cable ties or harness tape
from the bottom of the machine.
as necessary.
LN-25™
GAS SOLENOID VALVE AND/OR SOLENOID PC

BOARD (IF PRESENT) REPLACEMENT
WARNING
manual.
TOOLS REQUIRED

3/4" Wrench
Pliers
LN-25™
GAS SOLENOID VALVE AND/OR SOLENOID PC BOARD (IF

PRESENT) REPLACEMENT (continued)

FIGURE F.27. – GAS SOLENOID ASSEMBLY WIRING (CODES 10148 THRU 10500).
SOLENOID GAS SOLENOID

PC BOARD VALVE
PURGE SWITCH
LEADS
SOLENOID
LEADS
PLUG J11
REPAIR PROCEDURE the two solenoid leads from the gas solenoid
valve, and disconnect the purge switch leads.
1. pen ̀ the case door. emove ̀ the wire reel by See Figure F.27.
4a. For codes above 10500 remove leads #690 &
2. emove ̀ the screws holding the control box #691 from the solenoid valve. See Figure F.28.
cover. See Figure F.5. 4b. Using a 5/16” nut driver remove the two screws
holding the solenoid & purge button assembly
NOTE: If only the gas solenoid valve needs replacing, to the case. Remove the assembly.
it may not be necessary to disconnect all of the wiring.

Disconnect wiring only as needed.
3. For codes 10148 thru 10500, remove plug J11

from the solenoid PC board. Also, disconnect
FIGURE F.28. – GAS SOLENOID ASSEMBLY WIRING (FOR CODES ABOVE 10500).
691 690
LN-25™


FIGURE F.29. – SOLENOID ASSEMBLY WIRING (CODES 9812 AND BELOW).
SOLENOID
PC BOARD
SOLENOID
LEADS
PURGE SWITCH
LEADS
4c. Remove the gas hose from the solenoid nipple. See Figure F.30.
4d. Using the 3/8” nut driver, remove the purge 4f. Reassemble in reverse order and reconnect
button nut from the assembly. Remove the leads as necessary.
purge button.
4e. Remove any necessary brass fittings required.
FIGURE F.30. GAS SOLENOID ASSEMBLY (FOR CODES ABOVE 10500)

BRASS
FITTING
GAS SOLENOID
VALVE
GAS SOLENOID
NIPPLE
GAS HOSE
GAS SOLENOID
VALVE MOUNTING
SCREW
GAS SOLENOID
ASSEMBLY BRACKET
LN-25™


FIGURE F.31. – GAS SOLENOID ASSEMBLY FOR EARLIER CODES.
BRASS
FITTING
GAS SOLENOID
ASSEMBLY
MOUNTING
SCREW
GAS SOLENOID
VALVE
GAS SOLENOID
NIPPLE
GAS HOSE
GAS SOLENOID
ASSEMBLY BRACKET
GAS SOLENOID
VALVE MOUNTING
SCREW
SOLENOID
PC BOARD
PC BOARD
MOUNTING
SCREW
5. For codes 9812 and below, remove the two 11. Install the replacement gas solenoid valve onto
solenoid leads from the solenoid PC board and the assembly bracket and secure with the two
disconnect the purge switch leads. See Figure mounting screws.

F.31. Also, remove plug J2 from the control
board. 12. Install the gas solenoid assembly bracket into
the case and secure with the two mounting
6. Remove the gas hose from the gas solenoid screws.
nipple. Remove the brass fitting connected to
the gas solenoid valve from the outside of the 13. Install the gas hose onto the gas solenoid
case. See Figure F.31. nipple. Install the brass fitting into the solenoid
valve from the outside of the case.
7. Remove the two screws mounting the gas
solenoid and assembly bracket to the case. 14. For codes 10148 thru 10500, install plug J11
Carefully remove the assembly. onto the solenoid PC board. Connect the leads
to the gas solenoid valve and purge switch.
8. Remove the two screws mounting the gas
solenoid valve to the assembly bracket. Remove 15. For codes 9812 and below, install the two leads
the gas solenoid valve. from the gas solenoid valve onto the solenoid
PC board and connect the purge switch leads.
9. Remove the two screws mounting the solenoid Also, install plug J2 onto the control board.
PC board to the assembly bracket. Remove the

solenoid PC board. 16. Install the control box cover and secure by
installing the three screws previously removed.
10. Install the replacement solenoid PC board onto
the assembly bracket and secure with the two 17. Install the wire reel and retaining collar and
mounting screws. close the case door.
LN-25™
DRIVE MOTOR AND GEARBOX REPLACEMENT AND

ACCESS TO HALL EFFECT MODULE
WARNING
manual.
TOOLS REQUIRED

3/4" Wrench
5/8" Wrench
7/16" Wrench
Slot Head Screwdriver
LN-25™
DRIVE MOTOR AND GEARBOX REPLACEMENT AND ACCESS TO

HALL EFFECT MODULE (continued)
FIGURE F.32. – WIRE DRIVE ASSEMBLY REPLACEMENT.

MYLAR
INSULATION IN-LINE
CONNECTORS
ELECTRODE
CABLE
1/2" BOLT
WIRE DRIVE
ASSEMBLY
WIRE DRIVE ASSEMBLY

MOUNTING BOLTS
(4 PLACES)
REPAIR PROCEDURE line connectors behind the mylar insulation.

See Figure F.32. For codes 9812 and below,
1. Observe the static electricity precautions remove the two armature leads (539 and 541)
detailed in PC Board Troubleshooting and the three hall effect module leads (500, 512
Procedures at the beginning of this section. and 555) from the control board. See Figure
F.33.

removing the retaining collar. See Figure F.5. 5. Remove the 1/2" bolt securing the electrode
cable to the gear box conductor block. Remove
the four bolts mounting the wire drive assembly
to the bottom of the case. See Figure F.32.
6. Carefully remove the wire drive assembly. See
4. For codes 10148 and above, separate both in-
Figure F.32.
LN-25™


7. emove ̀ the two screws and loc ̀ washers four bolts. Secure the electrode cable to the
holding the rear end plate to the gearbox and conductor bloc ̀ with the 12 Ԁ̀ bolt. See Figure
remove the rear end plate. emove ̀ the three F.32.
drive motor mounting screws, flat washers and
loc ̀ washers one ̀ is inside the gearbox 11. For codes 10148 and above, connect both in-
housing. ̀ See Figure F.34. line connectors and position them behind the
mylar insulation. See Figure F.32. For codes
8. Carefully remove the drive motor from the 9812 and below, install the two armature leads
gearbox. (539 and 541) and the three hall effect module
leads (500, 12 ̀ and 555) onto the control
NOTE ̀ o ̀ access all ̀ Effect Module for board. See Figure F.33.
adustment ̀ or replacement see Adjusting
Speed Sensor Module in the maintenance 12. Install the control box cover and secure by
section of this manual. installing the screws previously removed.
9. Install the replacement drive motor onto the 13. Install the wire reel and retaining collar and
gearbox and secure with the three screws, flat close the case door.
washers and lock washers. Install the rear end
plate, lock washers and screws.
10. Position the wire drive assembly inside the case

and secure to the bottom of the case with the
FIGURE F.33. – CONTROL BOARD
539 541
G1757
500 555 512
LN-25™


FIGURE F.34. – DRIVE MOTOR REPLACEMENT.
DRIVE
MOTOR
HALL EFFECT MODULE
GEARBOX
REAR END PLATE
LOCKWASHER
FLAT WASHER END PLATE
MOUNTING SCREW
LOCKWASHER
DRIVE MOTOR
MOUNTING SCREW
LN-25™
RETEST AFTER REPAIR

If a failed test indicates that any mechanical part that

could affect the machine’s electrical characteristics
must be replaced or if any electrical components are
repaired or replaced, the machine must be retested
and meet the following standards.
Wire Feed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 through 700 Inches Per Minute
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Must be operative from 0 through 40 VDC
Gas Solenoid (optional) . . . . . . . . . . . . . . . . . . . . . .

Must operate when gun trigger is activated
Contactor (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .
Must operate when gun trigger is activated

LN-25™
LN-25™
NOTES
F-52
G-1 ELECTRICAL DIAGRAMS G-1
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-

ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
WIRING DIAGRAM - ABOVE CODE 11140 (G4679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
WIRING DIAGRAM - CODE 10556 THRU 10558 (L10925) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
WIRING DIAGRAM - CODE 10100 THRU 10500 (L9644) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
WIRING DIAGRAM - BELOW CODE 9900 (L7545) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
COMPLETE MACHINE SCHEMATIC - CODES ABOVE 11140 (G5366) . . . . . . . . . . . . . . . . . . . G-6
COMPLETE MACHINE SCHEMATIC - BELOW CODE 9900 ONLY (G1833) . . . . . . . . . . . . . . . G-7
CONTROL PC BOARD SCHEMATIC - ABOVE CODE 11140 (G4616-3) . . . . . . . . . . . . . . . . . . G-8
CONTROL PC BOARD SCHEMATIC - CODE 10556 THRU 10558 (G3424-1) . . . . . . . . . . . . . . G-9
CONTROL PC BOARD SCHEMATIC - CODE 10100 THRU 10500 (G2194). . . . . . . . . . . . . . . . G-10
CONTROL PC BOARD ASSEMBLY - CODES ABOVE 11140 (L12253-3) . . . . . . . . . . . . . . . . . G-11
CONTROL PC BOARD ASSEMBLY - CODE 10556 THRU 10558 (G3425-3) . . . . . . . . . . . . . . . G-12
CONTROL PC BOARD ASSEMBLY - CODE 10100 THRU 10500 (G2196-1) . . . . . . . . . . . . . . . G-13
CONTROL PC BOARD ASSEMBLY - BELOW CODE 9900 (G1757-6) . . . . . . . . . . . . . . . . . . . . G-14
CONTACTOR PC BOARD SCHEMATIC - ABOVE CODE 10500 (M10965) . . . . . . . . . . . . . . . . G-15

CONTACTOR PC BOARD SCHEMATIC - CODE 10100 THRU 10500 (M17621) . . . . . . . . . . . . G-16
CONTACTOR PC BOARD SCHEMATIC - BELOW CODE 9900 (L7535-[ ] CONTACTOR - M15428)) . . . . G-17
CONTACTOR PC BOARD SCHEMATIC - BELOW CODE 9900 (L9185-[ ] CONTACTOR - M17139). . . . . G-18
CONTACTOR PC BOARD ASSEMBLY - ABOVE CODE 10500 (L10863-1) . . . . . . . . . . . . . . . . G-19
CONTACTOR PC BOARD ASSEMBLY - CODE 10100 THRU 10500 (L9670-1) . . . . . . . . . . . . . G-20
CONTACTOR PC BOARD ASSEMBLY - BELOW CODE 9900 (L9185-2) . . . . . . . . . . . . . . . . . . G-21
LN-25™
G-2 ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ABOVE CODE 11140 (G4679)
N.B., N.D.,
S4 J7
OPTIONAL REMOTE
KIT PLUG
TIMER P.C. N.H.
COLD INCH CONTROL BOARD
530C 1 6 1 530
PUSHBUTTON 530B P.C. BOARD 2 530A
SWITCH 500C 500B 7 N.A.
2 3 607
9 J10
4 512
6 1 5 500
7 530A 2 530A 5 J14 7 500 6 606
9 512 4 512 4 15
1 606 6 606 8 9 607
5 607 3 3 16 622
N.M. 530 512
OPTIONAL TIMER KIT
4 1 530 10 13
8 500 5 500 2 12 530A
10 ARC VOLTS
3
10 14 624 R3
OPTIONAL J11
ARC J14 2 J3 8 500A 75 75 A
TIMER PLUG 77 76
VOLTMETER N.G. 11 530 76 B
N.H. 77 C
621 621 3 1 606
+ 667 621 D
667 1 J1 6 E
VM
500A 2 5 622A F
621 667 622A 4 3
2 OPTIONAL REMOTE VOLTAGE CONTROL
4
J5 A 622A
2
TRIGGER B 1
N.B. C 500A 621 1 2 41
CONNECTOR
TO S1 S1 D 608 4 3 42
J4
BLACK 621 POLARITY E 5 J12 4 4 41 A

J2 REMOTE 5 42 B
WORK CLIP SWITCH 2
690 P.C. BOARD 6 2 C
NEG S5 691
3
6
7 4 D
POS PURGE 8 E
621 8 1 9 10 4 3 11 2 6 12 7 5 13 14 75 F
PUSHBUTTON
SOLENOID P.C. 1 622A 76 G
608 77 H
N.L. BOARD PLUG N.D. J6 2 621
667
523A
S5
523B
3 500A
539
S1
541
509
524
633
631
632
522
512
500
555
4 530A
N.L. N.D. 76
690 5 530
67 GAS N.G. 6 624 77 75
1 2 34 5 6 J8
WHITE
BLACK
RED
BLACK
SOLENOID 7 606 R3
BLUE
VALVE 8 622
ARC VOLTS
691 9 607
N.H. 10 512
530
530A
607
512
500
606
11
12 500
TO J3 ON
S1 CONTROL BOARD
TO TIMER P.C. BOARD
OPTIONAL 42 VOLT REMOTE OUTPUT CONTROL
BLACK
N.F.
632
BLUE
75 A
523B
RED
N.B. REMOTE
523A
701
522
N.F. 1 76 B
509
524
631
633
CW J16 P.C. BOARD 2 700 77 C
ESD SNUBBER J13
P
R1 N.L. 3 700 D
N.J.,N.K HI LO 3 1 2 4 4 702 701 E
67 CV VV
10K W
BLACK
WHITE
702 F
INPUT
CABLE
N.B. WIRE SPEED S2 S3 1 622A 76
CONTROL RHEOSTAT WIRE SPEED DIAL J6 2 621 77 75
U B R
WIRE FEED
RANGE SWITCH 3 500A

N.B. MODE SWITCH 2 1 4 530A R3
J15
CONTACTOR S1 S2 HALL 5 530 ARC VOLTS
COIL S5 EFFECT N.G. 1 2 34 5 6 6 624
J8
SWITCH 7 606
8 622
9 607
N.H. 10 512
530
530A
607
512
500
606
11
12 500
BLACK
WHITE
CONTACTOR TO J3 ON
541
539
N.F. GUN CABLE CONTROL BOARD
02/07/2005
OPTIONAL REMOTE OUTPUT CONTROL
N.D.,N.E.
NOTES
N.A. JUMPER PLUG MUST BE INSTALLED IF REMOTE KIT IS NOT PRESENT. 66 667 A
REMOTE 1 34 7
N.B. CONNECTIONS AS VIEWED FROM BACK OF RHEOSTAT AND SWITCHES. 621 4 B
P.C. BOARD J13 2 33 33 C
N.D. ITEM FACTORY INSTALLED ON SOME MODELS AND OPTIONAL EQUIPMENT ON SOME MODELS. 3 34 D
1 1 2 N.E. CONTACTOR CAN BE INSTALLED IN UNITS WITH AN L12253-1 CONTROL PC BOARD. 21
1 3 1 5 4 4 21 E
N.F. WHEN A CONTACTOR IS NOT USED, THE '67' LEAD TO THE POLARITY SWITCH COMES FROM THE CONDUCTOR 75 F
BLOCK AND THE INPUT CABLE CONNECTS DIRECTLY TO THE CONDUCTOR BLOCK. 1 622A 76 76 G
3 4 4 6 E
J6 2 621 77 75 77 H
2 6 10 D A N.G. IF TIMER KIT IS NOT INSTALLED:
3 500A 621 I
J7,J15 J1,J16 J2,J11 J14 -ON UNITS WITHOUT REMOTE PC BOARD, JUMPER MUST BE INSTALLED IN J11. 4 530A R3
C B
1 -ON UNITS WITH REMOTE PC BOARD, JUMPER MUST BE INSTALLED IN J6 OF REMOTE PC BOARD. 5 530 ARC VOLTS
7 1 8
N.H. TIMER KIT HARNESS INSTALLATION: N.G. 1 2 34 5 6 J8
6 624 TO
- ON UNITS WITH REMOTE PC BOARD, TIMER HARNESS MUST PLUG INTO J6 OF REMOTE PC BOARD.
7 606 POLARITY
J5 8 622
8 14 9 16 - ON UNITS WITHOUT REMOTE PC BOARD, TIMER HARNESS MUST PLUG INTO J11. N.H. 9 607 SWITCH
N.J. PROVIDES AN ESD PATHWAY FROM EXPOSED METAL SURFACES TO WORK. 10 512
J4 J3
530
530A
607
512
500
606
N.K. PRESENT ON EUROPEAN MODELS ONLY. 11
12 500 TO J3 ON
N.L. CONNECTS TO BUSHING OF COMPONENT.
ELECTRICAL SYMBOLS PER E1537 CONTROL BOARD
N.M. J14 JUMPER PLUG USED ON K428 ONLY.
CONNECTORS VIEWED FROM INSERTION END R TO TIMER P.C. BOARD
OPTIONAL PULSE POWER ADAPTOR KIT B
CLEVELAND, OHIO U.S.A. G4679
L N-25.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
¤
WIRING DIAGRAM - CODE 10556 THRU 10500 (L10925)
L N-25™
¤
WIRING DIAGRAM - CODE 10100 THRU 10500 (L9644)
L N-25™
¤
WIRING DIAGRAM - BELOW CODE 9900 (L7545)
L N-25™
¤
SCHEMATIC - COMPLETE MACHINE - CODES ABOVE 11140 (G5366)
G5366 ENGINEERING CONTROLLED CHANGE DETAIL: NEW

MANUFACTURER: No CAVITY NUMBERING SEQUENCE
Input Power
GENERAL INFORMATION
LN-25 ACROSS THE ARC MODEL

(COMPONENT SIDE OF P.C. BOARD)
ELECTRICAL SYMBOLS PER E1537
15V-110VDC
1 2 1 3 1 5
COLOR CODE
J1 J2 J14
B - BLACK
3 4 4 6 6 10
WHITE
1 7 1 8
R - RED
CODES 11144,11145,11146 +35V

INPUT VOLTAGE LN-25 FEEDHEAD
J4
8 14
J3
9 16
U - BLUE
MONITOR
P.C. BOARD
ARC SchematicG4616
VOLTAGE
21 FEEDBACK COM
+35V
67 NOTE:
S1 J14-1 OLDER OPTION BOARDS MAY BE LEFT
CC 4.5 A PEAK IN CIRCUIT OR REMOVED. IF REMOVED,
J14-9
SENSE COM
CURRENT A PROPER JUMPER PLUG NEEDS TO BE
LIMIT INSTALLED.
+VM
+35V
+Vin
POWER +15V U
Gas Solenoid
COM
COM SUPPLY
667 J1-1 +13.5V
+ U
+5V
Vin
Circuit
.05uF
Wire Drive
OLD
VOLTM ETER +15V_ISO CONTACTOR BD
- (optional)
621 J1-3 +Vin (500)
to Timer Bd
COM (621)
Circuit
(667)
ISO J3-10 667 JS JC (624)
J3-14 624 +V C LOGIC
MOTOR SUPPLY JR
VOLTAGE MONITOR
(624) +V (621)
REMOTE BD
(optional)
21 (MOTOR FETS ARE + VM J3-6 621
Positive
COM
BOTH OFF WHEN INPUT AVERAGE J3-15 500
CURRENT
VOLTAGE DROPS DRIVE
PWM LIMITING
BELOW 20V) MOTOR COM
MOTOR_VSENSE
TOROID
Voltage
TOROID CONTROL
PULSE BY PULSE
ARC_VSENSE
J2 BRAKE
+35V_SENSE
BRAKE_DRV
PEAK CURRENT
CONT_DRV
CC_SENSE
LIMIT
+13.5V
8 Motor+ 541 J4-14 COM
IM_AVG
+13.5V TIMER BD
Feedback
7 Motor-
539 J4-13 (optional)
+35V (512)
552 J14-4 512
GasSolenoid+
690 J2-3 .05 (606)
MeasureB toU GasSolenoid-
691 J2-6 J14-8 606 JT TIMER
ACTIVATE (500)
130 Hz@ 50 in/min 4.25 VDC when gasflowing
COM SOLENOID
COM P J14-2 500
VIM_PEAK REF
W B 1.85 kHz@ 700 in/min Coilmeasures21 ohms COM OLD
COM PWM_DRV REMOTE BD
GAS PW M controlled (optional)
553 OLD CONTACTOR BD
SOL_DRV +13.5V JR (optional)
MOT OR / +13.5V +13.5V
Located under the cover
SOLENOID +V
+V (512)
GEARBOX
TOROID
1
at the rear of the feeder
13.5VDC Tach Supply
512 J4-5 PSOC J3-13 512
(512)
(606) (606)
TIMER
1.9VDC @ 50 in/min 2 10K J3-1 606 JC (530) (530)
TOROID JS C LOGIC C LOGIC
20.1VDC @ 700 in/min R 3 TachSig
nal TACHOMETER J3-11 530
555 J4-12 ACTIVATE JR (530A)
8secaverage CurrentlimitTACH. U 4 COM P TIMER
Located behind the insulating B 5
Tach COM
500 J4-7
FEEDER
REF (530A)
=3.5Amps TIMER BD
wire drive panel. Remove the 6 COM (530) (optional)
(Limitissoftwareset) J14-10 530
wire drive ably to gain access. +5V JS JT
21 Access this connector
TIMER
WIRE FEED SPEED 10K J14-5 530A (530A)
by removing the wire CONTROL Ohms POT Supply
TRIGGER J3-3 530A JS
631 J4-9 LOGIC 530A
JC
J3-12
drive asbly. POTENTIOM ETER 1
W ip
er WFS POT
JR
2 632 J4-1 OLD
REMOTE BD
Located behind the wire drive 3 100K
(optional)
Located on the case front. COM
633 J4-8
(EuropeanModels Only) COM +V
TOROID Remove the wire drive W ipertoCOM COM
MO V ASBLY asbly to gain access. N.C. 5VDC at700 ipm
Not aPC board; no schemati
c. 0VDC at50 ipm SWITCH
INPUTS
67 GND-S1 (622) (622A)
1M ohms 1M ohms GND-S2 COM J3-16 622 JS
GND-S5 JR
WORK COM J3-5 622A JC*
WFS RANGE COM
CLIP COM J1-4 622A
COM J3
523B J4-4 For programming at LECo J1-2 500A Located on the lower left
A
FEEDPLATE +13.5V
factory only. 3.3K
of the front of the case.
WFS
.0047/.005 mfd, .0047/.005 mfd, 500A
522 J4-10 J3-8 JS B

JR
1400VDC 1400VDC Not field reprogrammable. J3-7 500
JC*
(500) (500A) C
DATA SCLK XRES /SS MOSI
Located on front of case, J2-1 J14-7 J4-3 J4-11 J14-6 J2-4 J2-2 J2-5 J4-6 J3-2 J3-4 COM
-DC D GUN TRIGGER
COM
Control
above WFS control knob. 621 500 509 523 530 608 OLD E INPUT
The WFS switch shown in lowrange. REMOTE BD
TRIGGER
(optional)
The low WFS range is 50-350in/min.
Mode
Circuit
Located behind CONNECTOR
GasPurge
ColdInch
ThehighWFSrangeis 50-700in/min.
the glastic panel 509 523 Trigger
next to the motor. MODE 13.5VDC when Open,
Input
0VDC when TriggerClosed
Bussbarfrom input
stud tocontactor CC CV
Voltage
The mode switch is
Gun Trigger
CONTACTOR shown inCC mode.
Located inside case.
Protection
300A 60%
250A 100%
Circuit
578 COLD
Coilmeasures4.4ohms. INCH N.O.
507
Contactor
0VDC Open 530(B)
500(B)
3.0VDC Closed
INPUT ELECTRODE 12 VDC coil Located inside case
CABLE CONNECTION
PW M Controlled below voltmeter.
PURGE N.O.
621 608
N.A.CAVITY NUM BERING SEQUENCE AS VIEW ED FROM COM PONENT SIDE OF BOARD.
N.B.CAVITY NUM BERING SEQUENCE AS VIEW ED FROM LEAD SIDE OF CONNECTOR. Located on rear
N.C. O
TGGLE SWITCHES AND POTENTIOM ETERS SHOW N FROM CONNECTION SIDE OF SWITCH. of case.
OPTION BOARD EXPLANATION

Therearethree optionalboardsavailableforthe LN-25. The wiring associated
withthese boardsisindicated bydashed lines.and the abbreviationsareas

Inch/Purge/Mode
follows:
Model Ranger 8,9 Classic Ranger 250, 305 V350 DC-400, 600 Square Wave TIG Miller Inverters STT II Note:
Commander 300,400,500 (Common Digital 300/355 Most semiautomatic wire JS -StandardW iring,No Option BoardsInstalled. Thiswiring jumpermustbe installed ifremotekitisnotpresent.
(Common Analog Controls) welding processes
Input Switches
JC -OptionalContactorBoard.
Controls) perform better using JR -OptionalRemoteBoard.
K449 Recommended Recommended for CV Recommended for CV Recommended for Recommended Not recommended Recommended Not recommended constant voltage power JT -OptionalTimerBoard. Iftimerkitisnotinstalled,and remoteboardisnotpresent,then jumperisinstalled inJ11.
Across the Arc all CV operation. operation. (Wire operation. CV operation. for CV and CC for CC operation for CV voltage for STT operation. sources. Be sure the Ifremoteboardispresent,then jumperisinstalled inJ6 ofremoteboard.
Feed Module Not recommended operation. because the sense proper power source is
Required) for use when customer may operation. used for your application. The OptionalBoardsaredivided on thisprintforclarity.
pulse welding. experience short Not Contactor life may be
contactor life from recommended shortened in applications
inductive nature of for use when using CC machines with PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
the power source. pulse welding. high OCV. TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
Not recommended EQUIPMENT TYPE: LN-25 (ACROSS THE ARC)
REFERENCE:
SOLID EDGE
UNLESS OTHERWISE SPECIFIED TOLERANCE: DESIGN INFORMATION
PAGE ___ 1
1 OF ___
with high frequency ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: M. DIDION G4198-1 DOCUMENT
MACHINE SCHEMATIC
DOCUMENT
TIG starting. ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: M. DIDION SCALE:
SUBJECT: NUMBER: REVISION:
G5366
EN-170
WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING APPROVED: NONE
MATERIAL
DISPOSITION: NA
APPROVAL
DATE: 10/4/2004
PROJECT
NUMBER: CRM36946 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
¤
L N-25™
SCHEMATIC - COMPLETE MACHINE - BELOW CODE 9900 ONLY (G1833)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. L N-25™
¤
SCHEMATIC - CONTROL PC BD - ABOVE CODE 11140 (G4616-5)
L N-25™
¤
SCHEMATIC - CONTROL PC BD - CODE 10556 THRU 10558 (G3424-3)
L N-25™
¤
SCHEMATIC - CONTROL PC BD - CODE 10100 THRU 10500 (G2194)
L N-25™
¤
PC BOARD ASSEMBLY - CONTROL - ABOVR CODE 11140 (L12253-3)
L12253-3 ENGINEERING CONTROLLED REVISED D48 AND MANUFACTU RED PART NUM BER, DENTIFIC
CHANG E DETAIL: I ATION CO DE AND SCHEM ATIC REFERENCE ITEM QTY PART NUMBER DESCRIPTION
MANUFACTURER: No J1 1 S18248-4 CONNECTOR,MOLEX,MINI,PCB,4-PIN
ITEM (USED WITH) * QTY PART NUMBER DESCRIPTION
J2 1 S18248-6 CONNECTOR,MOLEX,MINI,PCB,6-PIN
1 1 L12253-F PC BOARD BLANK N.A. J3 1 S18248-16 CONNECTOR,MOLEX,MINI,PCB,16-PIN
2 8 S14020-4 PLASTIC EXPANSION NUT, 0.25
3 (Q8) * 1 S20590-1 HEAT SINK,SLIP ON,FOR TO-220
4 (Q3, Q4, D48) * 3 S20590-3 HEAT SINK, EXTRUDED,FOR TO-247
Q1, Q2, Q9 3 T12704-68 TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
5 (X4)* 1 Y00750-4 SOFTWARE
Q3 1 T12704-106 TRANSISTOR,NMF,TO247,600V,47A(SS)
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW Q4 1 T12704-102 TRANSISTOR,NMF,TO247,600V,26A(SS)
N.B. Q5, Q6 2 T12704-104 TRANSISTOR,N,TO220,47A,55V,P77N06S2-12(SS)
REFERENCES QTY PART NUMBER DESCRIPTION Q7, Q8 2 T12704-103 TRANSISTOR,N,TO220,11A,600V,IRFB16N60L(SS)
C1, C2, C3, C4, C5, C6, C7, C8, C9, Q10 1 T12704-101 TRANSISTOR,NMF,TO92,.120A, 200V,BS107(SS)
C10, C11, C12, C13, C14, C15, C16, 20 S16668-11 CAPACITOR,CEMO,0.1, 50V,10% R1 1 S25365-0R05 RESISTOR,STAND-UP,WW,5W,0.05,5%
P.C.BOARD BLANK REFERENCE N
IFORMATION R2, R3, R4, R119 4 S19400-1000 RESISTOR,MF,1/4W,100,1%
C17, C18, C19, C33
C20, C31 2 S16668-6 CAPACITOR,CEMO,4700pF,50V,10% R5 1 S19400-1500 RESISTOR,MF,1/4W,150,1%
BUY COMPLETE AS L12253-F (4LAYER BOARD PER E3281) C21, C46 2 S16668-8 CAPACITOR,CEMO,330pF,100V,5%
C22, C23, C37 3 S16668-3 CAPACITOR,CEMO,100pF, 100V,5% R6 1 S19400-15R0 RESISTOR,MF,1/4W,15.0,1%
(MAKES 4BOARDS PER PANEL,SEE ELECTRONIC FILE FOR ADDITIONAL N
IFORMATION)
C24, C32 2 S16668-9 CAPACITOR,CEMO,150pF, 100V,5%
C26, C27, C47 3 S13490-173 CAPACITOR,PEMF,1.0,63V,10% R7, R9, R10, R11, R12, R13, R14,
PANEL SIZE PER E1911 C29 1 T11577-46K CAPACITOR,CD,.05,600V,+80/-20% R15, R16, R17, R70, R97, R111, 14 S19400-1001 RESISTOR,MF,1/4W,1.00K,1%
C30, C42 2 S20500-16 CAPACITOR,PPMF,0.0033,630V,5%,BOX R112
C34, C44 2 S13490-199 CAPACITOR,ALEL,220,25V,20%,LOW-ESR R18, R67, R118, R120 4 S19400-4751 RESISTOR,MF,1/4W,4.75K,1%
C35, C36, C43 3 S13490-197 CAPACITOR,ALEL,82,35V,20%,LOW-ESR R19, R20, R21, R22, R24 5 S19400-2672 RESISTOR,MF,1/4W,26.7K,1%
C38, C39 2 S13490-209 CAPACITOR,ALEL,470,350V,20% R23, R63, R64, R65 4 S19400-1502 RESISTOR,MF,1/4W,15.0K,1%
C40 1 S20500-17 CAPACITOR,PPMF,0.1MF,630V,5%,BOX
R25, R26, R27, R28, R29, R30, R31,
C41 1 S13490-210 CAPACITOR,ALEL,8200,50V,20%

9 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
C45 1 S13490-212 CAPACITOR,ALEL,180,350V,20% R32, R33
C48 1 S16668-5 CAPACITOR,CEMO,.022,50V,20% R34, R36, R108 3 S25923-5101 RESISTOR,STAND-UP,MF,5W,5.1K,5%
D1, D9, D46, D51 4 T12705-59 DIODE,AXLDS,3A,600V,UFR R35, R37 2 S25923-3301 RESISTOR,STAND-UP,MF,5W,3.3K,5%
D2, D3, D4, D5, D6, D7, D8 7 T12705-34 DIODE,AXLDS,1A,400V,FR,1N4936 R38, R41 2 S19400-1503 RESISTOR,MF,1/4W,150K,1%
D10, D11, D12, D13, D14, D15, D16, R43, R44 2 S19400-2000 RESISTOR,MF,1/4W,200,1%
D17, D18, D19, D21, D22, D24, D25, R45, R46, R47, R48, R49 5 S19400-68R1 RESISTOR,MF,1/4W,68.1,1%
D26, D27, D28, D29, D32, D33, D34, 34 T12199-1 DIODE,AXLDS,1A,400V R50, R51, R52, R53 4 S19400-2001 RESISTOR,MF,1/4W,2.00K,1%
D35, D36, D37, D38, D39, D40, D41, R54 1 S19400-4750 RESISTOR,MF,1/4W,475,1%
D42, D43, D49, D53, D54, D56 R55, R56, R57, R58, R95 5 S19400-1003 RESISTOR,MF,1/4W,100K,1%
D20, D52 2 T12199-4 DIODE,AXLDS,1A,600V R59, R60, R61, R62, R94, R109 6 S19400-2212 RESISTOR,MF,1/4W,22.1K,1%
D44 1 T12199-2 DIODE,AXLDS,1A,1000V R66, R96 2 S19400-2211 RESISTOR,MF,1/4W,2.21K,1%
D47, D55 2 T12705-65 DIODE,AXLDS,1A,600V,FR,1N4937 R68, R69 2 S19400-5111 RESISTOR,MF,1/4W,5.11K,1%
D48 1 T12705-66 DIODE,TO247,30A,600V,UFR R71 1 S19400-2671 RESISTOR,MF,1/4W,2.67K,1%
DZ1, DZ2, DZ3, DZ11 4 T12702-45 ZENER DIODE,1W,18V,5%,1N4746A R72 1 S19400-2002 RESISTOR,MF,1/4W,20.0K,1%
DZ4, DZ13, DZ14 3 T12702-29 ZENER DIODE,1W,15V,5%,1N4744A R73 1 S19400-3012 RESISTOR,MF,1/4W,30.1K,1%
DZ10 1 T12702-50 ZENER DIODE,5W,17V,5%,1N5354B R74, R86, R92 3 S19400-3321 RESISTOR,MF,1/4W,3.32K,1%
DZ12 1 T12702-37 ZENER DIODE,1W,43V,5%,1N4755A
DZ15, DZ16, DZ17 3 T12702-38 ZENER DIODE,1W,30V,5%,1N4751A R75, R91 2 S25831-00R2 RESISTOR,MF,FLAMEPROOF,3W,0.2,5%
DZ18 1 T12702-53 ZENER DIODE,1W,3.3V,5%,1N4728A
1 3 R76, R77, R78, R79, R80, R81, R82,
R83, R98, R99, R100, R101, R102, 16 S19400-10R0 RESISTOR,MF,1/4W,10.0,1%
R103, R104, R105
6.00±.04 2 R84, R106 2 S19400-33R2 RESISTOR,MF,1/4W,33.2,1%
R85 1 S19400-3011 RESISTOR,MF,1/4W,3.01K,1%
MANUFACTURED AS
5.62 R88, R89, R107 3 S19400-3010 RESISTOR,MF,1/4W,301,1%
C36
R108 R36
Q1
CONTROL
R76
R77
R79
R78
R83
R81
R80
R82
D19
D20
R65
R62
R27
R21
R17
R18
R20
R67
C34
R4
C6
R90 1 S19400-6810 RESISTOR,MF,1/4W,681,1%
D8
T1
Q7 X6
L12253-3F1
R75
D7 L12253-3 R110 1 S19400-3921 RESISTOR,MF,1/4W,3.92K,1%
Q2
DZ10 R84 DZ1 C30
D55
R113 1 S19400-5621 RESISTOR,MF,1/4W,5.62K,1%
D43
D22
X5 IDENTIFICATION CODE
C44
R114, R115 2 S19400-3320 RESISTOR,MF,1/4W,332,1%
R66
C31
R86
R94
C35
R69
R33
R24
R64
C19
R15
R60
X1
C5
D21
D29
R116 1 S19400-3322 RESISTOR,MF,1/4W,33.2K,1%
C40
D52
R117 1 S19400-3922 RESISTOR,MF,1/4W,39.2K,1%

R113
C32
R55
R90
R70
C22
R85
DZ13
DZ14
D47
D53
D56
C33
R100
R105
R102
R103
C41
SCHEMATIC REFERENCE G4616-

- 3F1 R121 1 S19400-1212 RESISTOR,MF,1/4W,12.1K,1%
T2
R101
R104
D9
R99
R98
T1 1 S20375-22 TRANSFORMER,PWM,FLYBACK,ICA-1313
D34
D6
R61
C27
R32
R23
R14
R63
R59
R68
R19
R72
C21
DZ12 DZ17
C4
C3
C2
D35
D28
D42
C42
T2 1 S20375-23 TRANSFORMER,PWM,FLYBACK,ICA-1314
DZ15
D49
DZ16
DZ4
R115
R114
R91
C10
R88
R89
R121 TP1 1 T13640-11K MOV,150VRMS,45J,14MM
C17
C45 D1 N.B. X1 1 S15128-4 OP-AMP,QUAD, GEN-PURPOSE,224N
Q8
R13
C14
R71
DZ11
D12
D13
D51
N.B.X2 1 S17900-24 IC,CMOS,GATE,NAND,2-INPUT,QUAD,SCHM(SS)
D40
D41
R22
R74
R48
C8
R9
D25
N.B. X3 1 S15018-29 IC,CMOS,DRIVER,MOSFET,2113(SS)
DZ18
C43
D46 Q10
D3
R119
R112 R106
R2
N.B.N.C.X4 1 S25073-9 IC,CMOS,PSOC,8-BIT,CY8C27443,DIP-28(SS)

Q3
DZ3
D54 R92 C18

R120
N.B.X5, X7 2 M15458-8 IC,PWM-CONTROLLER,IMODE,2843A
X4
R110
3.00 X7
N.B.X6 1 S15128-5 IC,VOLT REG,FIXED,3-T,(+),1A,5V,TO220
C47
D24
N.C.
C12
R11
C7
R7
D11
D36
R109
R96
C37
R12
C13
D17
D18
C15
C16
R16
X3 X2
R6
R35
C38
R107
R97
C24
R95
C20
C1
D10
R3
D26
D15
D16
R34
Q9
D38
D27
D39
R116
R117
R118
R56
R38
R73
R31
C48
C9
R54
R46
R47
DZ2
R49
R5
D2
2.02
R45
R52
R53
C26
Q4
R37 NOTES:
D48
R58
R41
D37
CAPACITORS =MFD /VOLT

C23
R25
R26
R10
C11
R50
R51
D14
D32
R1
R28
R44
R30
Q6 Q5
R43
R29
D4
D5
C39 N.A. DO NOT COAT W ITH ENCAPSULATION MATERIAL. RESISTORS =OHMS

TP1
R57
D44
C29
D33
R111
N.B. CAUTION:THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC MAKE PER E1911
C46
ELECTRICITY.SEE E2454 BEFORE HANDLING. ENCAPSULATE TW ICE W ITH E1844
J3 J4 J14 J2
TEST PER E4143-C
J1
.38 N.C. PROGRAM X4 PER ITEM 5AND LABEL X4 W ITH PART

NUMBER OF ITEM 5.
.00 FOR PARTS ORDERS:
INCLUDE T13498-21
.25
.00 4.15 5.00 8.75
PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
4 (3 PLACES)
UNLESS OTHERWISE SPECIFIED TOLERANCE
9.00±.04 MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
REFERENCE:
EQUIPMENT TYPE: LN-25 PAGE ___
1 OF ___
1
SOLID EDGE
ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI L12253-2
SUBJECT:
DOC UME NT DOCUMENT
ON ALL ANGLES IS ± .5 OF A DEGREE CONTROL P.C.BOARD ASSEMBLY
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: SCALE: NUMB ER: REVISION:
L12253-3 B
EN-168
EF
WITH PUBLISHED STANDARDS. MATERIAL APPROVAL PROJECT
DO NOT SCALE THIS DRAWING APPROVED: - 1:1 DISPOSITI
ON:
UF DATE: 10/1
2/20
06 NUMBER:
CRM37434
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine. L N-25™
¤
PC BOARD ASSEMBLY - CONTROL - CODE 10556 THRU 10558 (G3425-3)
G3425-3 ENGINEERING CONTROLLED CHANGE DETAIL: ADDED OBSOLETE NOTE WITH PARTS ORDERS INFORMATION AND REMOVED PARTS ORDERS INFORMATION.
MANUFACTURER: No
ITEM REQ'D PART NO. DESCRIPTION
C1 1 T11577-46 CAPACITOR,CD,.05,600V,+80/-20%
C2,C8,C9 3 S13490-106 CAPACITOR,ALEL,470,350V,+30/-20%
C3,C6,C12,C15,C20,C28,C33 13 S16668-5 CAPACITOR,CEMO,.022, 50V,20%
C34,C35,C36,C37,C43,C47
C4,C23 2 S13490-8 CAPACITOR,ALEL,50,25V,+75/-10%
C5 1 S13490-92 CAPACITOR,ALEL,3300, 50V,+30/-10%
C7,C30,C31,C61 4 S13490-19 CAPACITOR,TAEL,1.8,20V,10%
P.C. BOARD BLANK REFERENCE INFORMATION C10 1 S13490-73 CAPACITOR,ALEL,20,50V,+75/-10%
C11,C56 2 S16668-4 CAPACITOR,CEMO, 2700PF, 50V,5%
BUY COMPLETE AS G3425-F 4
(LAYER BOARD PER E3281) C13,C46,C48,C49 4 S16668-3 CAPACITOR,CEMO,100P, 100V,5%
C14,C18,C19,C25 4 S13490-39 CAPACITOR,TAEL,18,15V 10%
(MAKES 4BOARDS PER PANEL,SEE ELECTRONIC FILE FOR ADDITIONAL NFORMATI
I ON) C16 1 S13490-62 CAPACITOR,PCF,.0033,200V,10%
C17 1 S13490-95 CAPACITOR,TAEL,.33,50V,10%
PANELSIZE PER E1911 C21 1 S13490-76 CAPACITOR,PEF,.001,400V,10%
C22 1 S13490-12 CAPACITOR,ALEL,10,25V,+75/-10%
C24,C44,C57 3 S16668-7 CAPACITOR,CEMO,820p,50V,5%
C26 1 S20500-1 CAPACITOR,PPMF,0.1,1000V,10%,BOX
C27,C45 2 S13490-25 CAPACITOR,TAEL,4.7,35V 10%
C29,C32,C51 3 S13490-42 CAPACITOR,TAEL,1.0,35V,10%
C38,C39,C40,C41,C42,C53 8 S16668-11 CAPACITOR,CEMO,0.1, 50V,10%
C54,C60
C50 1 S16668-6 CAPACITOR,CEMO,4700p,50V,10%
C59 1 S16668-13 CAPACITOR,CEMO,10p,100V,10%
D1,D4,D27 3 T12199-4 DIODE,AXLDS,1A,600V
D2,D3,D5,D7,D8,D10,D11,D13 22 T12199-1 DIODE,AXLDS,1A,400V
D14,D16,D17,D18,D19,D20
D21,D22,D23,D24,D25,D28
D29,D33
D6 1 S18395-32 DIODE,T220,25A,400V,WITH S18104-3HS
D9,D34 2 T12705-34 DIODE,AXLDS,1A,400V,FR,1N4936
D12 1 T12705-46 DIODE,AXLDS,3A,1000V

D32 1 T12199-2 DIODE,AXLDS,1A,1000V

DZ1 1 T12702-19 ZENER DIODE, 1W,12V,5% 1N4742A
{
DZ2,DZ3,DZ4,DZ5 4 T12702-11 ZENER DIODE, 1W,16V,5% 1N4745A
N.A. J3 1 S18248-16 CONNECTOR,MOLEX,MINI,PCB,16-PIN
OCI1 1 S15000-10 OPTOCOUPLER,PHOTO-Q,70V,CNY17-3
Q1 1 S18105-3 TRANSISTOR,N,T220,5A,1000V,MJE18004& S18104-1HS
Q2 1 T12704-55 TRANSISTOR,NPN,TO226,0.3A, 400V,MPS-A44
Q3,Q4,Q5,Q6,Q10,Q12,Q13 9 T12704-68 TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
Q14,Q16
Q7,Q11,Q17 3 T12704-69 TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403
N.B. Q8
{
Q9
Q15
1
1
1
S18397-3
S18395-33
S20630-1
TRANSISTOR,IGBT,T247,1200V,45A,FAST(SS) WITH S1
TRANSISTOR,IGBT,T247,1200V,45A,FAST(SS)
SBS,TO226,7.5-9.0V,MBS4993
N.B. Q18 1 T12704-72 TRANSISTOR,NMF,T220,8A,500V,IRF840(SS)
R1 1 T14648-25 RESISTOR,WW,5W,10,5%,SQ
R2,R72,R86 3 T14648-5 RESISTOR,WW,5W,3.3K,5%,SQ
R3,R5,R17,R73,R109 5 S19400-1000 RESISTOR,MF,1/4W,100,1%
R4,R119 2 S19400-10R0 RESISTOR,MF,1/4W,10.0,1%
R6 1 S19400-3012 RESISTOR,MF,1/4W,30.1K,1%
R7,R95 2 S19400-6811 RESISTOR,MF,1/4W,6.81K,1%
R9,R81,R83,R96,R97,R98,R99 10 S19400-1001 RESISTOR,MF,1/4W,1.00K,1%
R100,R101,R111
R10,R52,R64 3 S19400-1372 RESISTOR,MF,1/4W,13.7K,1%
R11 1 S16296-3 TRIMMER,MT,1/2W,500, 10%,LINEAR
R12,R43,R84,R85,R94 5 S19400-4751 RESISTOR,MF,1/4W,4.75K,1%
R13,R14 2 T14648-11 RESISTOR,WW,5W,4.7K,5%,SQ
R15,R20,R21,R29,R30,R34 23 S19400-2212 RESISTOR,MF,1/4W,22.1K,1%
R39,R40,R49,R67,R68,R71
R79,R80,R82,R89,R90,R102
R104,R105,R106,R115,R116
R16,R61,R107 3 S19400-1003 RESISTOR,MF,1/4W,100K,1%

ITEM REQ'D PART NO. DESCRIPTION R18,R19,R24,R26,R60,R63 7 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
1 1 G3425-F P.C.BOARD BLANK R76
2 8 S14020-4 EXPANSION NUT R22 1 S16296-2 TRIMMER,MT,1/2W,100K, 10%,LINEAR
3 .040Z E2861 SEALANT R23 1 S19400-6812 RESISTOR,MF,1/4W,68.1K,1%
R27 1 S19400-1004 RESISTOR,MF,1/4W,1.00M,1%
R31 1 S19400-1822 RESISTOR,MF,1/4W,18.2K,1%
R33,R62,R66 3 S19400-1503 RESISTOR,MF,1/4W,150K,1%
R35,R56,R59,R70,R75 5 S19400-2672 RESISTOR,MF,1/4W,26.7K,1%
SCHEMATIC REFERENCE -G3424-3F0 R36,R45 2 S19400-1501 RESISTOR,MF,1/4W,1.50K,1%
R37 1 S19400-33R2 RESISTOR,MF,1/4W,33.2,1%
R38 1 T14648-18 RESISTOR,WW,5W,68,5%,SQ
MANUFACTURED AS R41 1 S19400-3922 RESISTOR,MF,1/4W,39.2K,1%
G3425-3F0 R44 1 S19400-8251 RESISTOR,MF,1/4W,8.25K,1%
{
IDENTIFICATION CODE R46 1 S19400-4752 RESISTOR,MF,1/4W,47.5K ,1%
R47 1 T12300-77 RESISTOR,WW,7W,0.1,1%
MAKE PER E1911 R51 1 S19400-1652 RESISTOR,MF,1/4W,16.5K,1%
ENCAPSULATE W ITH E1844 R54 1 S19400-1023 RESISTOR,MF,1/4W,102K,1%
TEST PER E2747-C R55 1 S19400-2801 RESISTOR,MF,1/4W,2.80K,1%
R57 1 S19400-2670 RESISTOR,MF,1/4W,267,1%
CAPACITORS =MF D /VOLTS R78,R110 2 S19400-3322 RESISTOR,MF,1/4W,33.2K,1%
RESISTORS =OHMS R87 1 S19400-7681 RESISTOR,MF,1/4W,7.68K,1%
R91 1 S19400-1301 RESISTOR,MF,1/4W,1.30K,1%
R112 1 S19400-1821 RESISTOR,MF,1/4W,1.82K,1%
R114 1 T12300-79 RESISTOR,WW, 1W,1.0,1%
R117,R118 2 S19400-4750 RESISTOR,MF,1/4W,475,1%
TP1 1 T13640-11 MOV,150VRMS,45J,14MM
X1,X2 2 S15128-10 VOLTAGE REF,ADJ, PRECISION,431I
Notes: N.B. X3 1 S15018-4 IC,CMOS,INVERTER,SCHMITT, HEX,4584(SS)

X4 1 M13552-2 IC,CONVERTER,F/V,2907
ETE-
X5,X6 2 S15128-4 OP-AMP,QUAD, GEN-PURPOSE,224N

S:
OBSOL RTS ORDER OL
{
N.A. DO NOT COAT W ITH ENCAPSULATION MATERIAL. X7,X8,X9,X12 4 S15128-11 IC,COMPARATOR,QUAD,2901N
OR PA ONT R X10 1 S15018-10 IC,CMOS,FLIP-FLOP,"D",DUAL,4013(SS)

F 3C
M2063
N.B. CAUTION:THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
KIT
X11 1 S15018-6 IC,CMOS,SWITCH,ANALOG,QUAD, 4066(SS)
SEND PLACEMENT
ELECTRICITY.SEE E2454 BEFORE HANDLING. N.B.
X13 1 S15018-9 IC,CMOS,MULTIVBRTR_MONO_DUAL_4538(SS)
B RE
N.D. ANCHOR ITEMS C2,C5,C8 AND C9 TO BOARD W ITH .25 W IDE,
PC
.50 LONG BEAD OF ITEM "3".
MANUFACTURING TOLERANCE PER E2056
SCALE: EQUIPMENT TYPE: LN-25
SOLID EDGE
UNLESS OTHERWISE SPECIFIED TOLERANCE: DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE PAGE ___ 1
1 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: bwilliam DOCUMENT
CONTROL P.C. BOARD
DOCUMENT
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER:
IF PRINTED
@ A1 SIZE SUBJECT: NUMBER: REVISION:
DO NOT SCALE THIS DRAWING APPROVED: -
UNITS:
INCH
MATERIAL
DISPOSITION: UF
APPROVAL
DATE: 2/7/2005
PROJECT
NUMBER: CRM35795
REFERENCE:
-
G3425-3 B
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the L N-25™
¤
machine.
PC BOARD ASSEMBLY - CONTROL - CODE 10100 THRU 10500 (G2196-1)
Q9
Q8
¤
machine.
PC BOARD ASSEMBLY - CONTROL - BELOW CODE 9900 (G1757-6)
1757-6 G
ITEM REQ’D PART NO. DESCRIPTION
.25 2.275 5.05 10.75
~.04
6.00
XX X XX X
XX X XX X
X X
5.60
X
X
X
X
3.20
X
XX
XX X
X
X
2.05
1.10
X
X
XX X G1757-6 .25
XX X LN-25 CONTROL
0
0 1.90 4.20 6.25 11.00 ~.04
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
LN-25
EQUIP.
9-13-91B THE LINCOLN ELECTRIC CO. TYPE
1-31-92E CLEVELAND, OHIO U.S.A.
3-4-94
SUBJECT CONTROL P.C. BOARD
SCALE FULL
G
SHT.
1757-6
3-17-95B
DR FM DATE 1-21-94 CHK REF. SUP’S’D’G 8-23-91
2-21-97E NO.
¤
machine.
SCHEMATIC - CONTACTOR PC BD - ABOVE CODE 10500 (M10965)
M19065
CONTROL BOARD 7W BACK-UP COIL SUPPLY

D1 2.7 A
J9
667 R30
TO
1
Q1 D2
J9 3A 600V 1N4007
5A
624
4 400V
1A
1000V
CONTACTOR
2.7 R2
J9 J9
621
R31
512 5W 33.2
2 Q2 512A 13
3300 300mA
J9
530 5W 400V D3
3
1A
J9 2.7 E 1000V
R1
R32
10 5W J9
REF
J9 14
150K
22.1K
R22
11 2.8K
R20
15.0K 5.62K + -
X2
R25
R27
J9
R24
Q6
12 2N4401 TL431
10
22.1K 22.1K 5.62K
R10
Q3
R9
R6
J9 13
500 Q8 2N4401
9 13 4
X5 20A 100 RST
R3
J9 11 9 7
11 2 R29 500V B /Q Q5
512 5 X5
15.0K 12 X4 10 1 7.8A
100 X3
5
A Q R11
R4
J9 D 800V
606 6
T1 T2
6 C9 C10 +
2N4403
100
J9 0.1 C1 15 14
530A Q7 X1 REF
7 50V 5600 22.1K 2N4403 DZ1
R28
R7
TL431 35V C2 Q4 16V
J9 2.21K 22.1K
607 .0047
R21
R23
8 DZ2 - 1W
16V 50V
22.1K 1.82K
2.8K 1W
TIMER BOARD 621
R26
R5
J6 512A
607 5 621
3
2
J6 X3
530A 2 4 10K
621 621 C
R16
512A
J6
606 6
J6
D10
D6
512 10
R36
4 R18
22.1K 8
13
J6 X5 X3 2.67K
500 14
5 11
R37 9 512A
J6 D11
530 3.32K C14
1
2700p
50V
PULL-IN TIMER
C4
COLD INCH 820p 1.0
B
5.62K
511
100K
R19
22.1K
SWITCH 621
R15
R17
50V 1W
D9
R14
R13
3
3.32K
CONTACTOR ON 5
RST
7 8
R12 B /Q
J7
D8 4 X4 6 14
500 A Q X3
1
9
J7 T1 T2
530
COLD INCH LOCK OUT 1 2 CURRENT LIMIT
2
621
C8 C3
512A 2700pf 1.0
50V 35V
D5
1 621
X5
7 GENERAL INFORMATION LAST NO. USED
3 16 3
R- 37
ELECTRICAL SYMBOLS PER E1537
C- 14
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
C5 C6 X3 C7 X4 C11 X5 RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 11
3300 1.8 621 DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)

SUPPLY VOLTAGE NET
50V LM2901 MC14538B 20V LM2901
POWER SUPPLY SOURCE POINT
NOTES :
12 8 12
COMMON CONNECTION
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY FRAME CONNECTION
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
EARTH GROUND CONNECTION
NUMBER.
FILE: M19065_1BA
Ch’ge.Sht.No.
621 EQUIP.
THE LINCOLN ELECTRIC CO. TYPE
LN-25
2-20-98A
10-23-98E CLEVELAND, OHIO U.S.A. SUBJECT CONTACTOR SCHEMATIC

SCALE NONE
SHT.
DR. MCW DATE
9/28/90
CHK. SUP’S’D’G. NO. M19065
L N-25™
¤
SCHEMATIC - CONTACTOR PC BD - CODE 10100 THRU 10500 (M17621)
y ( yy ) g
R i i D S STANDARD This print is Current
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. L N-25™
¤
SCHEMATIC - CONTACTOR PC BD - BELOW CODE 9900 (L7535-[ ] CONTACTOR - M15428)
L N-25™
¤
SCHEMATIC - CONTACTOR PC BD - BELOW CODE 9900 (L9185-[ ] CONTACTOR - M17139)
y ( yy ) g
L N-25™
¤
PC BOARD ASSEMBLY - CONTACTOR - ABOVE CODE 10500 (L10863-1)
L10863-1
ENGINEERING CONTROLLED CHANGE DETAIL: REVISED COM PON ENTS AND PART NUM BERS AND UPDATED GR APHICS PART NO. IDENTIFICATION
ITEM REQ'D
MANUFACTURER: No
C1 1 S13490-107 5600/35V
C2 1 S16668-6 4700pF/50
C3 1 S13490-42 1.0/35
C4 1 S16668-7 820pF/50
C5 1 S13490-92 3300/50
C6,C7,C9,C15 4 S16668-5 .022/50
C8,C14 2 S16668-4 2700pF/50
C10 1 S16668-11 .1/50
C11 1 S13490-19 1.8/20
C16 1 S16668-1 22pF/100
C17 1 S13490-39 18/15
D1 1 T12705-29 DIODE
P.C.BOARD BLANK INFORMATION D2 1 T12199-2 1N4007
MAKE FROM S19399 (MAKES 10BOARDS PER PANEL, D3 1 T12705-59 DIODE 600V/3A
SEE ELECTRONIC FIL
E FOR ADDITIO
NAL NIFO RMATION) D5,D6,D8,D9,D10,D11 6 T12199-1 1N4004
BLANK PART NUMBER L10863-C DZ1,DZ2 2 T12702-11 1N4745A
J6 1 S18248-6 HEADER
N.A. J7 1 S18248-2T HEADER
J9 1 S18248-14 HEADER
Q1 1 T12704-56 5A.,1000V. TRANSISTOR
Q2 1 T12704-55 TRANSISTOR
Q3,Q6 2 T12704-68 2N4401
Q4,Q7 2 T12704-69 2N4403
N.C. Q5 1 T12704-87 TRANSISTOR,NMF (SS)
±.04 N.B.
Q8 1 T12704-71 HEXFET TRANS. (SS)
5.00
C14 C10 R23
R1 1 T14648-5 3.3K 5W
x R2 1 S19400-33R2 33.2 1/4W
x
L10863-1
C11
x
X5
R3,R11,R29 3 S19400-1000 100 1/4W
R22
R21
R26
R27
R28
R25
C9
+
x
-
C1
x R24 R4,R24 2 S19400-1502 15K 1/4W
R9
x R5 1 S19400-1821 1.82K 1/4W
x
R36
x
R37
C7
C2
R6,R7,R9,R13,R25,R26,R28 8 S19400-2212 22.1K 1/4W
(3.80)
X4
x
xx R36
x
x R10,R27 2 S19400-5621 5.62K 1/4W
R5
D5
R4
X1
R14
x
C8
R38
C3
R15
R13
C15
C16
R39
R17
x R12,R37 2 S19400-3321 3.32K 1/4W
-
x
C5
R14 1 S19400-1003 100K 1/4W
LN-25 CONTACTOR
x
X2
1
C6
R3
R2
x X3 R15 1 S19400-5110 511 1/4W
x
R12
R16
R16 1 S19400-1002 10K 1/4W
C17
R18
Q7
R17 1 S19400-3921 3.92K 1/4W
D11
C4
2
Q2
R18 1 S19400-2671 2.67K 1/4W
R31
R32
Q6
D8
R19 1 T12300-79 1 WATT 1 OHM 1% RESIS.
Q3
R7
R1
R6
Q8
R20 1 S19400-1503 150K 1/4W
D6
DZ2
Q4
Q1
R29
R21,R22 2 S19400-2801 2.8K 1/4W
D2
R10
R20
R23 1 S19400-2211 2.21K 1/4W
D10
D9
R19
R30 1 T12300-85 7 WATTS, 2.7 OHMS
R30
J6
D1
R31,R32 2 T13165-11 2.7 OHM, 5 WATT RESIS.
DZ1 R11
J7 D3 R38,R39 2 S19400-1001 1K 1/4W
X1,X2 2 S15128-10 IC,431,VOLTAGE REF.
(.55) Q5
X3,X5 2 S15128-11 14 PIN QUAD COMP.
J9
N.B. X4 1 S15018-9 CMOS MC14538B (SS)
0
MANUFACTURED AS: ITEM PART NO. DESCRIPTION REQ'D
(.25) (3.25)
1 SEE BLANK INFORMATION CONTACTOR P.C. BOARD BLANK 1
0 3.50
±.04
L10863-1C0 N.A. 2
3
T13498-22
E2861
JUMPER PLUG
ADHESIVE
1
.03 oz.
IDENTIFICATION CODE
INDUCTANCE = HENRYS
CAPACITORS = MFD/VOLTS
MAKE PER E1911
ENCAPSULATE WITH E1844
NOTES: TEST PER E2747-K FOR PARTS ORDERS:
SCHEMATIC REFERENCE: M19065-1C0
N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL. INCLUDE (1) T14477PRINT

N.B. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
ELECTRICITY. SEE E2454 BEFORE HANDLING.
N.C. ANCHOR CAPACITORS TO BOARD WITH .25 WIDE, .50 LONG UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE:
EQUIPMENT TYPE: LN-25 PAGE ___
1 OF ___
1
SOLID EDGE
BEAD OF ITEM 3 (2 PLACES)
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI L9670-1
SUBJECT:
DOC UME NT DOCUMENT
ON ALL ANGLES IS ± .5 OF A DEGREE CONTACTOR P.C.BOARD ASSEMBLY
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: SCALE: NUMB ER: REVISION:
DO NOT SCALE THIS DRAWING APPROVED: - 1:1
MATERIAL
DISPOSITI
ON:
NA APPROVAL
DATE: 11/2
5/20
02
PROJECT
NUMBER:
CRM32207 L10863-1 A
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- L N-25™
¤
machine.
PC BOARD ASSEMBLY - CONTACTOR - CODE 10100 THRU 10500 (L9670-1)
L N-25™
¤
machine.
PC BOARD ASSEMBLY - CONTACTOR - BELOW CODE 9900 (L9185-2)
y ( yy )
L N-25™
R i i 8 17 2001D Status- STANDARD T
¤
machine.

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View Safety Info

LN-25 ™ PORTABLE CV/CC

9220 9812 11144

9383 10556 11145

SVM114-C | Issue D­ate 08, Jul

CALIFORNIA PROPOSITION 65 WARNINGS

FOR ENGINE 1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.h. Never simultaneously touch electrically “hot” parts of

5.e. Read and understand the manufacturer’s instructions for this

5.f. Also see item 1.b.

WELDING and CUTTING CYLINDER may explode

SPARKS can if damaged.

6.j. Do not use a welding power source for pipe thawing.

PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

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

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

5. Toujours porter des lunettes de sécurité dans la zone de

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G

Parts Manual (below code 10500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-175

Parts Manual (above code 10500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-333

Wire Feed Drive Roll and Guide Tube Kits . . . . . . . . . . . . . . . . . . . . . . . . A-5

TECHNICAL SPECIFICATIONS – LN-25™

Constant Voltage (CV)

Rated current without contactor 500 Amps 60% Duty Cycle

Rated current with contactor 300 Amps 60% Duty Cycle

50 – 700 Inches Per Minute (IPM)

HEIGHT WIDTH DEPTH WEIGHT

14 Inches 7.4 Inches 21 Inches 28 lbs

(354 mm) (187 mm) (531 mm) (13 kg)

OPERATION: - 40o C to +40o C (- 40o F to +104o F)

STORAGE: - 40o C to +70o C (- 40o F to +158o F)

ENVIRONMENTAL RAT ING

• Do not touch metal portions

the open circuit voltage is less than 110V DC.

c. Place “Set to CV Electrode Cable Polarity” switch

Assemblies Section), the power source output must

energized when the power source is turned on.

DC-600™ NOTE: Refer to the Instruction Manual provided with

Code 8200, also jumper N to S.) NEWER LINCOLN POWER SOURCES

d. Set toggle switch to “Constant Voltage” and set

SA-200™, –250™ OR SAE-300™, –400™

female inert gas fitting on the front panel of the LN-

with the drive roll kit, to install these parts on new

60% Duty Cycle 50'-100' 100'-150' 150'-200' 200'-250'

ELECTRODE CABLE CONNECTION Kit Instructions

Steel Wire Sizes:

with the nut and bolt provided. Tape the bolted

Aluminum Wire Sizes:

WORK CABLE CONNECTION

Connect a work lead of sufficient size between the

Setting Constant Wire Feed Speed (CV Mode) . . . . . . . . . . . . . B-7

SVM114-C | Issue Date 08, Jul