LN-25™ Pro Wire Feeder

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SVM179-B
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April, 2011
LN-25™ PRO WIRE FEEDER

For use with machines having Code Numbers: 11387, 11388
11507, 11508
11620, 11621
11716, 11717
11746, 11747
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Safety Depends on You
Lincoln arc welding and cutting

equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL
AND THE SAFETY PRE-
CAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
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SERVICE MANUAL
View Safety Info
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. 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.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
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. 2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
idler by pushing on the throttle control rods

while the engine is running.
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.
LN-25™ PRO
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 within applicable OSHA PEL and
3.e. Ground the work or metal to be welded to a good electrical ACGIH TLV limits using local exhaust or mechanical ven-
(earth) ground. tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
3.f. Maintain the electrode holder, work clamp, welding cable and cautions are also required when welding on galvanized
welding machine in good, safe operating condition. Replace steel.
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
3.g. Never dip the electrode in water for cooling.
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-

3.h. Never simultaneously touch electrically “hot” parts of
sure level should be checked upon installation and periodi-
electrode holders connected to two welders because voltage
cally thereafter to be certain it is within applicable OSHA PEL
between the two can be the total of the open circuit voltage
and ACGIH TLV limits.
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
3.i. When working above floor level, use a safety belt to protect
coming from degreasing, cleaning or spraying operations.
yourself from a fall should you get a shock.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.j. Also see Items 6.c. and 8.
ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
LN-25™ PRO
iii SAFETY iii
WELDING and CUTTING CYLINDER may explode

SPARKS can cause fire or if damaged.

explosion. 7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.If process used and properly operating
this is not possible, cover them to prevent the welding sparks regulators designed for the gas and
from starting a fire. 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 adjcent 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 through 8.b. Install equipment in accordance with the U.S. National
lifting chains, crane cables or other alternate circuits. This can Electrical Code, all local codes and the manufacturer’s
create fire hazards or overheat lifting chains or cables until recommendations.
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.

Refer to http://www.lincolnelectric.com/safety for additional safety information.
LN-25™ PRO
iv SAFETY iv
6. Eloigner les matériaux inflammables ou les recouvrir afin de

PRÉCAUTIONS DE SÛRETÉ
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
contre les chutes dans le cas ou on recoit un choc. Ne jamais LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi 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.
LN-25™ PRO
I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I
RETURN TO MAIN MENU
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-557
LN-25™ PRO
Return to Master TOC A-1 TABLE OF CONTENTS - INSTALLATION SECTION A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Frequency Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Wire Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Changing The Gun Receiver Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Procedure To Install Drive Rolls and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Pressure Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Loading Spools of Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Gun Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Power Source to LN-25™ PRO Cable Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7/A-8

MACHINES COVERED IN THIS MANUAL
PRODUCT CODE
PRODUCT NAME
NUMBER NUMBERS
LN-25™PRO K2613-1 11387, 11507
(NORMAL SPEED) 11620, 11716
LN-25™PRO K2613-2 11388, 11508
(EXTRA TORQUE) 11621, 11717
LN-25™PRO K2613-5 11746
(NORMAL SPEED)
LN-25™PRO K2613-7 11747
(EXTRA TORQUE)
LN-25™ PRO
A-2 INSTALLATION A-2
TECHNICAL SPECIFICATIONS – LN-25™ PRO (K2613-1, -2, -5, and -7)

Return to Section TOC
INPUT VOLTAGE and CURRENT

INPUT VOLTAGE ± 10% INPUT AMPERES
15-110 VDC 4A
(24-42 VAC with remote voltage control kit installed)
RATED OUTPUT @ 104°F (40°C)

DUTY CYCLE INPUT AMPERES
60% rating 450

100% rating 325
GEARING - WIRE FEED SPEED RANGE-WIRE SIzE

GMAW FCAW
GEARING
WFS RANGE WIRE SIzES WFS RANGE WIRE SIzES
Extra torque 50 – 400 ipm .023 – 1/16" 30 – 400 ipm .030 - 3/32”
K2613-2 & K2613-7 (0.8 – 10.1m/min) (0.6 – 1.6mm) (0.8 – 10.1m/min) (10.3 – 2.4mm)
Normal Speed 50 – 700 ipm .023 – 1/16" 50 – 700 ipm .030 - 5/64
K2613-1 & K2613-5 (1.3 – 17.7m/min) (0.6 – 1.6mm) (1.3 – 17.7m/min) (0.8 - 2.0mm)
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
14.8 Inches 8.7 Inches 22.2 Inches 36 lbs

(376 mm) (221 mm) (589 mm) (16 kg)
Handle folded down
TEMPERATURE RANGE
OPERATION: -40°F to 104°F (-40°C to 40°C)
STORAGE: -40°F to 185°F (-40°C to 85°C)
LN-25™ PRO
SAFETY PRECAUTIONS The LN-25™ PRO is rated IP23 and is suitable for
outdoor use.
WARNING
The handle of the LN-25™ PRO is intended for
moving the wire feeder about the work place only.
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the When suspending a wire feeder, insulate the
disconnect switch or fuse box hanging device from the wire feeder enclosure.
before attempting to connect or
disconnect input power lines, out- HIGH FREQUENCY PROTECTION
put cables or control cables.
• Only qualified personnel should
perform this installation. CAUTION
• Do not touch metal portions of the LN-25™ PRO
work clip when the welding power source is on.
• Do not attach the work clip to the wire feeder. Locate the LN-25™ PRO away from radio controlled
• Connect the work clip directly to the work, as machinery. The normal operation of the LN-25™
close as possible to the welding arc. PRO may adversely affect the operation of RF con-
• Turn power off at the welding power source trolled equipment, which may result in bodily injury
before disconnecting the work clip from the or damage to the equipment.
work. --------------------------------------------------------------------------
• Only use on power sources with open circuit WELD CABLE SIzE
voltages less than 110 VDC.
------------------------------------------------------------------------ Table A.1 Located below are copper cable sizes rec-
LOCATION ommended for various currents and duty cycles.
For best wire feeding performance, place the LN- Lengths stipulated are the distance from the welder to
25™ PRO on a stable and dry surface. Keep the work and back to the welder again. Cable sizes are
wire feeder in a vertical position. Do not operate the increased for greater lengths primarily for the purpose
wire feeder on an angled surface of more than 15 of minimizing voltage drop in the cables.
degrees.
Do not submerge the LN-25™ PRO.

TABLE A.1
RECOMMENDED CABLE SIzES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES PERCENT
DUTY 0 to 50Ft. 50 to 100Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.
(0 to15m) (15 to 30m) (30 to 46m) (46 to 61m) (61 to 76m)
CYCLE
200 60 2 2 2 1 1/0
200 100 2 2 2 1 1/0
225 20 4 or 5 3 2 1 1/0
225 40 & 30 3 3 2 1 1/0
250 30 3 3 2 1 1/0
250 40 2 2 1 1 1/0
250 60 1 1 1 1 1/0
250 100 1 1 1 1 1/0
300 60 1 1 1 1/0 2/0
325 100 2/0 2/0 2/0 2/0 3/0
350 60 1/0 1/0 2/0 2/0 3/0

400 60 2/0 2/0 2/0 3/0 4/0
400 100 3/0 3/0 3/0 3/0 4/0
500 60 2/0 2/0 3/0 3/0 4/0
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).
LN-25™ PRO
2. Remove the cylinder cap. Inspect the cylinder valves

CABLE CONNECTIONS
and regulator for damaged threads, dirt, dust, oil or

grease. Remove dust and dirt with a clean cloth. DO
There is one circular connector for the gun trigger on NOT ATTACH THE REGULATOR IF OIL, GREASE
the front of the LN-25™ PRO. OR DAMAGE IS PRESENT! Inform your gas supplier
of this condition. Oil or grease in the presence of high
pressure oxygen is explosive
Table A.2
.
Function Pin Wiring 3. Stand to one side away from the outlet and open the
cylinder valve for an instant. This blows away any dust
5-pin trigger A Trigger or dirt which may have accumulated in the valve outlet.
connector for B Not used
push-guns C Common 4. Attach the flow regulator to the cylinder valve and tight-
only. D Not used en the union nut(s) securely with a wrench. Note: if
E Not used connecting to 100% CO2 cylinder, insert regulator
adapter between regulator and cylinder valve. If
adapter is equipped with a plastic washer, be sure it is
seated for connection to the CO2 cylinder.
5. Attach one end of the inlet hose to the outlet fitting of

the flow regulator. Attach the other end to the welding
C B system shielding gas inlet. Tighten the union nuts with
a wrench.
E 6. Before opening the cylinder valve, turn the regulator
D A
adjusting knob counterclockwise until the adjusting
spring pressure is released.
7. Standing to one side, open the cylinder valve slowly a

fraction of a turn. When the cylinder pressure gage
SHIELDING GAS CONNECTION stops moving, open the valve fully.
WARNING 8. The flow regulator is adjustable. Adjust it to the flow

rate recommended for the procedure and process
CYLINDER may explode if being used before making a weld.
damaged.
• Keep cylinder upright and WIRE DRIVE CONFIGURATION

chained to support. (See Figure A.1)
CHANGING THE GUN RECEIVER
• Keep cylinder away from areas where it may be
BUSHING
damaged.
• Never lift welder with cylinder attached. WARNING
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live
ELECTRIC SHOCK can kill.
electrical circuits.
• Turn the input power OFF at the weld-
• BUILD UP OF SHIELDING GAS MAY
ing power source before installation
HARM HEALTH OR KILL.
or changing drive rolls and/or guides.
• Shut off shielding gas supply when not in
• Do not touch electrically live parts.
use.
• When inching with the gun trigger, electrode and
• See American National Standard z-49.1, "Safety
drive mechanism are "hot" to work and ground
in Welding and Cutting” Published by the
and could remain energized several seconds
American Welding Society.

after the gun trigger is released.
------------------------------------------------------------------------
• Do not operate with covers, panels or guards
Maximum inlet pressure is 100 psi. (6.9 bar.)
removed or open.
• Only qualified personnel should perform mainte-
Install the shielding gas supply as follows:
nance work.
------------------------------------------------------------------------
1. Secure the cylinder to prevent it from falling.
LN-25™ PRO
Tools required: PROCEDURE TO INSTALL DRIVE ROLLS

• 1/4" hex key wrench. AND WIRE GUIDES

1. Turn power off at the welding power source. WARNING
2. Remove the welding wire from the wire drive. • Turn the input power OFF at the weld-
ing power source before installation
3. Remove the thumb screw from the wire drive. or changing drive rolls and/or guides.
4. Remove the welding gun from the wire drive. • When inching with the gun trigger, electrode and
5. Loosen the socket head cap screw that holds the and could remain energized several seconds
connector bar against the gun bushing. after the gun trigger is released.
IMPORTANT: • Do not operate with covers, panels or guards
Do not attempt to completely remove the socket removed or open.
head cap screw. • Only qualified personnel should perform mainte-
nance work.
6. Remove the outer wire guide, and push the gun ------------------------------------------------------------------------
bushing out of the wire drive. Because of the pre- 1. Turn power off at the welding power source.
cision fit, light tapping may be required to remove
the gun bushing. 2. Release the idle roll pressure arm.
7. Disconnect the shielding gas hose from the gun 3. Remove the outer wire guide by turning the knurled
bushing, if required. thumbscrews counter-clockwise to unscrew them
from the feed plate. See Figure A.2.
8. Connect the shielding gas hose to the new gun
bushing, if required. 4. Rotate the triangular lock and remove the drive rolls.
9. Rotate the gun bushing until the thumb screw hole 5. Remove the inner wire guide
aligns with the thumb screw hole in the feed plate.
Slide the gun receiver bushing into the wire drive 6. Insert the new inner wire guide, groove side out,
and verify the thumb screw holes are aligned. over the two locating pins in the feed plate.
10. Tighten the socket head cap screw. 7. Install a drive roll on each hub assembly secure with
the triangular lock.

11. Insert the welding gun into the gun bushing and
tighten the thumb screw. 8. Install the outer wire guide by aligning it with the pins
and tightening the knurled thumbscrews.
NOTE: Some gun bushings do not require the use of
the thumb screw. 9. Close the idle arm and engage the idle roll pressure
arm. Adjust the pressure appropriately.
FIGURE A.1
THUMB SCREW
FIGURE A.2
GUN RECEIVER BUSHING
OUTER WIRE GUIDE

CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN TIGHTEN
LN-25™ PRO
PRESSURE ARM ADJUSTMENT 1. Squeeze the release bar on the retaining collar and
remove it from the spindle.
WARNING 2. Place the spindle adapter on the spindle, aligning

the spindle brake pin with the hole in the adapter.
• Turn the input power OFF at the weld-
3. Place the spool on the spindle and align the adapter
ing power source before installation or
brake tab with one of the holes in the back side of
changing drive rolls and/or guides.
the spool. An indicator mark on the end of the spin-
dle shows the orientation of the brake tab. Be cer-
• When inching with the gun trigger, electrode and
tain the wire feeds off of the spool in the proper
direction.
and could remain energized several seconds
4. Re-install the retaining collar. Make sure that the
release bar snaps out and that the retaining collar
removed or open.
fully engages the groove on the spindle.
nance work.
GUN CONNECTION
------------------------------------------------------------------------
The pressure arm controls the amount of force the
drive rolls exert on the wire. Proper adjustment of the
WARNING
pressure arm gives the best welding performance.
Set the pressure arm as follows: • Turn the input power OFF at the weld-
(See Figure A.3) ing power source before installation or
Aluminum wires between 1 and 3 changing drive rolls and/or guides.
Cored wires between 3 and 4 • Do not touch electrically live parts.
Steel, Stainless wires between 4 and 6 • When inching with the gun trigger, electrode and
FIGURE A.3 and could remain energized several seconds
removed or open.
nance work.
------------------------------------------------------------------------
Al ALUMINUM WIRES The LN-25™ PRO comes with a K1500-2 gun adapter
Fe, CrNi CORED WIRES installed. (See Figure A.4)
6 Fe, CrNi STEEL, STAINLESS WIRES
To install a gun,
1. Turn power OFF.
2. Remove the thumb screw.
3. Push the gun the completely into the gun bushing.
LOADING SPOOLS OF WIRE 4. Secure the gun in place with the thumb screw.
WARNING 5. Connect the trigger cable from the gun to the trigger
connector on the front of the feeder.
• Keep hands, hair, clothing and tools
away from rotating equipment. Note: Not all gun bushings require the use of the
• Do not wear gloves when threading thumb screw.
wire or changing wire spool.
• Only qualified personnel should install, FIGURE A.4
use or service this equipment.
THUMB
------------------------------------------------------------------------ SCREW
Loading 10 to 15 lb. (4.5 – 6.8kg) Spools. GUN
A K468 spindle adapter is required for loading 2"

(51mm) wide spools on 2" (51mm) spindles. Use a
K468 spindle adapter for loading 2-1/2" (64mm) wide
spools.
LN-25™ PRO
POWER SOURCE TO LN-25™ PRO

CABLE CONNECTION DIAGRAMS

ACROSS THE ARC SET-UPS
CC Power Sources with Output Terminals Always

Hot (See Figure A.5)
CC Power Source
Ranger 250, 250 LPG
Ranger 305G, 305D
FIGURE A.5
Commander 300
Vantage 300, 400, 500
Air Vantage 500 LN-25 PRO
Electrode
Ranger 10,000 (Across the Arc)

Ranger 3 phase
SAE 400 with CV adapter Work clip
Engine Driven welder with Work
Wire Feed Module
K# Description
If the power source has a Remote/Local switch, place
K2613-1 LN-25™ PRO Wire Feeder
the switch in the Local position.
K2613-2 LN-25™ PRO Extra Torque
KP1695-XX
Place the Power Source CC/CV switch (if present) or
KP1696-XX Drive Roll Kit
Range Switch in the CV position if possible.
KP1697-XX
See Magnum Literature Welding Gun
Set the CV/CC switch in the feeder to match the power
CC power Source
source.
K1803-1 Welding Cables
CV Power Sources with Stud Connectors and

Remote/Local Switch (See Figure A.6)
FIGURE A.6
CV-655
CV-400
LN-25 PRO
DC-400 Electrode
(Across the Arc)
DC-600
DC-655
V450-Pro Work clip
Work
K# Description
Place the power source Remote/Local switch in the K2613-1 LN-25™ PRO Wire Feeder
Local position.
KP1695-XX
Place CV/CC switch in the feeder in the "CV" position. KP1696-XX Drive Roll Kit
KP1697-XX
See magnum Literature Welding Gun
CV power Source
K1803-1 Welding Cables
LN-25™ PRO
CV Power Source with Twist-Mate Connectors and

Remote/Local Switch. (See Figure A.7)
FIGURE A.7
LN-25 PRO
V350-Pro Electrode
(Across the Arc)
Wor k clip
Work
Place CV/CC switch in the feeder in the "CV" position. K# Description


KP1695-XX
KP1697-XX
CC power Source
K1841 Welding Cables
CV Power Source with Twist-Mate Connectors and

no Remote/Local Switch. (See Figure A.8)
Jumper FIGURE A.8

CV-250
CV-300 LN-25 PRO
Electrode
CV-305 (Across the Arc)
Wor k clip
Work
K# Description
Place CV/CC switch in the feeder in the "CV" position.
KP1695-XX
KP1697-XX
CV power Source
K1841- Welding Cables
K484 Jumper Plug kit
LN-25™ PRO
Return to Master TOC B-1 TABLE OF CONTENTS - OPERATION SECTION B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions and Graphic Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4 / B-8
CV Wire Feed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
CC Wire Feed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
CV Wire Feed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Constant Current vs Constant Voltage Wire Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Internal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Description of Internal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10 / B-11
Rear Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-12
Gas Purge/Flow Meter/Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13

LN-25™ PRO
B-2 OPERATION B-2
SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON

READ AND UNDERSTAND ENTIRE SECTION THIS MACHINE OR IN THIS MANUAL

BEFORE OPERATING MACHINE.
INPUT POWER
WARNING
• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED fea-
ON
ture, when feeding with gun trig-
ger, the electrode and drive
mechanism are always electri-
cally energized and could OFF
remain energized several sec-
onds after the welding ceases..
• Do not touch electrically live part or electrode WIRE FEEDER
with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards POSITIVE OUTPUT

removed or open.
---------------------------------------------------------------------
• FUMES AND GASSES can be NEGATIVE OUTPUT
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing INPUT POWER
zone.
---------------------------------------------------------------------
• WELDING SPARKS can cause DIRECT CURRENT
fire or explosion.
• Keep flammable material away.
U0 OPEN CIRCUIT
----------------------------------------------------------------------
ARC RAYS can burn.
VOLTAGE
• Wear eye, ear and body protec-

tion. U1 INPUT VOLTAGE
---------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MANU- U2 OUTPUT VOLTAGE
AL.
----------------------------------------------------------------------
I1 INPUT CURRENT
I2 OUTPUT CURRENT
PROTECTIVE
GROUND
WARNING OR
CAUTION
LN-25™ PRO
B-3 OPERATION B-3
DEFINITION OF WELDING TERMS General Functional Description

The LN-25™ PRO as designed is a simple, robust

WFS
feeder. Standard features include a calibrated wire
• Wire Feed Speed
feed speed dial, 2 step/trigger interlock switch, CV-CC
switch, Gas Purge and Cold Feed. Some newer codes
CC
also have a Wire Speed range switch for more precise
• Constant Current
setting at lower speeds.
CV
• Constant Voltage
RECOMMENDED PROCESSES
GMAW • GMAW
• Gas Metal Arc welding • FCAW
SMAW PROCESS LIMITATIONS

• Shielded Metal Arc welding
• GMAW-P procedures must be qualified by the cus-
FCAW tomer.
• Flux Core Arc Welding • Across-the-Arc models are not recommended for
stitch or spot welding.
GENERAL DESCRIPTION
EQUIPMENT LIMITATIONS
General Physical Description • The duty cycle of the wire feeder is 325A, 100% and
The LN-25™ PRO is specially engineered to be the 450A, 60%. Duty cycle is based upon the amount of
most rugged portable wire feeder available. The mod- welding performed in a 10 minute period.
els covered by this manual are designed for “across • The maximum spool size is 45 lb, 12" diameter.
the arc” operation only. • Maximum FCAW gun length is 15 ft.
• Maximum GMAW gun length is 25 ft.
Several models of the LN-25™ PRO are offered to • Push-pull guns do not work with the wire feeder.
best meet individual welder needs. The Extra Torque • K2330-1 Timer kits do not work with this feeder, use
model features additional torque gearing for reliable K2330-2 kits
feeding of large diameter FCAW wires. The Standard
model features wire drive gearing for optimal perfor- RECOMMENDED POWER SOURCES
mance for both FCAW and GMAW wires of common

sizes. All of the models include a gas solenoid and • Ranger 3 Phase
• CV-305
flow meter for the flexibility to run most wire processes. • Ranger GXT
• CV-400
The plastic case is molded from a high impact, flame • Ranger 250
• CV-655
retardant plastic for durability and low weight. The • Ranger 305
• DC-400
patent pending design keeps the internal components • SAE-400
• DC-600
protected and dry. • Pipeliner 200G
• DC-655
• Invertec V-350 PRO • Classic 300
The heart of the LN-25™ PRO is the 2 roll MAX- • Vantage 300
• Invertec V-450 PRO
TRAC™ drive. The patented features on the wire drive • Vantage 400
• Multi-Weld 350
offer tool-less changing of the drive rolls and wire • Vantage 500
• Ranger 10,000
guides for quick spool changes. A tachometer con-
trolled motor powers the patent pending drive rolls for
smooth, steady feeding without slippage.
With only one p.c. board, the LN-25™ PRO is

designed to be simple, reliable and easy to service.
The p.c. board is mounted with Lincoln’s leading envi-

ronmental design protection that consists of mounting
the board in a plastic tray and potting it with epoxy.
With a 325 amp 100% duty cycle rating, these feeders

are ready for heavy duty welding.
LN-25™ PRO
B-4 OPERATION B-4
FIGURE B.1
1 1 5
6
6
2
2
7
3
4 4
K2613-1 & K2613-2 K2613-5 & K2613-7
CASE FRONT CONTROLS (See Figure B.1)

Models with analog voltmeters have a calibrated
ITEM DESCRIPTION scale printed around the wire feed speed knob using
1. Analog Voltmeter "in/min" units. A separate decal with "m/min" units is
2. Wire Feed Speed Control included with these models wire feeder. Units with a
range switch have two calibrated scales.
3. 5-Pin Gun Trigger Receptacle
4. Work Sense Lead Connector
5 Thermal LED (Motor Overload) Wire Feed Speed, CV Operation
6. Polarity LED
When Across the Arc models are operated with CV
7. Wire Feed Speed Range Switch power sources, the wire feed speed will remain a con-
1. ANALOG VOLTMETER stant value, independent of arc voltage changes, as
long as the arc voltage does not drop below the mini-
The analog voltmeter shows the voltage between
mum values per the following table.
electrode and work. The voltmeter shows open cir-
cuit voltage when the wire feeder is not welding. As TABLE B.1 - CV OPERATION
a result, it is not unusual to see the needle “pegged” Minimum Maximum WFS Maximum WFS
when not welding. The voltmeter is polarity insensi- Arc Voltage (Standard) (Extra Torque)
tive and the range is 0 - 40VDC.
15 V 280”/min. 210”/min.
2. WIRE FEED SPEED KNOB 17V 340”/min. 235”/min.

The large, calibrated wire feed speed knob makes
for easy and accurate adjustment of the wire feed 21V 440”/min. 400”/min.
speed. The knob rotates 3/4 turn. Turn the knob
clockwise to increase the wire feed speed, and 24V 520”/min. 400”/min.
counter clockwise to reduce the wire feed speed.
27V 600”/min 400”/min.
LN-25™ PRO
B-5 OPERATION B-5
Wire Feed Speed, CC Operation (See Figure B.2 or

See Table B.2)
When Across the Arc models are operated with CC 4. Determine the vertical line representing the CC
power sources, the wire feed speed changes as the arc representing the CC Wire Feed Speed setting
voltage changes. When the arc voltage increases, the where the above two lines cross. (See Figure B.2
wire feed speed will increase; and when the arc voltage arrow line for 450.) Set the LN-25™ PRO wire feed
decreases, the wire feed speed will decrease. speed knob to this value.
To preset the wire feed speed on CC power sources:

CC WFS dial setting = desired WFS x 35
1. Set the Wire Feed Mode switch inside the LN-25™ Arc Volts
PRO to "CC".
Example: 375 in/min. (Horizontal Line) x 35
2. Refer to the Figure B.2 graph for the setting for the 29 Arc Volts (Diagonal Line)
wire feed speed knob setting. Select the horizon-
tal line representing the Desired Wire Feed Speed. = 13125 = 452-5 (Vertical Line)
(See Figure B.2 arrow for 375 in/min.) 29
3. Select the diagonal line representing the Arc Volts. Set the Wire Speed Control at 450”/min.,
(See Figure B.2 for 29 volts.) and when welding at 29 volts the average
actual speed should be approximately
375“/min.
FIGURE B.2
V
700 35
33
650
31
600
29
550
27
500 25
23
450
21
400
19
350 17
15
300
250
200
150
100
50
50 100 150 200 250 300 350 400 450 500 550 600 650 700
CC
LN-25™ PRO
B-6 OPERATION B-6
TABLE B.2 - VV (CC) WIRE SPEED SETTING

Desired Arc Volts Used

In/Min 16 18 20 22 24 26 28 30 32 34
50 109 97 88 80 73 67 63 58 55 51
60 131 117 105 95 88 81 75 70 66 62
70 153 136 123 111 102 94 88 82 77 72
80 175 156 140 127 117 108 100 93 88 82
90 197 175 158 143 131 121 113 105 98 93
100 219 194 175 159 146 135 125 117 109 103
110 241 214 193 175 160 148 138 128 120 113
120 263 233 210 191 175 162 150 140 131 124
130 284 253 228 207 190 175 163 152 142 134
140 306 272 245 223 204 188 175 163 153 144
150 328 292 263 239 219 202 188 175 164 154
160 350 311 280 255 233 215 200 187 175 165
170 372 331 298 270 248 229 213 198 186 175
180 394 350 315 286 263 242 225 210 197 185
190 416 369 333 302 277 256 238 222 208 196
200 438 389 350 318 292 269 250 233 219 206
210 459 408 368 334 306 283 263 245 230 216
220 481 428 385 350 321 296 275 257 241 226
230 503 447 403 366 335 310 288 268 252 237
240 525 457 420 382 350 323 300 280 263 247
250 547 486 438 398 365 337 313 292 273 257
260 569 506 455 414 379 350 325 303 284 268
270 591 525 473 430 394 365 338 315 295 278
280 613 544 490 445 408 377 350 327 306 288
290 634 564 508 461 423 390 363 338 317 299
300 656 583 525 477 438 404 375 350 328 309
310 678 603 543 493 452 417 388 362 339 319
320 700 622 560 509 467 431 400 373 350 329
330 642 578 525 481 444 413 385 361 340
340 661 595 541 496 458 425 397 372 350
350 681 613 557 510 471 438 408 383 360
360 700 630 572 526 484 450 420 394 370
380 666 604 554 512 472 444 416 392
400 700 636 584 538 500 466 438 412
420 668 612 566 526 490 460 432
440 700 642 592 550 514 482 452
460 670 620 576 536 504 472
480 700 646 600 560 526 494
500 674 626 584 546 514
520 700 650 606 568 536

540 676 630 590 556
560 700 654 612 576
580 676 634 598
600 700 656 618
620 678 638

640 700 658
660 680
680 700
700
LN-25™ PRO
B-7 OPERATION B-7
CONSTANT CURRENT VS CONSTANT

VOLTAGE WIRE WELDING
Most semiautomatic welding processes perform better If the contact tip to work distance is properly main-
using constant voltage power sources. tained, a satisfactory operating voltage range may be
achieved, and a sound weld may result. However,
Welding codes usually do not address the power when a welder uses a longer contact tip to work dis-
source selection or specifically, whether the welding tance, an arc-sensing wire feeder compensates by
process is to be operated in the constant voltage or increasing the wire feed speed to regulate the voltage.
constant current mode. Instead, codes typically spec- Even if the voltage and current remain unchanged, the
ify limitations on the current, voltage, heat input and increased wire feed speed may result in a deposition
preheat temperature based on the material to be weld- rate well beyond the specified range of the electrode.
ed. The intention is to assure that proper weld materi- Under these conditions, the specified weld metal prop-
al properties will develop. erties may not be achieved.
Welding is sometimes performed using constant cur- Constant voltage power sources deliver large current
rent power sources. The operation can be more con- surges to stabilize the arc when the electrode is short-
venient because it may allow the use of an existing ed or the arc length is very short. However, a constant
stick (SMAW) power source and the power source can current power source does not provide such a
be placed at a distant location without any provision for response to stabilize the arc. It may be difficult to
adjusting the output settings. achieve required weld metal properties, or to achieve
the required quality of welds needed to pass nonde-
For constant current operation, the power source is set structive tests, when such welds are made under con-
to deliver the specified current. The power source reg- stant current operation.
ulates this current regardless of changes in the weld-
ing circuit, including cable length, electrode diameter, For these reasons, Lincoln Electric does NOT recom-
wire feed speed, contact tip to work distance, etc. mend constant current semiautomatic welding for
applications which need to meet specified weld metal
Changes in the wire feed speed (WFS) or contact tip to chemical or mechanical property requirements or weld
work distance (CTWD) affect the arc voltage when quality requirements.
constant current power sources are used. Lowering
the wire feed speed raises the voltage, raising the wire
feed speed lowers the voltage. Lengthening the con-
tact tip to work distance raises the voltage, shortening
the contact tip to work distance lowers the voltage.
(See Figure B.3)
FIGURE B-3
Current
Wire
+ Feeder
CTWD
Constant Current WFS
Power Source
Current
-
LN-25™ PRO
B-8 OPERATION B-8
3. 5-PIN GUN TRIGGER CONNECTOR

(See Figure B.1)
4. WORK SENSE LEAD

(See Figure B.1)
Must be connected for the drive motor to operate.
5. THERMAL LED, MOTOR OVERLOAD

(See Figure B.1)
The thermal light illuminates (yellow)

when the wire drive motor draws too M
much current. If the thermal light illumi-
nates, the wire drive will automatically
shutdown for up to 30 seconds to allow
the motor to cool. To start welding
again, release the gun trigger, inspect the gun cable,
liner (and conduit). Clean and make repairs as nec-
essary. Start welding again when the problem has

been safely resolved.
For best results, keep the gun cable and conduit as

straight as possible. Perform regular maintenance
and cleaning on the gun liner, conduit and gun.
Always use quality electrode, such as L-50 or L-56
from Lincoln Electric.
6. POLARITY LED
(See Figure B.1)
The Polarity LED

lights (green) when
the wire feeder is
connected for posi-
tive polarity. and is

not lit in Negative
Polarity. Use the polarity LED to verify the wire
feeder is connected properly for the process being
used.
NOTE: Both LED’s will flash briefly when power is

applied to the feeder.
7. WIRE FEED SPEED RANGE SWITCH (K2613-5

and K2613-7 only.)
Used to select either HIGH or LOW range for the

Wire Feed Speed Control. LOW range allows for
more precise setting at lower feed rates. On the
Standard Torque models, selecting the LOW range
DOES NOT increase the torque of the wire drive
system.
LN-25™ PRO
B-9 OPERATION B-9
INTERNAL CONTROLS
FIGURE B.4
4 5 6
3
2
1
9 10 11 12
ITEM DESCRIPTION
1 2 Step Trigger Interlock Switch
2 CV / CC Switch
3 Pressure Adjustment Arm
4 Optional Timer Kit (See Accessories Section)
5 Spool Retainer
6 Spindle Brake
7 Gun Bushing
8 Thumb Screw for securing the welding Gun
9 Socket Head Cap Screw for securing the Gun Bushing

10 Drive Hubs
11 Inlet Wire Guide
12 Cold Feed Pushbutton
LN-25™ PRO
B-10 OPERATION B-10
INTERNAL CONTROLS DESCRIPTION CV/CC SWITCH

(See Figure B.4) (See Figure B.4)
The CV/CC switch sets the wire

2 STEP - TRIGGER INTERLOCK feed speed control method for the
SWITCH wire feeder. CC
The 2 Step - Trigger Interlock In the CV position, the wire feed

switch changes the function of the speed remains constant during
gun trigger. 2 Step trigger opera- welding. A steady arc voltage is
tion turns welding on and off in regulated by the power source by
CV
direct response to the trigger. adjusting the arc current.
Trigger Interlock operation allows
welding to continue when the trig- In the CC position, the wire feed
ger is released for comfort on long speed varies during welding. The
welds. arc length is maintained by chang-
ing the wire feed speed.
Place the toggle switch in the DOWN position for 2

Step operation or in the UP position for Trigger COLD FEED PUSHBUTTON

Interlock operation. (See Figure B.4)
2 Step Trigger When cold feeding, the wire drive

will feed electrode but neither the
2 Step trigger operation is the most common. When power source nor the gas solenoid
the gun trigger is pulled, the welding power source will be energized. Adjust the speed
energizes the electrode output and the wire feeder of cold feeding by rotating the WFS
feeds wire for welding. The power source and wire knob. Cold feeding, or “cold inching”
feeder continue welding until the trigger is released. the electrode is useful for threading
the electrode through the gun.
Trigger Interlock
Trigger Interlock operation provides for operator com-

fort when making long welds. When the gun trigger is
first pulled, the welding power source energizes the
output and the wire feeder feeds wire for welding. The
gun trigger is then released while the weld is made. To
stop welding, the gun trigger is pulled again, and when
it is released the welding power source output turns off
and the wire feeder stops feeding wire.
CAUTION
If the arc goes out while welding with

trigger interlock operation, the elec-
trode output from the welding power
source remains energized and the wire
feeder will continue to feed wire until
the gun trigger is again pulled and
then released.
------------------------------------------------------------------------
LN-25™ PRO
B-11 OPERATION B-11
OPTIONAL PREFLOW, BURNBACK AND

POSTFLOW TIMER KIT (K2330-2)
The preflow, Burnback and Postflow Timer Kit gives

you control over the shielding gas at the beginning and
end of the weld and prepares the end of the wire for
the next arc start. Additional shielding gas protection
is often required when welding aluminum, stainless
steel or exotic alloys.
NOTE: When stitch welding, set the postflow time to

maximum for best results.
Preflow Timer
The preflow timer range is OFF to 10 seconds.
Preflow time is the time delay from when the trigger is
pulled to when the wire starts to feed and is energized.
Preflow is used purge the welding gun with shielding
gads and helps to maximize porosity at the start of the
weld.
Burnback Timer
The Burnback timer range is OFF to 0.25 seconds.
The burnback timer controls the additional amount of
time the power source output remains ON after the

wire drive has stopped feeding wire. Burnback adjust-
ment prevents the wire from sticking to the weld at the
end of a weld and helps to condition the wire for the
next weld.
To set the burnback time, adjust the knob to approxi-

mately 0.03 seconds and then decrease or increase
the time as desired.
Postflow Timer
The postflow timer range is OFF to 10 seconds.
Postflow is the time from when the power source out-
put turns OFF until the postflow timer expires. Use
postflow to protect the weld while the weld cools.
LN-25™ PRO
B-12 OPERATION B-12
REAR CONTROLS:
FIGURE B.5
3
5
ITEM DESCRIPTION
1 Gas Purge Pushbutton
2 Flow Meter Ball
3 Flow Meter Valve
4 Shielding Gas Inlet
5 Electrode Lead
6 Optional Water cooled gun
connections
LN-25™ PRO
B-13 OPERATION B-13
GAS PURGE PUSHBUTTON POWER-UP SEQUENCE

The gas solenoid valve will energize but neither the

power source output nor the drive motor will be turned For feeders with analog voltmeters, the thermal LED
on. The Gas Purge switch is useful for setting the and the Polarity LED will light breifly during power-up.
proper flow rate of shielding gas and for purging the
lines.. Flow meters should always be adjusted while If the gun trigger is activated during power up, the feed-
the shielding gas is flowing. er will not operate unless the gun trigger is released
and re-activated.
FLOW METER
The flowmeter shows the flow rate of shielding gas and

has a valve to adjust the flow. The flow meter is scaled
for CO2, Ar, and Ar/CO2 blends. The middle of the ball
indicates the flow rate of shielding gas.
Adjust the flow rate while depressing the GAS PURGE

switch by turning the valve at the bottom of the meter.
Most weld procedures require 25-40 scfh (11.8 - 18.9

lpm) for sufficient shielding gas coverage. Gun angle,
nozzle diameter, joint configuration and wind condi-
tions may effect the amount of shielding gas required.
When using a wire feeder with

a flow meter, adjust the regula-
tor at the shield gas bottle or
supply to a flow rate that is
higher than the flow rate indi-
cated on the feeder flow meter.
Note that most regulators are
calibrated based upon having
low restrictions on the outlet.
The valve on the feeder flow
meter creates a high restric-
tion and may cause errors in

the readings at the supply reg-
ulator. Set the gas flow rate
using the feeder flow meter
reading and not the supply
regulator reading.
SCFH Liter/Min.
10 4.7
20 9.4
30 14.2
40 18.9
50 23.6
60 28.3
70 33.1
80 37.8
LN-25™ PRO
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 B-14
NOTES
LN-25™ PRO
B-14
Return to Master TOC C-1 TABLE OF CONTENTS - ACCESSORIES SECTION C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Factory Installed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3/C-5
Installation of the K590-6 Water Cooling Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

LN-25™ PRO
C-2 ACCESSORIES C-2
FACTORY INSTALLED EQUIPMENT

• K1500-2 Gun Receiver Bushing.
DRIVE ROLL KITS

WIRE TYPE ELECTRODE SIzE KP KIT
Steel Wires: .023-.030 (0.6-0.8mm) KP1696-030S
.035 (0.9mm) KP1696-035S
.045 (1.2mm) KP1696-045S Includes: 2 V groove
.052 (1.4mm) KP1696-052S drive rolls and inner
1/16 (1.6mm) KP1696-1/16S wire guide.
.035,.045 (0.9, 1.2mm) KP1696-1
.040 (1.0mm) KP1696-2
.030-.035" (0.8-0.9mm) KP1697-035C
Cored Wires: .040-.045" (1.0-1.2mm) KP1697-045C
.052" (1.4mm) KP1697-052C Includes: 2 Knurled
drive rolls and inner
1/16" (1.6mm) KP1697-1/16C

.068-.072" (1.7-1.8mm) KP1697-068 wire guide.
5/64" (2.0mm) KP1697-5/64
3/32” (2.4mm) KP1697-3/32
.035" (0.9 mm) KP1695-035A
Aluminum Wires: .040" (1.0mm) KP1695-040A Includes: 2 polished
3/64" (1.2mm) KP1695-3/64A U groove drive rolls,
1/16" (1.6mm) KP1695-1/16A outer wire guide and
inner wire guide.
LN-25™ PRO
C-3 ACCESSORIES C-3
Includes: a complete alu-

K2596-1 Aluminum Case minum case. Decals, skids,

insulation and latches are all
preassembled.
Includes: a complete engi-

K2596-2 Plastic Case neered plastic case. Decals
and latches are all preassem-
bled.
Includes: 1/0 Coaxial weld

cable of length "xx". Ends of
K1796-xx AWG 1/0 Co-Axial Power Cable the weld cable have lug con-
nections. Use for Pulse weld-
ing.
Includes: AWG #1 Coaxial

weld cable of length "xx".

K2593-xx AWG #1 Coaxial Power Cable Ends of the weld cable have
lug connections. Use for
Pulse or STT™ welding.
Includes: Twist-Mate to Lug

2/0 cable 14' (1.2m) long with
K1803-1 Work and Feeder Cables Package Ground Clamp, and Twist-
Mate to Lug 2/0 Cable 9'
(2.7m) long.
K1840-xx Weld Power Cable, Twist-Mate to Includes: Twist-Mate to Lug,

Lug 1/0 cable of length "xx".
Includes: Lug to Lug, 3/0

Cable of length "xx" for
K1842-xx Weld Power Cable, Lug to Lug lengths up to 60' (18.3m).
Lug to Lug, 4/0 Cable of

length "xx" for lengths greater
than 60' (18.3m).
Includes: 14 pin circular con-

nector with jumper for leads 2-
K484 Jumper Plug Kit 4. For use in power sources
for turning the weld terminals
"ON" at all times.
Includes Panel and harness.

K2330-2 Timer Kit Provides adjustable Preflow,
post flow and Burnback.
LN-25™ PRO
C-4 ACCESSORIES C-4
K910-1 Ground Clamp Includes: One 300 Amp

Ground Clamp.
K910-2 Ground Clamp Includes: One 500 Amp

Ground Clamp.
K1500-1 Gun Receiver Bushing (for guns Includes: Gun receiver bush-
with K466-1 Lincoln gun connec- ing, set screw and hex key
tors; Innershield and Subarc guns) wrench.
with K466-2, K466-10 Lincoln gun ing with hose nipple, set
connectors; Magnum 200/300/400 screw and hex key wrench.
guns and compatible with Tweco®
#2-#4)
with K613-7 Lincoln gun connec- ing with hose nipple, set
tors; Magnum 550 guns and com- screw and hex key wrench.
patible with Tweco® #5)
LN-25™ PRO
C-5 ACCESSORIES C-5
K1500-4 Gun Receiver Bushing (for gun Includes: Gun receiver bush-
with K466-3 Lincoln gun connec- ing with hose nipple, set
tors; compatible with Miller® screw and hex key wrench.
guns.)
K1500-5 Gun Receiver Bushing (compatible Includes: Gun receiver bushing

with Oxo® guns.) with hose nipple, 4 guide tubes,
set screw and hex key wrench.
K489-7 * Gun Receiver Bushing (for Lincoln Includes: Gun receiver bushing
Fast-Mate guns.) with trigger connector.
K435 Spindle Adapter, for mounting 14 Includes: Spindle Adapter made

lb. (6.4 kg) Innershield Coils on 2 from 2 coil retainers. (Electrode
in (51 mm) spindles. not included.)
K468 Spindle Adapter, for mounting 8in Includes: 2 Spindle Adapters,

(203mm) diameter spools on 2 in one for 2" wide spools and the
(51 mm) spindles. other for 3" wide spools.
K590-6 Water Connection Kit (for Includes: 2 hoses with female

European and Control cable mod- quick connectors at each end, 2
els only) male connectors for 3/16" ID
hose, 2 male connectors for _" ID
hose, and mounting hardware.
K586-1 Deluxe Adjustable Gas Regulator Includes: Deluxe Gas Regulator

for Mixed Gases, Adapter for
CO2 and 10' (3.0m) Hose.
* Not compatible with K2613-5 & K2613-7 feeders (Codes 11746, & 11747)
LN-25™ PRO
C-6 ACCESSORIES C-6
INSTALLATION OF THE K590-6 WATER 4. Use a 5/16" nut driver to remove the screws holding
COOLING KIT the water cooling cover on the case front of the inner
module and on the rear of the case.
WARNING
• Turn the input power OFF at the dis-
connect switch before working on
this equipment.
• Do not touch electrically hot parts.
• Only qualified personnel should
install, use or service this equipment.
------------------------------------------------------------------------
The K590-6 components are rated up to 70 psi (5 bar)
and 158°F (70°C). Use a coolant fluid that is compati-
ble with the water cooler and the gun.
5. Install the fitting and hose assembly to the case
front. Route the hoses along the bottom of the inner
Tools required:
• 3/8" wrench module and out through the cutout of the cover.
• 5/16" nut driver Slide the module back into the case.
• medium flat bladed screw driver
• cutting tool
1. Turn power off at the welding power source.

2. Remove the screws securing the case to the inner
module using a 3/8" wrench.
6. Secure the module to the case with the screws.

(Shown in Step 2)
7. Install the fitting assembly to the rear of the case
3. Remove the module from the case by lifting the front 20

01
he
re
wa
s
jo
e
20
01
he
re
wa
s
jo
e
of the module approximately .25" (6 mm) and then

ALUMINUM CASE
sliding forward. PLASTIC CASE
8. Slide the hose clamps on to the hoses. Trim the

hoses to length so that they lay flat on the case bot-
tom. Slide hose clamps on the hose. Slide the hoses
on to the fittings on the case rear and secure with
the hose clamps.
LN-25™ PRO
Return to Master TOC D-1 TABLE OF CONTENTS - MAINTENANCE SECTION D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Calibration Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Flow Meter Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Wire Feed Speed Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

LN-25™ PRO
D-2 MAINTENANCE D-2
SAFETY PRECAUTIONS
5. Energize the output circuit of the power source.

Adjust the power source output to 20±1 VDC as
WARNING measured on the reference meter.
• Do not operate with covers 6. Verify that LN-25™ PRO voltmeter reads between
removed. 19 and 21 volts.
• Turn off power source before
installing or servicing. If the voltmeter reading is out of range, check for loose
• Do not touch electrically hot connections or replace the voltmeter. There is no cal-
parts. ibration adjustment for the LN-25™ PRO voltmeter.
• Turn the input power to the welding power
source off at the fuse box before working in the Flow Meter Validation
terminal strip.
• Only qualified personnel should install, use or Tools required:
service this equipment.
---------------------------------------------------------------------- • Flow meter reference standard.
• Constant voltage DC welding power source (DC-

ROUTINE MAINTENANCE
400, V-350, CV-400 or equivalent).
• Check weld cables and gas hoses for cuts.
To verify the flow meter accuracy:
• Clean and tighten all weld terminals.
1. Turn power OFF.
PERIODIC MAINTENANCE
2. Connect the LN-25™ PRO to the constant voltage
• Clean drive rolls and inner wire guide and replace if DC welding power source. The work lead of the
worn. LN-25™ PRO must be connected to the work ter-
• Blow out or vacuum the inside of the feeder. minal of the power source.
CALIBRATION SPECIFICATION 3. Connect a supply of CO2 to the wire feeder. Do not

exceed the maximum inlet pressure of the wire
The voltmeter and flow meter are not calibrated and feeder.
are for reference purposes only.
4. Disconnect the shielding gas hose that connects to
Voltmeter Validation, Across the Arc Analog Meter the gun bushing.
Models
5. Connect the shielding gas hose to flow meter refer-
Tools required: ence standard.
• DC voltmeter reference standard 6. Orient the LN-25™ PRO in a vertical position.

• Constant voltage DC welding power source with
adjustable no-load voltage (DC-400, V-350, CV-400 7. Turn power ON.
or equivalent).
8. Adjust the flow meter on the LN-25™ PRO to 40
To verify the analog voltmeter accuracy: scfh while pressing the GAS PURGE button.
1. Turn power OFF. 9. Measure the gas flow with the calibrated flow meter
while pressing the GAS PURGE button.
2. Connect the LN-25™ PRO to the constant voltage
DC welding power source. The work lead of the 10. The measured flow rate should be between 35
LN-25™ PRO must be connected to the work ter-
and 45 scfh.
minal of the power source.

The LN-25™ PRO flow meter cannot be calibrated. If
3. Connect the reference voltmeter between the brass the flow meter reads incorrectly, check for leaks or
block of the LN-25™ PRO and the work lead. kinks in the gas hose. Replace the flow meter if neces-
sary.
4. Turn power ON.
LN-25™ PRO
D-3 MAINTENANCE D-3
Wire Feed Speed Validation To change the wire feed speed calibration:
(See Figure D.1) (See Figure D.2)

Calibration of the LN-25™ PRO may be required when Tools required:
the p.c. board, wire feed speed potentiometer or motor is
replaced or serviced. Calibration matches the scale on • 5/16" nut driver
the name plate to the actual wire feed speed. • RPM meter
• Shorting plug. LE CO.part # S18250-982 - The short-
Tools required: ing plug shorts pins 4 & 8 of connector J3 on the Control
P.C. Board. J3 is an 8 pin Molex connector.
• RPM meter
• Constant voltage DC welding power source (DC-400, 1. Turn power OFF.
V-350, CV-400 or equivalent)
• 7/16" open end wrench 2. Remove the 4 screws holding the rear cover inside the
feeder and remove the cover.
To verify if calibration is necessary:
3. Open the idle arm.
1. Turn power OFF.
4. Set the wire feed speed per the table.

2. Set the wire feed speed per the table.
Model gearing Wire Feed Speed
Model gearing Wire Feed Speed Acceptable Range Normal Speed 400 in/min
Normal Speed 400 in/min 69 - 77 rpm Extra Torque 150 in/min
Extra Torque 150 in/min 25 - 31 rpm
5. Connect the LN-25™ PRO to the constant voltage DC
3. Remove the plastic cover from the lower portion of the welding power source. The work lead of the LN-25™
wire drive with a 7/16" wrench. PRO must be connected to the work terminal of the
power source.
4. Connect the LN-25™ PRO to the constant voltage DC
welding power source. The work lead of the LN-25™ 6. Turn power ON.
PRO must be connected to the work terminal of the
power source. 7. Insert the shorting plug into connector J3 on the Control
P.C. Board. The shorting plug shorts pins 4 & 8.
5. Turn power ON.
8. Remove the shorting plug.

6. Measure the motor rpm when the COLD FEED button
is pressed. 9. Turn power OFF.
7. Verify the rpm is within the acceptable range. 10. Replace the cover and secure with the screws.
FIGURE D.1 FIGURE D.2
COVER
MOTOR
SHAFT
COVER
P.C. BOARD
LN-25™ PRO
D-4 MAINTENANCE D-4
FIGURE D.3. - MAJOR COMPONENT LOCATION

1. FRONT PANEL ASSEMBLY

2. CONTROL BOX ASSEMBLY
3. SPINDLE & MAST ASSEMBLY
4. WIRE DRIVE ASSEMBLY
5. CASE ASSEMBLY
5
2
3
4
LN-25™ PRO
Return to Master TOC E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Trigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Feedback and Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Optional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Digital Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

FIGURE E.1 — BLOCK LOGIC DIAGRAM.
ELECTRODE
INPUT 67
CONTACTOR CURRENT TRANSDUCER FEEDPLATE

INPUT
SOLENOID
POLARITY
VM TIMER OPTION
MOTOR TACH
GUN
MOTOR
OVERLOAD
ARMATURE
21 CONTROL BOARD TACH FEEDBACK
1
GUN TRIGGER
WIRE REMOTE
14 PIN AMPHENOL SPEED VOLTAGE
COLD CC TRIGGER GAS
FEED CV INTERLOCK PURGE
21
DIGITAL
RUN IN DISPLAY
BOARD
LN-25™ PRO
E-2 THEORY OF OPERATION E-2
FIGURE E.2 — GENERAL DESCRIPTION

ELECTRODE
INPUT 67
INPUT
SOLENOID
POLARITY
VM TIMER OPTION
MOTOR TACH
GUN
MOTOR
OVERLOAD
ARMATURE
1
GUN TRIGGER
WIRE REMOTE
COLD CC TRIGGER GAS
21
DIGITAL
RUN IN DISPLAY
BOARD
GENERAL DESCRIPTION
Several models of the LN-25™ PRO are offered to best The heart of the LN-25™ PRO is a 2 roll MAXTRAC
meet the individual welders needs. The Extra Torque wire drive system. The patented features on the wire
model features additional torque for reliable feeding of drive offer tool-less changing of the drive rolls and wire
large diameter FCAW wire. The standard and control guides for quick changeovers. A tachometer controlled
motor powers the patent pending drive rolls for smooth,
cable models feature wire drive gearing for optimal per-

formance with both FCAW and GMAW wires of com- steady feeding without slippage.
mon sizes. All the models include a gas solenoid and
flow meter for the flexibility to run most wire processes. With only one p.c. board, the LN-25™ PRO is designed
Control Cable models also includes digital meters and to be simple, reliable and easy to service. The p.c.
remote voltage control. board is manufactured with Lincoln’s industry leading
environmental design protection which involces mount-
The plastic case is molded from high impact, flame ing the board in a plastic tray and potting it with epoxy.
retardant plastic for durability and low weight. The
patent pending design keeps the internal components With a 325 amp, 100% duty cycle rating, these feeders
protected and dry. are ready for heavy duty welding.
NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion
LN-25™ PRO
FIGURE E.3 — INPUT POWER & TRIGGER CIRCUIT

ELECTRODE
INPUT 67
INPUT
SOLENOID
POLARITY
VM TIMER OPTION
MOTOR TACH
GUN
MOTOR
OVERLOAD
ARMATURE
1
GUN TRIGGER
WIRE REMOTE
COLD CC TRIGGER GAS
21
DIGITAL
RUN IN DISPLAY
BOARD
INPUT POWER TRIGGER CIRCUIT

The DC input voltage is applied from the power source When the gun trigger is closed, the control board is sig-
via the electrode cable and the work sensing lead on naled to apply armature voltage to the drive motor and
the across the arc model. With the control cable model to activate any auxiliary circuits that may be incorpo-
24 to 42VDC is supplied from the power source via the rated within the LN-25PRO.
control cable and the work sense lead.

Trigger interlock is used for long welds. When an arc
This voltage is applied through a bridge rectifier and an is established the trigger can be released. To stop
analog voltmeter (across the arc), or digital meter (con- welding, the gun trigger is pulled again, and when it is
trol cable) and then is supplied to the control board. released the second time, the welding power source
output turns off and the wire speed stops.
The control board the regulates and disperses the var-
ious supply voltages needed for machine operation.

LN-25™ PRO
FIGURE E.4 — FEEDBACK & CONTROL CIRCUITS

ELECTRODE
INPUT 67

INPUT
SOLENOID
POLARITY
VM TIMER OPTION
MOTOR TACH
GUN
MOTOR
OVERLOAD
ARMATURE
1
GUN TRIGGER
WIRE REMOTE
COLD CC TRIGGER GAS
21
DIGITAL
RUN IN DISPLAY
BOARD
FEEDBACK AND CONTROL CIR-

CUITS
The wire speed pot provides command signal to the These three factors are monitored and compared, then
control board indicating the desired wire speed. The the appropriate armature voltage is applied to the wire
tachometer transforms the motor RPM to a digital fre- drive motor.
quency that is fed back to the control board.

When the Run-in Switch is on, the wire speed is
When operating in constant voltage (CV) mode, the reduced until an arc is struck. When it is off the run-in
control board monitors the feedback signal, compares wire speed is the same as the welding wire feed speed.
it to the command signal and delivers the appropriate
voltage to the wire drive motor. Pressing the cold feed button activates the drive rolls
but neither the power source nor the gas solenoid will
When operating in constant current (CC) mode, a vari- be activated.
able wire speed is desirable to compensate for the
varying arc voltages associated with the constant cur-
rent process. To accomplish this, the control board
monitors the command voltage, the feedback signal
from the tach and the arc voltage.

LN-25™ PRO
FIGURE E.5 — OPTIONAL CIRCUITS & DIGITAL DISPLAY BOARD

ELECTRODE
INPUT 67
INPUT
SOLENOID
POLARITY
VM TIMER OPTION
MOTOR TACH
GUN
MOTOR
OVERLOAD
ARMATURE
1
GUN TRIGGER
WIRE REMOTE
COLD CC TRIGGER GAS
21
DIGITAL
RUN IN DISPLAY
BOARD
DIGITAL DISPLAY BOARD OPTIONAL CIRCUITS

(control cable models only)
When the wire feeder is not welding, the left display The preflow, burnback, and postflow timer kit gives
shows the wire feed speed. The default units are control over the shielded gas at the beginning and end
“in/min” and may be changed to “m/min” through the of the weld and prepares the end of the wire for the
setup menu. During welding the left display shows the next arc start.
average welding current, and will continue to hold the
last value for 5 seconds after the trigger is released. The preflow timer range is zero to 10 seconds. Preflow
is used to purge the welding gun with shielding gas and
When the wire feeder is in idle the right display shows helps to minimize porosity at the start of a weld.
the preset voltage. This voltage will change with dif-
ferent power sources and can be changed through the The burnback timer range is zero to 0.25 seconds.
setup menu. During welding, the right display shows Burnback controls the additional amount of time the
the average welding voltage, and will hold the last power source output remains on after the wire drive
value for 5 seconds after the trigger is released. has stopped feeding wire.
The postflow timer range is zero to 10 seconds. Use

postflow to protect the weld while it cools.

LN-25™ PRO
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-6
NOTES
LN-25™ PRO
E-6
Return to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR F-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Gas Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11

Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Drive Motor and Tach Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Motor Overload Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17
Contactor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Front Panel Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Wire Drive Motor and Gear Box Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
PC Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Gas Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31

Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33

LN-25™ PRO
F-2 TROUBLESHOOTING & 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
problems. referred 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™ PRO
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 5. Remove the replacement PC board and
connected. substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
a. If the original problem does not reappear by
board using standard practices to avoid static
substituting the original board, then the PC
electrical damage and electrical shock. Read
board was not the problem. Continue to look
the warning inside the static resistant bag and
for bad connections in the control wiring
perform the following procedures:
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity. b. If the original problem is recreated by the
- Remove your body’s static substitution of the original board, then the PC
charge before opening the static- board was the problem. Reinstall the
shielding bag. Wear an anti-static replacement PC board and test the machine.
wrist strap. For safety, use a 1 6. Always indicate that this procedure was
Meg ohm resistive cord connected followed when warranty reports are to be
ATTENTION to a grounded part of the submitted.
Static-Sensitive equipment frame.
NOTE: Following this procedure and writing on the
Devices - If you don’t have a wrist strap, warranty report, “INSTALLED AND SWITCHED PC
Handle only at touch an un-painted, grounded,
BOARDS TO VERIFY PROBLEM,” will help avoid
Static-Safe part of the equipment frame. Keep denial of legitimate PC board warranty claims.
Workstations touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must

be either conductive, anti-static or static-dissipative.
LN-25™ PRO
Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
Fault Code Description Possible Adjustment

Thermal LED Lit 1. The wire drive motor has over- 1. Remove any bends in the gun.
heated.
Motor overloaded, long term 2. Check to see if the wire moves
smoothly through the gun and
(Err 81 on Digital Models)
cable.
3. Check the tightness of the spin-
dle brake.
4. Wait for the motor to cool and
the error to reset.
Thermal LED Lit 1. The wire drive motor is in a 1. Verify that the motor can move
locked state causing the motor freely when the pressure arm is
Motor overloaded, short term
to exceed it’s maximum amper- released.
(Err 82 on Digital Models) age draw.
2. Verify that the drive system is
free of dirt and debris.
3. Perform the MOTOR OVER-
LOAD TEST.
OUTPUT PROBLEMS
The feeder does not power up - no 1 The work sense lead has an 1. Connect the work sense lead to
display (Digital Models) - no cold open or poor connection the work in a location free of dirt
feed. (across the arc model). or paint.
NOTE: Both LED’s should flash 2. The power source is off. 2. Turn on the power source.
briefly when power is
3. The circuit breaker for the feed- 3. Reset the circuit breaker.
applied.
er on the power source may
have tripped. (Control cable

model).
The wire feeder powers up but 1. The contactor coil connections 1. Verify the connections.
there is no welder output when the are loose.
2. Check for opens in the leads.
gun trigger is pulled. The shielding
2. The contactor has failed.
gas flows and the drive rolls turn. 3. Perform the CONTACTOR
TEST, replace if necessary.
(Across the arc models)
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LN-25™ PRO


OUTPUT PROBLEMS
Inconsistent wire feeding or wire not 1. The gun cable is kinked. 1. Keep the gun as straight as
feeding but the drive rolls are turn- possible. Avoid sharp corners
2. The wire is jammed in the gun
ing. or bends in the gun cable.
cable.
2. Remove the gun and clear the
3. The gun liner is dirty or worn.
jam.
4. The electrode is rusty or dirty.
3. Clear liner with pressurized air
5. The gun tip is worn or has splat- (40 PSI) or less. Change liner if
ter. worn.
6. Improper gun liner, tip, drive 4. Use only clean electrode. Use
rolls, or wire guides. only quality electrode, like L-50
or L-56 from the Lincoln

7. Incorrect pressure on the wire
Electric.
drive rolls.
5. Replace the contact tip.
8. Spindle brake to tight.
6. Verify the proper parts are
9. Worn drive rolls.
installed.
7. Adjust the tension arm per the
manual. Most electrodes feed
well with the tension at around
“3”.
8. Verify the spool moves with
minimal effort.
9. Replace the drive rolls if need-
ed.
Wire feed speed consistently oper- 1. The jumper lead for normal 1. Properly connect the jumper.
ates at the wrong value. The speed speed / extra torque is connect-
2. Install the proper pinion fear in
changes when the control knob is ed improperly.
the wire drive unit.
adjusted.
2. The wrong gear is installed in
3. Replace the motor/gearbox
the wire drive unit.
assembly.
3. The motor brushes are worn.
This wire feeds but cannot be con- 1. The tachometer is connected 1. Verify that tachometer leads
trolled with the wire speed pot. improperly. are properly connected.
2. The tachometer has failed. 2. Perform the MOTOR AND
TACHOMETER TEST. Replace
the tachometer if necessary.
3. Possible control board problem.
CAUTION
Call 1-888-935-3877.
LN-25™ PRO


OUTPUT PROBLEMS
Variable or “hunting” arc. 1. Wrong size, worn or melted tip. 1. Replace the tip.
2. Worn work cable or poor con- 2. Verify all the work and elec-
nection. trode connections are tight and
in good condition Clean if nec-
3. Wrong polarity’
essary and replace.
4. The gas nozzle is extended
3. Adjust polarity to recommended
beyond the contact tip or the
procedure verify DIP switch 7
wire stickout is too long.
setting matches the electrode
5. Poor gas shielding on process- polarity.
es requiring gas.
4. Adjust the gas nozzle and
shorten the stickout to 1/2 to

3/4 inches.
5. Check gas flow and mixture.
Remove or block sources of
drafts. Perform the GAS
SOLENOID TEST, replace if
necessary.
When the trigger is pulled, the wire The Run-in switch is “ON” Turn the run-in switch to the “OFF”
feeds slowly. position.
(Digital display models)
The preset voltage does not match The preset voltage calibration in the Use the setup menu to change the
the power source voltage. feeder has been selected for a dif- preset voltage in the feeder to
ferent power source. match the power source.
(Digital display models)
Poor arc starts with sticking or “ Improper procedures or techniques. See “Gas metal arc welding guide”
Blast-offs”, weld porosity, narrow or (GS-100)
ropy looking beads.
CAUTION
Call 1-888-935-3877.
LN-25™ PRO


GAS SHIELDING ISSUES

No shielding gas. 1. The gas supply is off or empty. 1. Verify the gas supply is ON and
flowing.
2. The gas hose is cut or crushed.
2. Reroute the gas hose to avoid
3. The flow meter is closed. Dirt
sharp corners and make sure
or debris is in the solenoid.
nothing is on it. Repair or
4. There is a loose connection at replace damaged hoses.
the solenoid.
3. Open the flow meter valve.
5. The solenoid has failed.
4. Apply 80 psi of filtered air to the
solenoid to remove dirt and
debris.
5. Remove the cover and verify

that all the connections are in
good condition.
6. Perform the GAS SOLENOID
TEST, replace if necessary.
CAUTION
Call 1-888-935-3877.
LN-25™ PRO
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-8
NOTES
LN-25™ PRO
F-8
CASE REMOVAL PROCEDURE

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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 procedure will aid the technician in the removal and replacement of the molded case
ssembly
MATERIALS NEEDED
Misc. Hand Tools
LN-25™ PRO
CASE REMOVAL PROCEDURE (CONTINUED)

FIGURE F.1 – CASE REMOVAL

PROCEDURE
1. Remove the input power from the LN25 PRO
unit.
2. Using the 1/4-20 nut driver, remove the 8

screws holding the control box. Loosen the
cord grip connector, and slide the control box
assembly out of the case. See Figure F.1
LN-25™ PRO
GAS SOLENOID TEST

WARNING
manual.
TEST DESCRIPTION
This test will determine if the gas solenoid circuit is faulty.
MATERIALS NEEDED
1/4-20 Nut driver

#10-24 Nut driver
Digital meter
LN-25™ PRO
GAS SOLENOID TEST (CONTINUED)

FIGURE F.2 – GAS SOLENOID

GAS SOLENOID
CONTROL BOX
CONTROL BOX COVER

PROCEDURE
6. If high voltage is seen (Approx. 35 volts) the
1. Perform the Case Removal Procedure. solenoid coil is open.
2. Remove the five #10-24 x .50 screws holding 7. Normal solenoid coil resistance is 22 ohms.
the control box cover and access the solenoid
leads. See Figure F2. 8. The solenoid can also be checked by discon-
necting the leads and applying 12VDC direct-
3. Apply the correct input voltage (15-110vdc) to ly to the terminals. If the solenoid does not
the unit. activate the solenoid is faulty.
4. While pressing the gas purge button or acti- 9. If the solenoid fails any of the above tests
vating the gun trigger, check for approximate- replace it.
ly 4VDC is present at the solenoid leads. If
the 4VDC is present the solenoid should acti- 10. Reassemble the feeder in reverse order.
vate. If the 8VDC is present but the solenoid
does not activate the solenoid may be faulty.
5. If the 4VDC is missing or low, check the leads

and connections between the solenoid and
the control board. See the Wiring Diagram.
If the leads and connections are ok, the con-
trol board may be faulty.
LN-25™ PRO
CONTACTOR TEST
WARNING
manual.
TEST DESCRIPTION
This test will determine if the contactor is faulty.
MATERIALS NEEDED
1/4-20 Nut driver

#10-24 Nut driver
Digital meter
LN-25™ PRO
CONTACTOR TEST (CONTINUED)

FIGURE F.3 – CONTACTOR
CONTROL BOX
CONTACTOR
PROCEDURE
1. Perform the Case Removal Procedure. 6. If high voltage is seen (Approx. 35 volts) the
Contactor coil is open.
2. Remove the 5 #10-24 x .50 screws holding
the control box cover to access the contactor 7. Normal solenoid coil resistance is 4 ohms.
leads. See Figure F.2.
8. The Contactor can also be checked by dis-
3. Apply the correct input voltage (15-110vdc) to connecting the leads and applying 12VDC
the LN25 PRO unit. directly to the terminals. If the solenoid does
not activate the solenoid is faulty.
4. Check for the correct voltage at leads 507 and
578 at the contactor. Look for 0VDC when the 9. If the contactor does not pass all the above
trigger is open and about 3VDC when it is tests it needs to be replaced. See contactor
closed. See wiring diagram. removal and replacement procedures.
5. If the 3VDC is missing or low, check the leads 10. Reassemble the feeder in reverse order.
and connections between the Contactor and
the control board. See the Wiring Diagram.
If the leads and connections are ok, the con-
trol board may be faulty.
LN-25™ PRO
DRIVE MOTOR AND TACH FEEDBACK TEST

WARNING
manual.
TEST DESCRIPTION
This test will help determine if the motor and tach circuit is faulty.
MATERIALS NEEDED
1/4-20 nut driver

#10-24 nut driver
Digital meter
LN-25™ PRO
DRIVE MOTOR AND TACH FEEDBACK TEST (CONTINUED)

FIGURE F.4 – CONTROL BOX ASSEMBLY
CASE
CONTROL BOX ASSEMBLY

PROCEDURE
1. Perform the Case Removal Procedure. 6. Check for 1.5 ohms of resistance between the
black and white leads. Also make sure there
2. Remove the 5 #10-24 x .50 screws holding is at least 550k ohms of resistance between
the control box cover to access the contactor both leads and the motor shell.
7. With the trigger activated and the motor run-
3. Remove the 5 #10-24 screws holding the con- ning check for 15.6VDC input on the black
trol box cover, and locate the two motor leads and red tach leads. Check for 6.2vdc at any
and the 3 tach leads See the Wiring speed or ≈72hz (min.). to ≈1.2Khz (max). on
Diagram. the black and blue return leads.
4. Apply the correct input voltage (15-110vdc) to 8. For further testing on the drive motor you can
the unit. use an isolated source and apply between
2.6VDC and 32VDC to the motor leads.
5. With trigger activated and the motor running
check for 2.6VDC min. to 32VDC max. 9. If all the above voltages are not there the
between the black and white motor leads motor or tach needs to be replaced. See Wire
(pins 7 and 8). Drive Motor and Gear Box Removal and
Replacement.
NOTE: If the tach feedback is missing the board
will limit the motor voltage to 10VDC no
matter where the w/s pot is set.
LN-25™ PRO
MOTOR OVERLOAD TEST

WARNING
manual.
TEST DESCRIPTION
This test will determine if the motor overload circuit is faulty.
MATERIALS NEEDED
1/4-20 nut driver

#10-24 nut driver
Digital meter
LN-25™ PRO
MOTOR OVERLOAD TEST (CONTINUED)

FIGURE F.5 – CONTROL BOX ASSEMBLY
CASE
CONTROL BOX ASSEMBLY

PROCEDURE
6. If the amperage exceeds 3.2 amps for more
1. Perform the Case Removal Procedure. than 8 seconds the motor will be disabled.
2. Remove the 5 #10-24 x .50 screws holding 7. If the motor armature current is normal and
the control box cover to access the contactor the motor still shuts down the control board
leads. See Figure F.2. may be faulty.
3. Remove the five #10-24 screws holding the 8. If the current is high check for restrictions in
control box cover, and locate the two motor the feed system. They can be caused by a
leads and 3 tach leads. See the Wiring clogged liner, spindle tightness, drive rolls to
Diagram. tight, fault drive motor or a faulty gearbox.
4. Apply the correct input voltage (15-110vdc) to 9. After testing replace faulty parts and reassem-
the unit. ble the feeder in reverse order of disassembly.
5. With the trigger activated and the motor run-

ning check the motor armature current.
Normal armature current is less then 3 amps.
LN-25™ PRO
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the contactor.
MATERIALS NEEDED
1/4-20 nut driver

#10-24 nut driver
Adjustable wrench
Torque wrench
LN-25™ PRO
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

FIGURE F.6 – CONTROL BOX
CONTROL BOX
REMOVAL PROCEDURE
1. Perform the Case Removal Procedure.

the control box cover to access the contactor
3. Disconnect both of the buss bar connectors.

DO NOT loosen the mounting block before
loosening the buss bar. See Figure F.6.
4. Remove the five #10-24 x .50 screws from the

wire drive panel, and separate the panel from
the control box.
5. Remove the two #10-24 x .50 screws at the

base of the control box that holds the contac-
tor and remove the contactor.
6. Disconnect the coil leads, and the buss bars

from the contactor.
LN-25™ PRO
CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

FIGURE F.7 – BUSS BAR AND MOUNTING BLOCK
BUSS BAR
MOUNTING BLOCK
REPLACEMENT PROCEDURE
1. Loosely connect the buss bars to the new 5. Slide the wire drive panel into place and reat-
contactor. tach using the five screws.
2. Reconnect the coil leads. Slide the buss bar 6. Reconnect the gas hose and tighten the other
into the mounting block and start the 1/2-13 two buss bar connections.
bolt.
7. Slide the control box into the case and
3. Using the two #10-24 x .50 screws reattach reassemble in reverse order.
the contactor to the control box.
4. Tighten the buss bars to the contactor to 15fp.

LN-25™ PRO
NOTES
LN-25™ PRO
F-22
FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the front panel.
MATERIALS NEEDED
1/4-20 Nut driver

LN-25™ PRO
FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

FIGURE F.8 – FRONT PANEL
FRONT PANEL
REMOVAL PROCEDURE REPLACEMENT PROCEDURE
1. Connect the work lead that was previously

1. Perform the Case Removal Procedure.
removed.
2. Reconnect the molex plugs.
3. Slide the front panel into the control box and
attach it with two 1/4-20 screws.
3. Remove the two 1/4-20 screws that hold the
front panel and lift it out. See Figure F.8.
4. Slide the control box into the case and attach
it with the remaining 1/4-20 screws.
4. Disconnect the molex plugs from the control
harness. See wiring diagram.
5. Disconnect the work lead and set it aside to

use with the new panel.
LN-25™ PRO
WIRE DRIVE MOTOR AND GEAR BOX

REMOVAL AND REPLACEMENT PROCEDURE
WARNING
manual.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the wire drive
motor and gear box.
MATERIALS NEEDED
1/4-20 Nut driver

#10-24 Nut driver
3/8 nut driver
Phillips head screwdriver
LN-25™ PRO

REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

FIGURE F.9 – BUSS BAR AND GAS HOSE REMOVAL
Gas Hose
Gas Solenoid
Buss Bar
REMOVAL PROCEDURE
1. Perform the Case Removal Procedure. 7. Remove the tach and motor leads by discon-
necting the P9 connector. see wiring diagram.
the control box cover to access the contactor 8. Remove the three M6 x 1.00 phillips pan head
leads. See Figure F.2. screws holding the motor to the motor panel
and lift out the motor.
3. Disconnect the gas hose and the buss bar
from the drive deck. See Figure F.9. 9. Remove the four 1/4-20 x .50 screws from the
back of the motor panel and remove the drive
4. Remove the four #10-24 x .50 screws holding deck. Note screw locations for reassembly.
the control box cover.

wire drive panel, and separate the panel from
the control box. See Figure F.10.
6. Remove the plastic drive gear cover and with

a phillips head screwdriver remove the drive
gear. See Figure F.10.
LN-25™ PRO


FIGURE F.10 – WIRE DRIVE PANEL REMOVAL
CONTROL BOX
WIRE DRIVE PANEL

DRIVE GEAR COVER

REPLACEMENT PROCEDURE
1. Line up the gear box with the four holes on the 7. Reconnect the gas hose and the buss bar
panel. Replace and tighten the four 1/4-20 x assembly.
.50 screws.
8. Replace the control box cover using the four
2. Insert the drive motor through the panel and #10-24 x .50 screws.
gear box. Line up and tighten the three M6 x
1.00 in. phillips pan head screws. 9. Slide the control box into the case and secure
it in reverse order.
3. Replace the drive gear and secure in place
using the screw and lock washer previously 10. Reinstall the gun.
removed.
4. Replace the drive rolls and secure the locking

rings.
5. Reconnect the motor and tach leads to har-

ness.
6. Reassemble the wire drive panel and the con-

trol box using the five #10-24 x .50 screws.
LN-25™ PRO
NOTES
LN-25™ PRO
F-28
PC BOARD REMOVAL AND REPLACEMENT PROCEDURE

WARNING
manual.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the Control PC
Board.
MATERIALS NEEDED
1/4-20 Nut driver

#10-24 Nut driver
3/8 Nut driver
LN-25™ PRO
PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

FIGURE F.11 – CONTROL PC BOARD LOCATION
CONTROL BOX
CONTROL BOARD
CONTROL BOX COVER

REMOVAL PROCEDURE REPLACEMENT PROCEDURE
1. Perform the Case Removal Procedure. 1. Remove the new control board from the static
bag and place it on the 4 studs.
the control box cover to access the contactor 2. Reassemble the 4 nuts and tighten hand tight.
3. Reassemble the harness plugs.
3. Disconnect the gas hose and the buss bar
from the drive deck. 4. Replace the wire drive panel and control box
assembly in reverse order.
wire drive panel and separate the panel from 5. Reconnect the buss bar and the gas hose.
the box to access the control board.
6. Replace the control box cover.
5. Locate the control board and remove the har-
ness plugs on the control board. Observe sta- 7. Slide the control box into the case and secure
tic electricity precautions. Label plugs for it in reverse order.
reassembly. See Figure F.11.
6. Remove the 4 nuts holding the board using

the 3/8 inch nut driver, and remove the board.
LN-25™ PRO
GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE

WARNING
manual.
TEST DESCRIPTION
The procedure will aid the technician in the removal and replacement of the gas solenoid.
MATERIALS NEEDED
#10-24 nut driver

Adjustable pliers
LN-25™ PRO
GAS SOLENOID

FIGURE F.12 – SOLENOID NUT AND HOSE
GAS SOLENOID
GAS HOSE
CONTROL BOX
LOCK NUT
CONTROL BOX COVER

PROCEDURE
1. Perform the Case Removal Procedure. 8. Reconnect the gas hose.
2. Remove the 5 #10-24 x .50 screws holding 9. Reconnect the wires to the solenoid coil.
leads. See Figure F.2. 10. Replace the control box cover.
3. Remove the 2 wires on the solenoid coil. See

wiring diagram.
4. Using the pliers remove the gas hose. Be

careful not to damage the hose. See Figure
F.12.
5. Remove the lock nut holding the solenoid.

See Figure F.12.
6. Remove the solenoid from the unit.
7. Install the new solenoid with the attached

hardware.
LN-25™ PRO
RETEST AFTER REPAIR

Retest a machine :
• If it is rejected under test for any reason that requires you to

remove any part which could affect the machine’s electrical charac-
teristics.
OR
• If you repair or replace any electrical components.
SET UP
1. Connect a supply of filtered compressed air at 80 psi to the gas inlet.

2. Supply 15 to 110 VAC to the machine.

3. Connect the gun to the connector block and connect the trigger.
OPERATION VERIFICATION
WIRE FEED SPEED (Standard) ...................50 through 700 IPM

WIRE FEED SPEED (Ext. Torque)...................50 through 400 IPM
VOLTMETER (Analog)..............Must read Inpit Voltage +/-2%
VOLTMETER (Digital)...............Must operate at 3 TO 12 VDC input volts
GAS SOLENOID.......................Must operate when Gun Trigger is activated.
CONTACTOR............................Must operate when Gun Trigger is activated
or after Pre-flow time if Timer Kit is installed.
LN-25™ PRO
NOTES
LN-25™ PRO
F-34
Return to Master TOC G-1 TABLE OF CONTENTS - DIAGRAM SECTION G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram - Code 11387, 11388 (G5681) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram - Code 11507, 11508 (G5681-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram - Code 11620, 11621,11716,11717 (G5681-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Wiring Diagram - Code 11746, 11747 (G5681-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Schematic - Complete Machine - Code 11387, 11388 (G5683) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6 / G-7
Schematic - Complete Machine - Code 11507, 11508 (G5683-1) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8 / G-9

Schematic - Complete Machine - Code 11620, 11621,11716, 11717 (G5683-2) . . . . . . . . . . . . . .G-10 / G-11
Schematic - Complete Machine - Code 11746, 11747 (G5683-3) . . . . . . . . . . . . . . . . . . . . . . . . .G-12 / G-13
Schematic - Control PC Board* - Code 11387/8, 11507/8 (G4745-1) . . . . . . . . . . . . . . . . . . . . . .G-14 / G-18
Schematic - Control PC Board* - Code 11620/1, 11716/7, 11746/7 (G4783-1) . . . . . . . . . . . . . . .G-19 / G-23
Schematic - Motor Filter PC Board* - Code 11746, 11747 (S27505-1) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-24
Schematic - K2330-2 Timer Kit PC Board* - All Codes (M21341-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-25
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered
and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.
LN-25™ PRO
G-2 ElECTriCal DiaGrams G-2
WiriNG DiaGram - lN-25 prO - CODEs 11387, 11388 (G5681)
WIRING DIAGRAM LN-25 PRO

ANALOG DISPLAY CASE FRONT
YELLOW S1 S2
1W 1B POLARITY 2W 2B 509D 509D
WIRE FEED SPEED TRIGGER
THERMAL INTERLOCK / 509C S4
CONTROL RHEOSTAT LED 509E
LED 2 STEP CC / CV
10K2W N.A. N.A. 587A 523A GAS PURGE
R1 N.B., N.F. N.B. PUSHBUTTON
SHOWN IN 2 STEP SHOWN IN CV SWITCH
577A 575A CONNECTS TO FLEX
ARC 576A J7 ON HARNESS
VOLTMETER CONNECTS TO J8 612
P16 509A ON PRESET P.C. BD. 610 N.O.
VM 721 1 N.B. 509C 1 509 509 530 523 509A 707 500 2W 3B
+ TRIGGER 500A S3 587A 2 587 612 587 708 610 622 1W
2
CONNECTOR COLD 523A 523 509B N.B.
721 667B
3 509E 3
A 622A 622A 4 FEED 530A 530A 4 530
B 500A 5 CONTROL P.C. BOARD 1 2 3 4 5 6 7 8 9 10
P14 C 575A
N.O. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
6 1 601
D
E 576A 7 2 509B
21A 577A 3
BRIDGE 8
9 P7 FEED P60 4 4B J6 J1
RECTIFIER 10 PLATE 5 605
6 606 1 601
AC
667A 11 7 608 2 606
21B
+
TO WORK CLIP
667B 12 TACH 8 607 3 608 GAS
1B 13 R 4
- AC D1 1W 14
MOTOR / SOLENOID
GEARBOX U CONNECTS 5 605
N.D. 67B
2B 15 B TO TIMER J2 6 607
621A 2W 16 KIT
7 EXTRA 690
CONNECTS TO J17
ON HARNESS 8 TORQUE
67B W B
1 9 N.E.
2 P9 10
691
667A 3
21A 4 P17 1
5 2 L4 1
R 3 531 2
621A 6
U 4 537 3
CONNECTS TO B 5 534 J5 J4 4
DIGITAL DISPLAY CASE FRONT P7 ON CASE
6 L5 J3
FRONT 5
B 7 551
-
J12 J8 PRESET P.C. BOARD J10 W 8 550 6 BLACK
1 2 3 4 5 6 7 9 10 11 12 FAN
8
1 2 3 4 5 6 7 8 7
8 RED
+
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 721A
2 500
41B 42B 801 707A 805 702 75B 3 667 2A 721A 67F 550 690 507 537 531 575
802 804 67 21 701 708 76B 77B 4 622 551 691 577 578 534 576
4A 21D 621
5 707
6 575
FLEX
7 576
CONNECTS TO J1 577
8
ON CONTROL BD J7 9 708
805 1 10 75C
WIRE FEED REMOTE 804 2 11 76C
SPEED 801 3 P11 77C 507 578
CONTROL S5
12
21D CONTACTOR COIL
67F
802 4 13 1B 3B
CONTROL VOLTAGE RUN- 67C
701 CONNECTS TO J11 14 1W 21E
RHEOSTAT RHEOSTAT ON HARNESS CURRENT 1 2 3 4
IN 15 2B 4B
21C
10K2W 10K2W N.C. 702 16 2W TRANSDUCER 67D 67E
R1 R2 N.B., N.C. INPUT ELECTRODE
CONNECTS TO J7
75A SHOWN OFF CABLE CONNECTION
577A 575A 77A
ON HARNESS 1 1 67G 1 67C J11
75B 500A L7
576A 76A 75 2 2 2
76B 3 J17 3 667C 667D 3 667
+
76 NOTES:
622A 4 4 21G 4 21C CONTACTOR
77B N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE
77 707A 5 5 5 N.D.
76C 21E 4A 42 LEAD OF LED SOCKET.
575A 6 6 621C 6 621 1 N.C.
576A 67E 75C 77C 2A 41 N.B. TOGGLE SWITCHES SHOWN FROM REAR CONNECTION SIDE OF SWITCH.
7 2 42
577A J18 N.C. PRESENT ON CONTROL CABLE MODELS ONLY.
41B 41C 8 3 41 J15 1 2 3 4 5 6 7 8 9 10
42C 708 9 P7 CONNECTS TO P17 CONNECTS TO P18 N.D. PRESENT ON ACROSS THE ARC MODELS ONLY.
CONNECT TO J18 ON CASE FRONT ON CASE FRONT 4 N.E. CONNECT "EXTRA" TO "TORQUE" ON EXTRA TORQUE MODELS ONLY.
41C ON HARNESS BRIDGE AC 75 10
+
667B 76 N.F. NOT PRESENT ON ALL MODELS.

RECTIFIER 11 TIMER KIT (OPTIONAL) 14 PIN CIRCULAR CONNECTOR J19 CONNECTS TO 14 PIN
1 2 3 4 P18 - AC D2 77 12
TO POWER SOURCE
CIRCULAR CONNECTOR
13 POST-FLOW BURNBACK A
42B 14
J60 B
D
E
A
TRIGGER 1 67 2 C OUTPUT
621B 42C 15 2 4 D CONTROL J14
CONNECTOR
C B CAVITY NUMBERING SEQUENCE
21 16 1 2 3 4 5 6 7 8 3 75D 77D E REMOTE
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)

4 76D 76D
A 622A 21A CONNECTS TO J17 P15 F VOLTAGE

CONTROL
GENERAL INFORMATION
B 5 77D 75D G
P14 500A AC
667B ON HARNESS
601 605 608 6 21F 21F H ELECTRICAL SYMBOLS PER E1537 1 2 1 3 1 4
C
+
J J3, J5, J9, J60

D BRIDGE 667A 67B 1 509B 4B 606 607 7 2 41A I LEAD COLOR CODING
A
I
J11, J16, J18 J12, J17
K
8 4 L6 42VAC 3 4 4 6 5 8
J B
E RECTIFIER 621B - AC D1 2
9 41A 42A K B - BLACK J12 N H
667A 3 C
L
G 1 5 1 6 1 8
21A 4 P17 10 42A L W - WHITE D M J1, J2, J8, J15 J4 J6, J7, J10
TO WORK CLIP 67B M F
21B 621A 67 5 TO P60 ON 67 N
E 6 10 7 12 9 16
621A 6 HARNESS
N.B. C
G5681
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lN-25™ prO
WiriNG DiaGram - lN-25 prO - CODEs 11507, 11508 (G5681-1)
WIRING DIAGRAM LN-25 PRO
S1 S2
509D 509D
TRIGGER
INTERLOCK / 509E 509C S4
2 STEP CC / CV
587A 523A GAS PURGE
N.B., N.F. N.B. PUSHBUTTON
SHOWN IN 2 STEP SHOWN IN CV SWITCH
FLEX
CONNECTS TO J8 612
P16 509A ON PRESET P.C. BD. 610 N.O.
N.B. 509C 1 509 509 530 523 509A 707 500 2W 3B
S3 587A 2 587 612 587 708 610 622 1W
COLD 523A 523 509B N.B.
509E 3
FEED 530A 530A 4 530
CONTROL P.C. BOARD 1 2 3 4 5 6 7 8 9 10
N.O. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 601
2 509B
3
FEED P60 4 4B J6 J1
PLATE 5 605
6 606 1 601
7 608 2 606
TACH 8 607 3 608 GAS
MOTOR / R 4
U
SOLENOID
GEARBOX CONNECTS 5 605
B TO TIMER J2 6 607
KIT
7 EXTRA 690
ANALOG DISPLAY CASE FRONT 8 TORQUE
W B
9 N.E.
YELLOW P9 10
691
WIRE FEED SPEED
1W 1B POLARITY 2W 2B
THERMAL
CONTROL RHEOSTAT LED 1
LED 2 L4 1
N.A. N.A. R 3 531 2
10K2W
U 4 537 3
R1 CONNECTS TO B 5 534 J5 J4 4
P7 ON CASE
6 L5 J3
577A 575A FRONT 5
B 7 551
CONNECTS TO -
ARC 576A J7 ON HARNESS W 8 550 6 BLACK
1 2 3 4 5 6 7 9 10 11 12 FAN
8
VOLTMETER 1 2 3 4 5 6 7 8 7
8 RED
+
VM 721 1 1 721A
+ TRIGGER 500A 2 2 500
CONNECTOR 3 3 550 690 507 537 531 575
721 667B 667 2A 721A 67F
A 622A 622A 4 4 622
4A 21D 621 551 691 577 578 534 576
B 500A 5 5 707
P14 C 575A 6 6 575
D
E 576A 7 7 576
21A 577A 577
BRIDGE 8
J7
8
RECTIFIER 9 P7 9 708
10 10 75C
AC
667A 11 11 76C
21B
+
TO WORK CLIP 77C 507 578

667B 12 12 CONTACTOR COIL
1B 13 13 1B 3B 21D 67F
- AC D1 1W 1W 67C
14 14 21E CURRENT
N.D. 2B 15 15 2B 4B 1 2 3 4
67B 21C TRANSDUCER
621A 2W 16 16 2W 67D 67E
CONNECTS TO J17 INPUT ELECTRODE
ON HARNESS CABLE CONNECTION
67B 1 1 67C J11
2 2
667A 3 J17 3 667C 667
+
P17 NOTES:
21A 4 4 21C CONTACTOR
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE
5 5 76C 21E 4A 42 N.D. LEAD OF LED SOCKET.
621A 6 6 621 1 67E 75C 77C 2A 41 N.C. N.B. TOGGLE SWITCHES SHOWN FROM REAR CONNECTION SIDE OF SWITCH.
2 42
667D
L7 667E J18 N.C. PRESENT ON CONTROL CABLE MODELS ONLY.
CONNECTS TO P17 3 41 J15 1 2 3 4 5 6 7 8 9 10 N.D. PRESENT ON ACROSS THE ARC MODELS ONLY.
CONNECTS TO P18
ON CASE FRONT ON CASE FRONT 4 N.E. CONNECT "EXTRA" TO "TORQUE" ON EXTRA TORQUE MODELS ONLY.
N.F. NOT PRESENT ON ALL MODELS.
TIMER KIT (OPTIONAL) 14 PIN CIRCULAR CONNECTOR J19 CONNECTS TO 14 PIN
CIRCULAR CONNECTOR
POST-FLOW BURNBACK
TO POWER SOURCE A
J60 B
D
E
A
1 67 2 C OUTPUT J14
2 4 D CONTROL C B CAVITY NUMBERING SEQUENCE
1 2 3 4 5 6 7 8 3 75D 77D E REMOTE (VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
4 76D 76D
F VOLTAGE
P15
CONTROL
GENERAL INFORMATION
5 77D 75D G
601 605 608 6 21F 21F H ELECTRICAL SYMBOLS PER E1537 1 2 1 3 1 4
A J J11, J16, J18 J12, J17 J3, J5, J9, J60

509B 4B 606 607 7 2 41A I LEAD COLOR CODING K
I
8 4 L6 42VAC 3 4 4 6 5 8
J B
H
9 41A 42A K B - BLACK J12 L
N
1 5 1 6 1 8
C G
10 42A L W - WHITE D M J1, J2, J8, J15 J4 J6, J7, J10
M E
F
6 10 7 12 9 16
TO P60 ON 67 N
HARNESS
G5681-1
lN-25™ prO
WiriNG DiaGram - lN-25 prO - CODEs 11620, 11621, 11716, 11717 (G5681-2)
WIRING DIAGRAM- LN-25 PRO ANALOG

MOTOR FILTER P.C. BOARD J61
S1 S2 1 2 3 4
TRIGGER 509D 509D
INTERLOCK / 509E 509C 667D B1
2 STEP CC / CV 667E B2
587A 523A
N.B. N.B.
(SHOWN IN 2 STEP) (SHOWN IN CV)
P16/J16 509A
N.B. 509C 1 509 509 530 523 509A 707 500 2W 3B
S3 587A 2 587 612 587 708 610 622 1W
COLD 523A 523 509B
509E 3
FEED 530A 530A 4 530
1 601
N.O. 1 2 3 4 5 6 7 8 9 10 2 606
1 601 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 3 608
2 509B 4
3
5 605
FEED P60 4 4B J6 J1 J2 6
5 605 607 N.D.
PLATE 7 EXTRA
6 606
7 608 8 TORQUE
TACH 8 607 9
MOTOR / R B2 10 555
GEARBOX U CONNECTS
B TO TIMER
KIT
CONTROL P.C. BOARD GAS PURGE
ANALOG DISPLAY CASE FRONT PUSHBUTTON
W B SWITCH
B1
YELLOW P20/J20 612
WIRE FEED SPEED
1W 1B POLARITY 2W 2B 610 N.O.
THERMAL
CONTROL RHEOSTAT LED 1
LED 2 L4 S4
N.A. N.A. R 3 531
10K2W U 1
4 537 N.B.
B 5 534 J4 2
R1
L5 J5 3
6
577A 575A B 7 551 J3 4
ARC 576A W 8 550 5
1 2 3 4 5 6 7 9 10 11 12
8
1 2 3 4 5 6 7 8
-
VOLTMETER P7/J7 6 BLACK
7 FAN
VM 721 1 721A RED
+ TRIGGER 8
+
500A 2 500
CONNECTOR 555A 3 555 550 690 507 537 531 575
721 667B 667 2A 721A 67F
A 622A 622A 4 622 551 691 577 578 534 576
4A 821B 621
B 500A 5 707 690
P14 C 575A 6 575 GAS
WORK A
555A
D 576A
E 622B 7 576 SOLENOID
BRIDGE 577A 8 577
9 708 691
RECTIFIER 10 75C
AC
667A 11 76C
WORK B
+
667B 12 77C 507 578 CONTACTOR COIL

1B 13 1B 3B 67F
- AC D1 1W 14 1W 67C
TO WORK CLIP 2B 15 2B 4B
67B
621A 2W 16 2W 67D 67E
67B 1 67C
2
667A 3 667C 667
WORK A 4 821B CONTACTOR
INPUT ELECTRODE
5 21E
621
CABLE CONNECTION
621A 6 1 76C 21E 4A 42
2 42
P17/J17 667D 667E J18 67E 75C 77C 2A 41
3 41
4
TIMER KIT (OPTIONAL) J15 1 2 3 4 5 6 7 8 9 10 CAVITY NUMBERING SEQUENCE

E
POST-FLOW BURNBACK D (VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
J60
A
J14
NOTES: C B J11, J16,
1 2 1 3
J12, J17
J18, J61
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE 3 4 4 6
1 2 3 4 5 6 7 8
LEAD OF LED SOCKET. 5 8
J3, J5, J9,
1 4
N.B. SWITCHES SHOWN FROM REAR CONNECTION SIDE OF SWITCH. J19 J20, J60
601 605 608 N.D. CONNECT "EXTRA" TO "TORQUE" ON EXTRA TORQUE MODELS ONLY. 1 5 8
GENERAL INFORMATION 4
509B 4B 606 607 1

ELECTRICAL SYMBOLS PER E1537 J1, J2, J15
5 1 6 1 8
J4 J6, J7
LEAD COLOR CODING 6 10 7 12 9 16
B - BLACK
TO P60 ON
HARNESS W - WHITE
A
G5681-2
lN-25™ prO
WiriNG DiaGram - lN-25 prO - CODEs 11746, 11747 (G5681-3)
WIRING DIAGRAM- LN-25 PRO ANALOG

MOTOR FILTER P.C. BOARD J61
S1 S2 1 2 3 4
TRIGGER 509D 509D
INTERLOCK / 509E 509C 667D B1
2 STEP CC / CV 667E B2
587A 523A
N.B. N.B.
(SHOWN IN 2 STEP) (SHOWN IN CV)
P16/J16 509A
N.B. 509C 1 509 509 530 523 509A 707 500 2W 3B
S3 587A 2 587 612 587 708 610 622 1W
COLD 523A 523 509B
509E 3
FEED 530A 530A 4 530
YELLOW 1 601
POLARITY N.O. 1 2 3 4 5 6 7 8 9 10 2 606
THERMAL 1 601 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 3
LED 608
LED 2 509B 4
3 5 605
J1
4 4B J6 J2
1W 1B 2W 2B FEED P60 6 607 N.D.

PLATE 5 605
6 606 7 EXTRA
7 608 8 TORQUE
N.A. N.A. TACH 8 607 9
MOTOR / R B2 10 555
GEARBOX U CONNECTS
B TO TIMER
KIT
CONTROL P.C. BOARD GAS PURGE
PUSHBUTTON
W B SWITCH
B1
WIRE FEED SPEED P20/J20 612
610 N.O.
WFS RANGE CONTROL 1
SWITCH POTENTIOMETER 2 L4 S4
S5 10K2W
R 3 531
U 4 537 1 N.B.
N.B.
B 5 534 J4 2
R1
L5 J5 3
6
577A 575A B 7 551 J3 4
ARC 576A W 8 550 5
1 2 3 4 5 6 7 9 10 11 12
8
1 2 3 4 5 6 7 8
-
VOLTMETER P7/J7 6 BLACK
622B 555A 7 FAN
VM 721 1 721A RED
+ TRIGGER 8
+
500A 2 500
CONNECTOR 555A 3 555 550 690 507 537 531 575
721 667B 667 2A 721A 67F
A 622A 622A 4 622 551 691 577 578 534 576
4A 821B 621
B 500A 5 707 690
P14 C 575A 6 575 GAS
D WORK A
576A 576 SOLENOID
7
E
BRIDGE 577A 8 577
9 708 691
RECTIFIER 10 75C
AC
667A 11 76C
WORK B
+
667B 12 77C 507 578 CONTACTOR COIL

1B 13 1B 3B 67F
- AC D1 1W 14 1W 67C
TO WORK CLIP 2B 15 2B 4B
67B
621A 2W 16 2W 67D 67E
67B 1 67C
2
667A 3 667C 667
WORK A 4 821B CONTACTOR
INPUT ELECTRODE
5 21E
621
CABLE CONNECTION
621A 6 1 76C 21E 4A 42
2 42
P17/J17 667D 667E J18 67E 75C 77C 2A 41
3 41
4
TIMER KIT (OPTIONAL) J15 1 2 3 4 5 6 7 8 9 10 CAVITY NUMBERING SEQUENCE

E
POST-FLOW BURNBACK D (VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
J60
A
J14
NOTES: C B J11, J16,
1 2 1 3
J12, J17
J18, J61
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE 3 4 4 6
1 2 3 4 5 6 7 8
LEAD OF LED SOCKET. 5 8

J3, J5, J9,
1 4
N.B. SWITCHES SHOWN FROM REAR CONNECTION SIDE OF SWITCH. J19 J20, J60
601 605 608 N.D. CONNECT "EXTRA" TO "TORQUE" ON EXTRA TORQUE MODELS ONLY. 1 5 8
GENERAL INFORMATION 4
509B 4B 606 607 1

ELECTRICAL SYMBOLS PER E1537 J1, J2, J15
5 1 6 1 8
J4 J6, J7
LEAD COLOR CODING 6 10 7 12 9 16
B - BLACK
TO P60 ON
HARNESS W - WHITE
A.01
G5681-3
lN-25™ prO
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11387, 11388 - (G5683) pG1
G5683 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED LEADS GOING TO P17.

MANUFACTURER: No
LN-25 PRO WIRE FEEDER
PRESET P. C. BOARD CIRCUIT

SCHEMATIC = G4748
(LOCATED ON CASE FRONT)
TIMER P. C. BOARD CIRCUIT MOTOR
THERMAL
3 LEDs
WFS/AMPS DISPLAY VOLTS DISPLAY

7 SEGMENT
{
DISPLAYS
Timer Board Summary (2 each)
701 J10-10
Has potentiometers for Burnback, Preflow and Postflow. WFS AMPS
Preflow range from 0ms to 10s. 0V = RUN IN ENABLED set=WFS
VOLTS
Burnback range from 0 to 250 ms. TO SWITCH S5 RUN IN actual = AMPS SIGNALS TO
Postflow range from 50ms to 10 s. 702 J10-11 DISPLAY & LED

SERIAL SPI
Receives “Gas Flow Enable” signal. COMMUNICATION TO J1
{
SPI (10 leads)
Outputs 16 ms pulses to turn Gas Flow On / Off.
77B J10-16 CONTROL
(LOCATED BEHIND WIRE TO REMOTE VOLTS + MICROCONTROLLER PC BOARD
REEL COVER) POTENTIOMETER R2 76B J10-14 - VOLTAGE
MEASUREMENT
OF REMOTE
(LOCATED ON CASE FRONT) AND POWER SOURCE VOLTS
ADJUST KNOB ADJUST KNOB
ADJUST KNOB 75B J10-15 - POTENTIOMETER
+ SETUP
PUSHBUTTON
+5V +5V SETUP
CW= +5 LED
CCW= 0V 10K
10K BURNBACK ARC VOLTAGE ELECTRODE 67 J10-6
{
POT.
POSTFLOW PREFLOW
POT.
MEASUREMENT ARC VOLTAGE
SETUP
POT. FEEDBACK
COM COM
FOR DISPLAY WORK 21 J10-8 PUSHBUTTON
COM +15V
{
(BOARDMOUNTED )
15V SIGNAL
15V 805 J10-9 -15V
15 ms PULSES
OUTPUT TOGGLE GAS FLOW ARC CURRENT MEASUREMENT 804 J10-4
ON/OFF 5V
FOR DISPLAY & ARC ESTABLISHED 801 J10-1
ARC CURRENT
TIMER KIT FEEDBACK J10-12 708 ARC ESTABLISHED OUTPUT
IF V> 10V RELATIVE TO COMMON
MICROCONTROLLER 802 J10-2
(OPTIONAL) 5V SIGNAL COM +4V = +500A 0V= ARC NOT ESTABLISHED
{
GAS FLOW
COM TO CONTROL BOARD (VIA P7)
SCHEMATIC = ENABLE -4V = -500A
J60-8 J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
M21342 INPUT CONTROL CABLE 41 J12-1
POWER INPUT POWER 42 J12-4 -15V J6-8 707 FROM CONTROL BOARD (VIA P7)
DETECTION
(<18 VAC TO DETECT)
607 608 606A 605 4B NOT 509B 601
USED
TO CONTROL BD. (VIA P60 plug)

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.
MANUFACTURING TOLERANCE PER E2056 CONTROL: SCALE:
CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
NONE
EQUIPMENT TYPE: LN-25 PRO 2
2 OF ___
PAGE ___
SOLID EDGE
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: ddietz IF PRINTED DOCUMENT DOCUMENT
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: ENYEDY
@ A2 SIZE SUBJECT: MACHINE SCHEMATIC NUMBER: REVISION:
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: -
UNITS:
INCH
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE: 11/16/2007
PROJECT
NUMBER: CRM39437
REFERENCE:
-
G5683 C
Insight
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lN-25™ prO
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11387, 11388 - (G5683) pG2
G5683 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED LEADS GOING TO P17.

MANUFACTURER: No
PRESET P. C. BOARD CIRCUIT

SCHEMATIC = G4748
TIMER P. C. BOARD CIRCUIT MOTOR
THERMAL
3 LEDs
WFS/AMPS DISPLAY VOLTS DISPLAY

7 SEGMENT
{
DISPLAYS
Timer Board Summary (2 each)
701 J10-10
Has potentiometers for Burnback, Preflow and Postflow. WFS AMPS
Preflow range from 0ms to 10s. 0V = RUN IN ENABLED set=WFS
VOLTS
Burnback range from 0 to 250 ms. TO SWITCH S5 RUN IN actual = AMPS SIGNALS TO
Postflow range from 50ms to 10 s. 702 J10-11 DISPLAY & LED

SERIAL SPI
Receives “Gas Flow Enable” signal. COMMUNICATION TO J1
{
SPI (10 leads)
Outputs 16 ms pulses to turn Gas Flow On / Off.
77B J10-16 CONTROL
(LOCATED BEHIND WIRE TO REMOTE VOLTS + MICROCONTROLLER PC BOARD
REEL COVER) POTENTIOMETER R2 76B J10-14 - VOLTAGE
MEASUREMENT
OF REMOTE
(LOCATED ON CASE FRONT) AND POWER SOURCE VOLTS
ADJUST KNOB 75B J10-15 - POTENTIOMETER
+ SETUP
PUSHBUTTON
+5V +5V SETUP
CW= +5 LED
CCW= 0V 10K
10K BURNBACK ARC VOLTAGE ELECTRODE 67 J10-6
{
POT.
POSTFLOW PREFLOW
POT.
MEASUREMENT ARC VOLTAGE
SETUP
POT. FEEDBACK
COM COM
FOR DISPLAY WORK 21 J10-8 PUSHBUTTON
COM +15V
{
(BOARDMOUNTED )
15V SIGNAL
15V 805 J10-9 -15V
15 ms PULSES
OUTPUT TOGGLE GAS FLOW ARC CURRENT MEASUREMENT 804 J10-4
ON/OFF 5V
FOR DISPLAY & ARC ESTABLISHED 801 J10-1
ARC CURRENT
TIMER KIT FEEDBACK J10-12 708 ARC ESTABLISHED OUTPUT
IF V> 10V RELATIVE TO COMMON
MICROCONTROLLER 802 J10-2
(OPTIONAL) 5V SIGNAL COM +4V = +500A 0V= ARC NOT ESTABLISHED
{
GAS FLOW
COM TO CONTROL BOARD (VIA P7)
SCHEMATIC = ENABLE -4V = -500A
J60-8 J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
M21342 INPUT CONTROL CABLE 41 J12-1
POWER INPUT POWER 42 J12-4 -15V J6-8 707 FROM CONTROL BOARD (VIA P7)
DETECTION
(<18 VAC TO DETECT)
607 608 606A 605 4B NOT 509B 601
USED

CLEVELAND
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
EQUIPMENT TYPE: LN-25 PRO PAGE ___ 2
2 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: ddietz IF PRINTED DOCUMENT DOCUMENT
UNITS:
INCH
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE: 11/16/2007
PROJECT
NUMBER: CRM39437
REFERENCE:
-
G5683 C
I i h
lN-25™ prO
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11507, 11508 - (G5683-1) pG1
G5683-1 ENGINEERING CONTROLLED CHANGE DETAIL: MISC. UPDATES PER SERVICE DEPARTMENT. When tach feed back is lost, Start-Up
MANUFACTURER: No
P7 = 16 PIN
P17 = 6 PIN (Both are located on lower front)
the voltage to the motor is a
constant 10VDC.
(controlled by software)
72 HZ TO 1.2 KHZ
Gearbox ratio is 23.5:1
On power-up, the LN-25 PRO will light the motor thermal LED and
polarity LED 2-3 seconds.
If the feeder is powered-up with the trigger depressed, welding will

3 not start until the trigger is released and then depressed again.
667C 667A Top of motor
R-B 15.0 VDC Motor case is at Motor resistance
6 1 of 2 P17 21A 667B Leads Pass through B-U 6.2 VDC ANY SPEED electrode potential is 1.5 ohms
P17 4 1 Notes:
621 621A toroid 2 times.
(METER DEPENDENT) Motor is located
2 of 2 2 R Motor overcurrent limit varies with WFS.
+
L4 behind PLASTIC HOUSED BOLTED
531 531 3 U glastic panel
WORK CLIP D1 21C FEED CONNECTION (BASE CENTER) Before 2-20-2009
1 537 537 4 B MOTOR / PLATE 67C Current
21B - 67B 534 534 5 GEARBOX Level
67D
6 From Power Source
case front Located on 551 7 B copper bar weld cable (Electrode Connection) 4.5
Case front 550 8 W copper bar
strain relief 67C
case back 3.5
P9 L12081 2.6 V @ 50 IPM TAKEN WITH 40 V INPUT gun connector strain relief
67B 27 V @ 700 IPM IN CV MODE. 67C & 67D
Preset
WFS
Leads Pass L13084 2.6 V @ 25 IPM TRIGGER CONNECTOR
through 32 V @ 400 IPM J14
EXTRA TORQUE TRIGGER
toroid 2 times. 622A A
Located on Wire B
INPUT
14 PIN REMOTE Drive Panel 500A
C Located on
LEADS ARE TRIGGER INTERLOCK 0V.=TRIGGER Case Front
After 2-20-2009
PRESENT BUT NOT L5 (NOT PRESENT ON K2613-3) CLOSED
D Current
Level
NOT USED IN USED S1, S2 & S3 Located E
S1 15VDC.=TRIGGER
THIS UNIT. 15V=2 STEP on Wire Drive Panel
J18 0V=TRIGGER OPEN 4.5
509E
INTERLOCK
3.5
Trigger Interlock does not stop 587
IN HARNESS 509B
9 CENTER BASE welding when the arc is broken.
10 AREA Pull and release to end the weld. 2-STEP Preset
509D WFS
5 77C COLD FEED 15V=CV 370 530 700
S2
4 76C 0V=COLD FEED 509E 0V=CC TIMER KIT P.C. BOARD *Extra Torque 180* 257* 400*
CC 4 509B
3 75C (N.O.) 530A (OPTIONAL)
622
J15 1 S3 SCHEMATIC = M21341 The WFS range of the LN-25 PRO
CV 500 Normal Speed = 40- 700 IPM.
N.O. SEE PAGE 2
667D 6 21E 2 Extra Torque = 25- 400 IPM.
LINE FILTER FOR NOISE ON 2 509C WFS limited by arc voltage when operating across the arc
667B 1 of 4
INVERTER INPUT POWER. 7 523
P7 607 608 606A 605 4B 509B 601
LOCATED ABOVE CONTROL
8 Maximum WFS
ANALOG 4 O COIL Feeder Input Volts Standard Gear Extra Torque
BOARD ON TOP CENTER OF P16 0 VDC OPEN
CONTROL BOX ASSEMBLY + VOLTMETER
Located on
4 2 3 1
3 VDC CLOSED
15 280 210
8 7 6 4 3 17 340 235
- 40V MAX. top of motor 12 VDC COIL 5 2 1 P60
667E
PWM CONTROLLED 21 440 400

721 24 520 400
Located under 27 600 400
10 75C Wire Drive Panel CONTACTOR
P7-1
11 76C 3 of 4 Control Board Summary
12 77C Converts arc power to a usable control circuit voltage.
Connector JUMPER TOGETHER FOR
P7 located EXTRA TORQUE MACHINE Receives switch signals from Trigger, Cold Feed, Gas Purge
4 of 4 behind case
front ISOLATED 2-4 TO Reads WFS potentiometer.
575A 6 575A 534 550 21D
POWER SOURCE Communicates with optional timer kit.
4
576A 7 576A 531
537 551 67F 721 530
622
607 608 606 605 601 EXTRA Controls motor speed with PWM.
Located on 500 2 578 507
Case Front 577A 8 577A 587 523 509A TORQUE
Turns Gas Solenoid on, off, PWM.
Reads the motor tachometer.
10K/2W 575A J6-9 J6-10 +35V
J4-11 J4-12 J4-6 J4-9 J4-7 J4-10 J4-2 J4-1 J5-7 J5-6 J5-5 J6-2 J6-3 J6-4 J6-6 +15V J5-4 J5-3 J4-8 J4-5 J2-6 J2-3 J2-2 J2-5 J2-1 J2-7 J2-8 Operating Voltage= 15-110 VDC.
R1 576A MOTOR +5V +15V
SUPPLY
100K +15V 20 Shut down Voltage= 130 VDC.
577A ohm
10K
ohm
TRIGGER MOV
ohm Thermal light turns on when shutdown voltage exceeded.
WIRE FEED SPEED 0 VDC MIN. WFS J5-1
MACHINE
OUTPUT +5V
CONTROL 5 VDC MAX. WFS COM +15V
TRIGGER INTERLOCK / 2 STEP
CC/VV
ENABLE CONTACTOR DRIVE Code and Serial numbers are below Wire Drive on plastic
POTENTIOMETER +15V SPI
+5V SPI .05 uF COLD FEED housing Nameplate.
POWER COM 600 V
-15V
SUPPLY +15V ISO
Thermal “Yellow” Light
MICRO
+5VDC 100K Motor Over Current
CONTROLLER
LED
METER
COM ohm
ISO 35VDC COMPENSATION
Motor and trigger disabled for 30 seconds.
CIRCUIT POLARITY
721 IS DRIVEN NEGATIVE TO COMPENSATE SENSE
4B Must retrigger to start welding after 30 seconds pass.
FOR THE METER FOR DIODE DROP ERROR GAS
667 ON THE BRIDGE ON - OFF Shutdown Voltage exceeded
+15
OVER POWER MOTOR May occur with some inverters.
SUPPLY 0V = OFF
VOLTAGE SUPPLY
621 J5-8 PROTECTION
-15
BURNBACK 20msec ---- 250msec May occur with some CC machines with high
COM DRIVE inductance.
(LOCATED AT
OUTSIDE REAR PWM Polarity “Green” Light
GAS PURGE OF FEEDER) +15V DRIVE
On= Positive Polarity
PUSHBUTTON 610 J6-7 BRAKE
MOTOR
DRIVE
BRAKE GAS
SWITCH (N.O.) S4 612 J6-1 CIRCUIT
MOTOR VOLTAGE YELLOW THERMAL LED FLOW Off= Negative Polarity
MOTOR CURRENT
0.05K
COM +5V SPI ENABLE
13.5 VDC WHEN
NOT DEPRESSED ohm 15
(OUTSIDE BACK 0-5V PULSE SIGNAL
TACH POLARITY LED COM J6-14 B 2B
OF CASE)
FREQUENCY = SPEED
FEEDBACK 13 (LOCATED AT TOP
Not present 0V = MIN SPEED WIRE FEED
1B FRONT OF FEEDER)
+35V 5V = MAX SPEED
GAS
on K2613-3 SPEED
690 J4-3
COM
ARC ESTABLISHED YELLOW
SOLENOID
GAS PURGE
14 MOTOR GREEN
22 O COIL
GAS SOLENOID J6-11 1W THERMAL POLARITY
0 VDC OPEN 691 J4-4 16 LED LED
25 TO 35 4 VDC CLOSED PROGRAM J6-12 2W
NORMAL 12 VDC COIL 9
FLOW RATE PWM CONTROLLED J6-5 708
(LOCATED AT REAR FLEXIBLE POWER P.C. BOARD
-15V
5
+5V SPI +5V +5V SPI +15V
SCLK
J6-8 707
MISO
OF FEEDER)
MOSI
CS3
CS2
CS1
SCHEMATIC = G4745
CS0
COM
BALL FLOAT 2 of 4
USE MIDDLE OF
BALL TO SET J3-8 J3-6 J3-7 J1-10 J1-2 J1-1 P7
J1-4
J1-8
J3-1
J1-7
J1-3
J1-6
J3-5
J1-9
J3-3
J3-2
J3-4
J1-5
(LOCATED INSIDEOF
CONTROLBOX)
+
ADJUST VALVE RED

FLOW METER
GOOD FOR Ar, CO2,
FAN BLOWS AIR ACROSS FAN PROGRAMMING PCB
SPI DIGITAlL COMMUNICATION
CONTROL PC BOARD - BLACK FACTORY USE ONLY
CO2/Ar BLENDS CONTINOUSLY AT 6200 RPMS.

Model Ranger 8,9 Classic Ranger 250, 305 V350 DC-400, 600 Square Wave TIG 300/355 Miller Inverters STT II Note:
Commander 300,400,500 (Common Digital Most semiautomatic wire
(Common Analog Controls) welding processes perform
Controls) better using constant voltage
K2613-1 Recommended Recommended for Recommended for CV Recommended Recommended Not recommended for CC operation Recommended Not recommended power sources. Be sure the
K2613-2 all CV CV operation. operation. for CV for CV and CC because the customer may for CV voltage for STT operation. proper power source is used
K2613-3 operation. (Wire Feed operation. operation. experience short contactor life from sense operation. for your application. Contactor
Module Required) May be used for inductive nature of the power source. Not life may be shortened in PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
pulse welding if Not recommended with high frequency recommended for applications using CC MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE:
the welding TIG starti ng. use when pulse machines with high OCV. ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
EQUIPMENT TYPE: LN-25 PRO PAGE ___ 2
1 OF ___
procedure is welding. ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: tpearn DOCUMENT DOCUMENT
qualified by the ON ALL ANGLES IS ± .5 OF A DEGREE
IF PRINTED
customer. WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING APPROVED: SCHOLTI
UNITS:
INCH
MATERIAL
DISPOSITION: NA APPROVAL
DATE:
2/12/2010 PROJECT
NUMBER: CRM40936
REFERENCE:
G5683
G5683-1 C
lN-25™ prO
G5683-1 ENGINEERING CONTROLLED CHANGE DETAIL: MISC. UPDATES PER SERVICE DEPARTMENT.
MANUFACTURER: No
TIMER P. C. BOARD CIRCUIT

Timer Board Summary
Has potentiometers for burnback, postflow and preflow.

Preflow range is 0 to 10 sec.
Burnback range is 0 to 0.25 sec.
Postflow range is 0.25 to 10 sec.
Receives “Gas Flow Enable” signal.
Outputs 100 msec pulses to turn Gas Flow On, Gas Flow Off.
(LOCATED BEHIND WIRE

REEL COVER)
ADJUST KNOB
+5V +5V
CW= +5
CCW= 0V 10K
10K BURNBACK
POT.
POSTFLOW PREFLOW
POT. POT.
COM COM
COM
15V SIGNAL
15V
15 ms PULSES
OUTPUT TOGGLE GAS FLOW
ON/OFF 5V
TIMER KIT
MICROCONTROLLER
(OPTIONAL) 5V SIGNAL
GAS FLOW
COM
SCHEMATIC = ENABLE
J60-8 J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
M21342
607 608 606A 605 4B NOT 509B 601

USED

CLEVELAND
NONE
EQUIPMENT TYPE: LN-25 PRO 2
2 OF ___
PAGE ___
SOLID EDGE
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: tpearn IF PRINTED DOCUMENT DOCUMENT
DO NOT SCALE THIS DRAWING APPROVED: SCHOLTI
UNITS:
INCH
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE: 2/12/2010
PROJECT
NUMBER: CRM40936
REFERENCE:
G5683
G5683-1 C
Insight
lN-25™ prO
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11620, 11621, 11716, 11717 - (G5683-2) pG1
G5683-2 ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED A.03 FROM "X". When tach feed back is lost, Start-Up
WORK
667C
MANUFACTURER: No
3
6 1 of 2 P17
667A
21A
P7 = 16 PIN
constant 10VDC.
72 HZ TO 1.2 KHZ

CLIP 621A P17 4 667B Motor case is at Motor resistance not start until the trigger is released and then depressed again.
21B 2 of 2 R-B 15.0 VDC
+
Top of motor B-U 6.2 VDC ANY SPEED electrode potential is 1.5 ohms
21C Leads Pass through
D1 1 1 (METER DEPENDENT) Motor is located Notes:
toroid 2 times. 2 R
case front - 67B L4 behind PLASTIC HOUSED BOLTED
Motor overcurrent limit varies with WFS.
Located on 531 531 3 U
667D strain relief glastic panel
FEED CONNECTION (BASE CENTER) Before 2-20-2009
Case front 537 537 4 B MOTOR / PLATE 67C Current
534 534 5 GEARBOX 67D
Level
6 From Power Source
IN HARNESS 551 7 B copper bar weld cable (Electrode Connection) 4.5
CENTER BASE 550 8 W copper bar
AREA 67C
case back 3.5
MOTOR FILTER P.C. P9 L12081 2.6 V @ 50 IPM TAKEN WITH 40 V INPUT gun connector strain relief
BOARD SCHEMATIC= 67B 27 V @ 700 IPM IN CV MODE. 67C & 67D
S27592 BEFORE 6/15/2009 667D Preset
WFS
S27505 AFTER 6/15/2009 Leads Pass L13084 2.6 V @ 25 IPM TRIGGER CONNECTOR
J61-1 USED FOR FILTERING through 32 V @ 400 IPM EXTRA TORQUE
J14
INVERTER NOISE toroid 2 times. 622A A TRIGGER
Located on Wire B
INPUT
J61-2 14 PIN REMOTE 500A
Drive Panel TRIGGER INTERLOCK C Located on
LEADS ARE After 2-20-2009
(NOT PRESENT ON K2613-3) 555A Case Front
J61-3 PRESENT BUT NOT
L5 S1, S2 & S3 Located D Current
Level
667E NOT USED IN S1 on Wire Drive Panel E 0V.=TRIGGER
USED 15V=2 STEP 622B
J61-4 THIS UNIT. CLOSED
J18 0V=TRIGGER
509E 15VDC.=TRIGGER 4.5
INTERLOCK OPEN
3.5
B2 509B
9 welding when the arc is broken.
10 Pull and release to end the weld. 2-STEP 509E Preset
509D WFS
B1 5 77C S3 15V=CV
J62-1 J62-2 S2 370 530 700

0V=CC 4 TIMER KIT P.C. BOARD

4 76C 667B
ANALOG
0V=COLD FEED CC 622 509B
*Extra Torque 180* 257* 400*
3 75C (N.O.) 530A 2 (OPTIONAL)

VOLTMETER 500 The WFS range of the LN-25 PRO
J15 1 + COLD FEED SCHEMATIC = M21341
Normal Speed = 40- 700 IPM.
USED TO DISCHARGE CV 555 SEE PAGE 2
POWER SUPPLY CAP 6 21E - 40V MAX. 3 4 O COIL Extra Torque = 25- 400 IPM.
AFTER A HIGH VOLTAGE 2 509C 0 VDC OPEN WFS limited by arc voltage when operating across the arc
721 1 of 4
TRANSIENT. LATER 7 523
P7
3 VDC CLOSED
607 608 606A 605 4B 509B 601
RELOCATED TO THE 12 VDC COIL
CONTROL BOARD. 8 PWM CONTROLLED
Maximum WFS
621 P7-1 P16 Feeder Input Volts Standard Gear Extra Torque
4 2 3 1
3 of 4 Located on Located under 15 280 210
NOT PRESENT Wire Drive Panel CONTACTOR 8 7 6 5 4 3 2 1 17 340 235
top of motor P60
ON S27505 21 440 400
10 75C 24 520 400
11 76C 27 600 400
12 77C
P7 Connector located Control Board Summary
4 of 4 behind case front JUMPER TOGETHER FOR Converts arc power to a usable control circuit voltage.
ISOLATED 2-4 TO
575A 6 575A POWER SOURCE
EXTRA TORQUE MACHINE Receives switch signals from Trigger, Cold Feed, Gas Purge
Located on Case Front 576A 7 576A Reads WFS potentiometer.
10K/2W 575A 577A 8 577A 534 21D Communicates with optional timer kit.
550 4
R1 576A 531
537 551 67F 721 530
622
577A 587 500 2 578 507 555 TORQUE
523 509A Turns Gas Solenoid on, off, PWM.
WIRE FEED SPEED 0 VDC MIN. WFS
CONTROL Reads the motor tachometer.
5 VDC MAX. WFS MOTOR
J6-9 J6-10 +35V
POTENTIOMETER SUPPLY J4-11 J4-12 J4-6 J4-9 J4-7 J4-10 J4-2 J4-1 J5-7 J5-6 J5-5 J6-2 J6-3 J6-4 J6-6 +15V J5-4 J5-3 J4-8 J4-5 J2-6 J2-3 J2-2 J2-5 J2-1 J2-7 J2-8 Operating Voltage= 15-110 VDC.
+5V +15V J2-10
667 J5-1 ohm
10K
COM ohm
TRIGGER MOV
B1 B1
MACHINE
OUTPUT +5V
+15V
CC/VV
B2 housing Nameplate.
B2 COM
.05 uF
600 V
COLD FEED
C1 Thermal “Yellow” Light

MICRO
C2 100K Motor Over Current
+15V SPI CONTROLLER

+5V SPI
METER
COM ohm
POWER -15V
COMPENSATION
SUPPLY
621 +15V ISO
+5VDC 721 IS DRIVEN NEGATIVE TO COMPENSATE
CIRCUIT POLARITY
SENSE
LED FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE Shutdown Voltage exceeded
(LOCATED AT OUTSIDE ISO 35VDC +15 GAS
ON - OFF
REAR OF FEEDER) C1 MOTOR May occur with some inverters.
GAS PURGE SUPPLY
-15 May occur with some CC machines with high
PUSHBUTTON 610
0V = OFF
20msec ---- 250msec
SWITCH (N.O.) S4
BURNBACK inductance.
612 OVER POWER DRIVE
VOLTAGE SUPPLY PWM Polarity “Green” Light
13.5 VDC WHEN PROTECTION
NOT DEPRESSED C2 DRIVE
On= Positive Polarity
BRAKE
MOTOR
DRIVE
BRAKE GAS
(OUTSIDE MOTOR VOLTAGE YELLOW THERMAL LED FLOW Off= Negative Polarity
CIRCUIT
MOTOR CURRENT
BACK OF
0.05K
COM +5V SPI ENABLE
CASE)
ohm 15
0-5V PULSE SIGNAL
POLARITY LED COM J6-14 B 2B
25 TO 35 FREQUENCY = SPEED TACH
13 (LOCATED AT TOP
FEEDBACK
NORMAL 0V = MIN SPEED WIRE FEED
1B FRONT OF FEEDER)
FLOW 5V = MAX SPEED SPEED
RATE J5-8 COM
GAS PURGE ARC ESTABLISHED YELLOW
+15V COM +35V 14 MOTOR GREEN
BALL FLOAT GAS SOLENOID J6-11 1W POLARITY
USE MIDDLE 610 J6-7 16
THERMAL
OF BALL TO 612 J6-1 LED LED
SET PROGRAM J6-12 2W
9
J6-5 708
ADJUST VALVE
J4-3 -15V
5
FLOW METER
GAS +5V SPI +5V FLEXIBLE POWER P.C. BOARD +5V SPI +15V
SCLK
J6-8 707
MISO
MOSI
CS3
CS2
CS1
J4-4 SCHEMATIC = G4783
CS0
GOOD FOR Ar, CO2,
CO2/Ar BLENDS SOLENOID COM
2 of 4
690 P7
J3-8 J3-6 J3-7 J1-10 J1-2 J1-1
J1-4
J1-8
J3-1
J1-7
J1-3
J1-6
J3-5
J1-9
J3-3
J3-2
(LOCATED INSIDEOF
J3-4
J1-5
22 O COIL
0 VDC OPEN CONTROL BOX)
+
4 VDC CLOSED RED

691
12 VDC COIL
PWM CONTROLLED
(LOCATED AT REAR CONTROL PC BOARD BLACK FACTORY USE ONLY
-
OF FEEDER) CONTINOUSLY AT 6200 RPMS.

Model Ranger 8,9 Classic Ranger 250, 305 V350 DC-400, 600 Square Wave TIG 300/355 Miller Inverters STT II Note:
Commander 300,400,500 (Common Digital Most semiautomatic wire
(Common Analog Controls) welding processes perform
Controls) better using constant voltage
K2613-1 Recommended Recommended for Recommended for CV Recommended Recommended Not recommended for CC operation Recommended Not recommended power sources. Be sure the
K2613-2 all CV CV operation. operation. for CV for CV and CC because the customer may for CV voltage for STT operation. proper power source is used
operation. (Wire Feed operation. operation. experience short contactor life from sense operation. for your application. Contactor
Module Required) May be used for inductive nature of the power source. Not life may be shortened in PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
pulse welding if Not recommended with high frequency recommended for applications using CC MANUFACTURING TOLERANCE PER E2056
the welding TIG starti ng. use when pulse machines with high OCV. ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
EQUIPMENT TYPE: LN-25 PRO ANALOG PAGE ___ 2
1 OF ___
procedure is welding. ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: tpearn DOCUMENT DOCUMENT
IF PRINTED

DO NOT SCALE THIS DRAWING APPROVED: BS
UNITS:
INCH
MATERIAL
DISPOSITION: UF APPROVAL
DATE:
11/6/2009 PROJECT
NUMBER: CRM40943
REFERENCE:
G5683-1
G5683-2 A
lN-25™ prO
sChEmaTiC - lN-25 prO - COmplETE maChiNE CODEs 11620, 11621, 11716, 11717 - (G5683-2) pG2
G5683-2 ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED A.03 FROM "X".

MANUFACTURER: No

Timer Board Summary


REEL COVER)
ADJUST KNOB
+5V +5V
CW= +5
CCW= 0V 10K
10K BURNBACK
POT.
POSTFLOW PREFLOW
POT. POT.
COM COM
COM
15V SIGNAL
15V
15 ms PULSES
ON/OFF 5V
TIMER KIT
MICROCONTROLLER
GAS FLOW
COM
SCHEMATIC = ENABLE
J60-8 J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
M21342
607 608 606A 605 4B NOT 509B 601

USED

CLEVELAND
2 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: tpearn IF PRINTED DOCUMENT DOCUMENT
DO NOT SCALE THIS DRAWING APPROVED: BS
UNITS:
INCH
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE: 11/6/2009
PROJECT
NUMBER: CRM40943
REFERENCE:
G5683-1
G5683-2 A
lN-25™ prO
G5683-3 ENGINEERING CONTROLLED CHANGE DETAIL: A.02, COMPLETELY REVISED When tach feed back is lost, Start-Up
WORK
667C
MANUFACTURER: No
3
6 1 of 2 P17
667A
21A
P7 = 16 PIN
constant 10VDC.
72 HZ TO 1.2 KHZ

CLIP 621A P17 4 667B Motor case is at Motor resistance not start until the trigger is released and then depressed again.
21B 2 of 2 R-B 15.0 VDC
+
Top of motor B-U 6.2 VDC ANY SPEED electrode potential is 1.5 ohms
21C Leads Pass through
D1 1 1 (METER DEPENDENT) Motor is located Notes:
toroid2 times. 2 R
case front - 67B L4 behind PLASTIC HOUSED BOLTED
Motor overcurrent limit varies with WFS.
Located on 531 531 3 U
667D strain relief glastic panel
FEED CONNECTION (BASE CENTER)
Case front 537 537 4 B MOTOR / PLATE 67C
534 534 5 GEARBOX 67D After 2-20-2009
6 From Power Source Current
IN HARNESS 551 7 B copper bar weld cable (Electrode Connection) Level
CENTER BASE 550 8 W copper bar
AREA
case back
67C
MOTOR FILTER P.C. P9 L12081-1 2.6 V @ 50 IPM TAKEN WITH 40 V INPUT gun connector strain relief 4.5
67B 27 V @ 700 IPM IN CV MODE. 67C & 67D
BOARD SCHEMATIC= 667D TRIGGER
S27505 Leads Pass CONNECTOR 3.5
L13084-1 2.6 V @ 25 IPM
J61-1 USED FOR FILTERING through 32 V @ 400 IPM J14
INVERTER NOISE toroid 2 times. EXTRA TORQUE 622A A TRIGGER Located on
INPUT Case Front Preset
Located on Wire B
J61-2 14 PIN REMOTE 500A 0V.=TRIGGER WFS
Drive Panel C
LEADS ARE TRIGGER INTERLOCK CLOSED 370 530 700
L5 S1, S2 & S3 Located 555A D
J61-3 PRESENT BUT NOT 15VDC.=TRIGGER *Extra Torque 180* 257* 400*
667E NOT USED IN S1 on Wire Drive Panel E OPEN
USED 15V=2 STEP
J61-4 THIS UNIT. Located on
J18 0V=TRIGGER
509E Case Front
INTERLOCK
622B
B2 Low Range High Range
9 welding when the arc is broken. (White) (Red) WFS limited by arc voltage when operating across the arc
10 Pull and release to end the weld. 2-STEP 509E WFS RANGE
509D Normal Speed 50-200 50-700
B1 5 77C S3 15V=CV SWITCH Maximum WFS
S2 Extra Torque 50-200 50-400

509B
0V=CC Feeder Input Volts Standard Gear Extra Torque
4 76C 667B
ANALOG
0V=COLD FEED CC
(N.O.) 15 400 220
3 75C VOLTMETER
530A
J15 1 + COLD FEED 4 509B 17 450 250
CV TIMER KIT P.C. BOARD 21 570 300
6 21E - 40V MAX. 622
2 4 O COIL
(OPTIONAL) 24 650 350
2 721
509C 500 0 VDC OPEN
27 700 400
7 523
555 3 VDC CLOSED SCHEMATIC = M21341
3 12 VDC COIL SEE PAGE 2
8 PWM CONTROLLED
621 P7-1 P16
4 2 3 1 1 of 4
3 of 4 Located on P7 Located under 607 608 606A 605 4B 509B 601
top of motor Wire Drive Panel CONTACTOR

10 75C
8 7 6 5 4 3 2 1 P60
11 76C
12 77C
P7 Connector located Control Board Summary
4 of 4 behind case front Converts arc power to a usable control circuit voltage.
ISOLATED 2-4 TO
575A 6 575A POWER SOURCE Receives switch signals from Trigger, Cold Feed, Gas Purge
Located on Case Front 576A 7 576A JUMPER TOGETHER FOR Reads WFS potentiometer.
EXTRA TORQUE MACHINE
10K/2W 575A 577A 8 577A 534 21D Communicates with optional timer kit.
550 4
R1 576A 531
537 551 67F 721 530
622
577A 587 500 2 578 507 555 TORQUE
523 509A Turns Gas Solenoid on, off, PWM.
WIRE FEED SPEED 0 VDC MIN. WFS
CONTROL Reads the motor tachometer.
5 VDC MAX. WFS MOTOR
J6-9 J6-10 +35V
POTENTIOMETER SUPPLY J4-11 J4-12 J4-6 J4-9 J4-7 J4-10 J4-2 J4-1 J5-7 J5-6 J5-5 J6-2 J6-3 J6-4 J6-6 +15V J5-4 J5-3 J4-8 J4-5 J2-6 J2-3 J2-2 J2-5 J2-1 J2-7 J2-8 Operating Voltage= 15-110 VDC.
+5V +15V J2-10
667 J5-1 ohm
10K
COM ohm
TRIGGER MOV
B1 B1
MACHINE
OUTPUT +5V
+15V
CC/VV
B2 housing Nameplate.
B2 COM
.05 uF
600 V
COLD FEED
Thermal “Yellow” Light

MICRO
100K
+15V SPI Motor Over Current

CONTROLLER
+5V SPI
METER
COM ohm
POWER -15V
COMPENSATION
SUPPLY
621 +15V ISO
+5VDC 721 IS DRIVEN NEGATIVE TO COMPENSATE
CIRCUIT POLARITY
SENSE
LED FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE Shutdown Voltage exceeded
(LOCATED AT OUTSIDE ISO 35VDC +15 GAS
ON - OFF
REAR OF FEEDER) MOTOR May occur with some inverters.
GAS PURGE SUPPLY
-15 May occur with some CC machines with high
PUSHBUTTON 610
0V = OFF
20msec ---- 250msec
SWITCH (N.O.) S4
BURNBACK inductance.
612 OVER POWER DRIVE
VOLTAGE SUPPLY PWM Polarity “Green” Light
13.5 VDC WHEN PROTECTION DRIVE
NOT DEPRESSED On= Positive Polarity
BRAKE
MOTOR
DRIVE
BRAKE GAS
(OUTSIDE MOTOR VOLTAGE YELLOW THERMAL LED FLOW Off= Negative Polarity
CIRCUIT
MOTOR CURRENT
BACK OF
0.05K
COM +5V SPI ENABLE
CASE)
ohm 15
0-5V PULSE SIGNAL
POLARITY LED COM J6-14 B 2B
25 TO 35 FREQUENCY = SPEED TACH
13 (LOCATED AT TOP
FEEDBACK
NORMAL 0V = MIN SPEED WIRE FEED
1B FRONT OF FEEDER)
FLOW 5V = MAX SPEED SPEED
RATE J5-8 COM
GAS PURGE ARC ESTABLISHED YELLOW
+15V COM +35V 14 MOTOR GREEN
BALL FLOAT GAS SOLENOID J6-11 1W POLARITY
USE MIDDLE 610 J6-7 16
THERMAL
OF BALL TO 612 J6-1 LED LED
SET PROGRAM J6-12 2W
9
J6-5 708
ADJUST VALVE
J4-3 -15V
5
FLOW METER
GAS +5V SPI +5V FLEXIBLE POWER P.C. BOARD +5V SPI +15V
SCLK
J6-8 707
MISO
MOSI
CS3
CS2
CS1
J4-4 SCHEMATIC = G4783
CS0
GOOD FOR Ar, CO2,
CO2/Ar BLENDS SOLENOID COM
2 of 4
690 P7
J3-8 J3-6 J3-7 J1-10 J1-2 J1-1
J1-4
J1-8
J3-1
J1-7
J1-3
J1-6
J3-5
J1-9
J3-3
J3-2
(LOCATED INSIDEOF
J3-4
J1-5
22 O COIL
0 VDC OPEN CONTROL BOX)
+
4 VDC CLOSED RED

691
12 VDC COIL
PWM CONTROLLED
(LOCATED AT REAR CONTROL PC BOARD BLACK FACTORY USE ONLY

-
OF FEEDER) CONTINOUSLY AT 6200 RPMS.
Model Ranger 8,9 Classic Multiweld, Rangers, V350 DC-400, 600 Square Wave TIG 300/355 Miller Inverters STT II Note:
Vantages, Flextec Most semiautomatic wire
welding processes perform
K2613-5 Recommended Recommended for Recommended for CV Recommended Recommended Not recommended for CC operation Recommended Not recommended better using constant voltage
K2613-7 all CV CV operation. and CC operation. for CV for CV and CC because the customer may for CV voltage for STT operation. power sources. Be sure the
operation. (Wire Feed operation. operation. experience short contactor life from sense operation. proper power source is used
Module Required) May be used for inductive nature of the power source. for your application. Contactor PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
pulse welding if Not recommended with high frequency life may be shortened in MANUFACTURING TOLERANCE PER E2056
the welding TIG starting. applications using CC ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
1 OF ___
procedure is machines with high OCV. ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: T. PEARN DOCUMENT DOCUMENT
IF PRINTED

UNITS:
INCH
MATERIAL
DISPOSITION: NA APPROVAL
DATE:
1/26/2011 PROJECT
NUMBER: XM6214-C
REFERENCE:
G5683-2
G5683-3 A.02
lN-25™ prO
G5683-3 ENGINEERING CONTROLLED CHANGE DETAIL: A.02, COMPLETELY REVISED

MANUFACTURER: No

Timer Board Summary


REEL COVER)
ADJUST KNOB
+5V +5V
CW= +5
CCW= 0V 10K
10K BURNBACK
POT.
POSTFLOW PREFLOW
POT. POT.
COM COM
COM
15V SIGNAL
15V
15 ms PULSES
ON/OFF 5V
TIMER KIT
MICROCONTROLLER
GAS FLOW
COM
SCHEMATIC = ENABLE
J60-8 J60-7 J60-6 J60-5 J60-4 J60-3 J60-2 J60-1
M21342
607 608 606A 605 4B NOT 509B 601

USED

CLEVELAND
2 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: T. PEARN IF PRINTED DOCUMENT DOCUMENT
APPROVED: -
UNITS:
INCH
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE: 1/26/2011
PROJECT
NUMBER: XM6214-C
REFERENCE:
G5683-2
G5683-3 A.02
lN-25™ prO
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11387, 11388, 11507, 11508 (G4745-1) pG 1
+5V +15V_ISO
TACHOMETER +15V +5V +VM
RED 9 J4 2 1
D30
1A/FR
R101
D32 4.75K
R230
0.063W 0.2A GND 0.063W 1K 400V PWM
30V Q5-G
R97
10K Q5
10K 4 2 47A
0.063W 3 9 6 3 X7-8 R110 600V
BLUE 7 J4 R98 R99 10 X8 8 TACH TACH_IN PSOC PWM_MOTR 5 X8
HC132 1 X8
HC132 R230-R231 100
100 HC132 X7 Vb 7
C58 DZ14
R231
100pF 2 +5V 12 HIN HO 8 C53 C75 1K 18V
100V Q7
R225
0.1uF 82uF
BLACK 10 J4 GAS ON/OFF 3 J2 R43
D7
3 0.2A 3.32K
0.1W
12
11 0.115A 13 SD
50V 35V 0.5W 541
(BLK)
70V 13 X8 R100 60V 14 LIN Vs 6 R102 J4-1 J4 1
GND 2.21K GAS_ON_OFF HC132 100 D31
0.1W 1 GAS_ON_OFF LO 1 15 1A/FR
2113 400V
C31 GND GND D26 BRAKE
0.1uF 3A Q9 MOTOR
R44
+15V 1K 26A
0.1W 50V 26.7K 600V ISO
BRAKE R118 600V
0.1W 150
6 J6 +5V R105 GND
J4 2
7 J6 GND DZ15
18V
539
(WH)
8 J6 IM_AVE IM_AVE R85 X6
13 1K 26.7K 0.5W
VAVE = 0.331*IAVE 14 0.063W 0.1W
2 2 2 26.7K R84 R83
D17 1 D22 1 D16 1 2 1 2 1 +5V +5V C46 0.1W 33074ADT 12
-15V 0.2A 0.2A 0.2A D20 D21 0.1uF
30V 30V 30V 0.2A 0.2A GND 50V 4.75K D24 C44 0.05
R87
30V 30V
R9
2 0.063W 1A/FR 0.1uF 5W
3 3 3 2 400V 50V
3 3 D23
D25 3 0.2A
R104
CUR_SENSE 5 J6 R77 CUR_SENSE 3 0.2A 20K 30V
30V 0.1W GND
4.75K 1
GAS_PURGE 1 J6 R93 GAS_PURGE VIM_PEAK = ((+5V - (IPK*RS))*R2.67/(R2.67+R20+RS))
1 2.67K GND
4.75K + (IPK*RS) 0.063W +35V
IM_PEAK
TRIG_INLK_2_STEP 3 J6 R89 TRIG_INLK_2_STEP IM_PEAK
15AMPS = 1.25VDC
R103
4.75K J4 3
C55
CV_CC 4 J6 R92 CV_CC 330pF D13 D12
4.75K 100V J4
1A/FR 1A/FR 8 SOL

COLD_FEED 2 J6 R79 COLD_FEED 400V 400V

4.75K 2K 2K CONFIG[0..3] GND J4 4
2K 2K 2K HIGH TORQUE
0.1W 0.1W
0.1W
C41 C48 C42
0.1W 0.1W 8 J2 R21 CONFIG[0]
C50 C49 CONFIG[0..3]
R76
R88
R78
R90
R91
0.1uF 0.1uF 0.1uF 1K 0.063W
50V 50V 50V 0.1uF 0.1uF 9 J2 R22 CONFIG[1] CONT
50V 50V 1K 0.063W Q3
+5V 10 J2 R23 CONFIG[2]
SOLENOID_DRIVE 47A J4 5
1K 0.063W PWM_SOL R57 55V
L3 7 J2 R20 CONFIG[3]
200 Q2
600 OHMS GND 1K 0.063W CONTACTOR_DRIVE 47A
6 J4 +5V PWM_CONT
+5V
R59 55V
C73 200
2 +5V
0.1uF
4 J2
R56
R58
50V D8 2 10K 10K
0.2A 0.063W 0.063W
CW 3 D1 R153 667
PSOC
GND 30V 0.2A
475 3 30V 100K
1
WFS 12 J4 GND WFS
10K
R155
POT R39 R40 WFS_POT 1 100K GND
10K
0.1W C30 +15V_ISO CC_SENSE GND 38.2V = 5.00V 667
CC_SENSE
R38
100K 0.1uF R33 +5V

0.1W 50V +VM +35V +15V -15V +5V +5SPI 1K
R156
0.063W C65 150K
11 J4
R145
R154
ISO 0.1uF 82.5K 47.5K 2
50V 0.1W 0.1W
15V_ISO 15V_ISO_COM D3
GND MOTOR_SUPPLY 3 0.2A
30V
R157
GND 1 150K ARC SENSE
35VDC_SUPPLY
667 1 J5 667 15VDC_SUPPLY ARCV_SENSE ARC_VSENSE R29
GND
155.0V = 5.00V
POWER_SUPPLY
INPUT POWER 667 1K
621 8 J5 NEG15V_SUPPLY
POLARITY_SENSE 0.063W C66
R146
5.0VDC_SUPPLY LED 0.1uF 10K +5SPI
LED 50V 0.063W
TRIGGER
STATUS_LED
LED[1]
THERMAL_LED
GND 5VSPI_SUPPLY +15V OUT_2_4
624 OUT_2_4 J6 14
VM_LIM GND
5V_ISO2 COM_ISO2 35V_SENSE
J6 11
7 J5 ELECTRODE ELECTRODE +5V L2 R94
15 J6 J6 16 600 OHMS J2 200 J6 13
R30
47.5K 2 R96
R217
R218
R219
C15
R216
2 100 100 100 100
0.05uF POLARITY_SENSE POLARITY_SENSE 0.1W
D4 C72 0.1W 0.1W 0.1W 0.1W Q13 R95
200 J6 12
600V 5V_ISO2 COM_ISO2
6 J5 WORK METER_COMP METER_COMP 3 0.2A
30V 0.1uF 0.115A Q12 200
50V 60V
WORK V13_VSENSE 0.115A Q14

+15V +5V 13V_SENSE 1 CW 60V 0.115A
ARC VOLTS READ
5 J5 C22
GND 60V
0.1uF 475
BURNBACK J2
R48
16.5K BB
10K
4.75K 50V R28 R27 5
R214
R213
R212
R4
R80
0.1W POT 10K 10K 10K

622A 9 J6 R5 R3 0.1W 10K 0.063W 0.063W 0.063W
TRIGGER C21 0.1W +15V
121 121
R26
500 0.1uF 100K
TRIGGER 1W 1W DATA DATA R106 J3 4 50V 0.1W
GND DATA
R8 332 200 J2 1
500A 10 J6 R6 R7 R82 Q4
0.5A SCLK SCLK R107 J3 3 SCLK GND GND
R144
R191
121 121 40V 200 1.82K 1.82K
1W 1W 500 XRES XRES R108 J3 2 XRES GND
C43 SPIBUS OUTPUT2 J5
221 200
R81
5.1V 0.1uF R15 4

3W 50V 0.1W +5V OCI1 OCI1 20
R226
R109
DZ3 10K 10K 1 4 5W
0.063W 0.063W J3 +5V 5
RXD TXD GAS_FLOW 7 S MOV2
GND 150V
2 2 6 80J
+5V 80J J5
+5SPI GND D5 3
0.2A OUTPUT4 +5V
+15V +5SPI 3 30V Q11
8 J3 PROGRAMMING 1
0.115A
60V 2 +35V
1 J1 2 1
2
D55 1 2 D53 1 1 J3 RS232_RX RS232_RX RXD GND D2 3
R215
D10 0.2A 0.2A 10K 0.2A +35V SUPPLY
2 J1 0.2A 30V 30V GND R25 R24 J2 6 GAS FLOW 0.063W 30V VOLTAGE
30V 5 J3 RS232_TX RS232_TX TXD 100 100
ENABLE SENSE
R42
3 3 1 26.7K
0.1W 0.1W
3 6 J3 GND GND
4 J1 R185 R188 CS1 RS232 +35V_SENSE R32 45.2V = 5.00V
332 100 0.1W GND 1K
5 J1 R186 R189 CS2 0.063W C23
3.32K
R31
332 100 0.1W 0.1uF
50V 0.063W
3 J1 /SS_P R69 R67 SS
332 100 0.1W +5V +5V +15V +15V
6 J1 R187 R190 CS3
GND
332 100 0.1W
9 J1 MOSI_P R51 R49 SPI_MOSI
LAST NO. USED
332 100 0.1W GENERAL INFORMATION 232 X- 14 OCI- 1 T- 2
8 J1 SCK_P SPI_SCLK R-
R68 R66 14 15 3 4
11 Vcc 82 32 83 14 Vcc
ELECTRICAL SYMBOLS PER E1537 C- 73 Q- 14 LED- 1 L- 3
332 100 0.1W CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)

3 +5V 3 Vdd
3 +5SPI C52 C51 C28 C38 AVDD VDD SMP C33 C54 C45 X6 RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 56 DZ- 18 MOV- 2
+5SPI X8 0.1uF X2 0.1uF X3 X7 0.1uF
D9 D6 D54 0.1uF X7 0.1uF 50V 50V CY8C29866 0.1uF 0.1uF 50V DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
SUPPLY VOLTAGE NET
0.2A 0.2A 0.2A 50V 50V MAX3221 VSS 50V 50V 2113 33074ADT
2 30V 1 2 30V 1 2 30V 1 2113 HC132 GND 15 34 65 84 85 GND POWER SUPPLY SOURCE POINT
Vss 7 14 2 11
5 15 COMMON CONNECTION
VCC
R34
4.75K FRAME CONNECTION

475 0.1W 475 LVC1G14GW
0.1W 0.1W GND MAIN EARTH GROUND CONNECTION
7 J1 MISO_P R35 R50 2 A X1 Y 4 MISO
GND GND
GND -15V
C24
22pF DZ13 NC GND C34
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
50V 5.1V 0.1uF
0.5W 1 3 50V
SINCE COMPONENTS OR CIRCUITRY ON A
PRINTED CIRCUIT BOARD MAY CHANGE EQUIPMENT TYPE: FLEXIBLE POWER FEEDER
DESIGN INFORMATION PAGE 01 OF 05
10 J1 WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: JPZ 10/20/2009 DOCUMENT DOCUMENT
GND
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT ENGINEER: JPZ SUBJECT:
REFERENCE:
SCHEMATIC, CONTROL PCB NUMBER: REVISION:
GND COMPONENTS OR CIRCUITRY OF CONTROLS
HAVING A COMMON CODE NUMBER. APPROVED:
MATERIAL
--------- APPROVAL
DISPOSITION: NA DATE: XX-XX-XXX PROJECT
NUMBER: CRM39801 G 4745-1H0 A
lN-25™ prO
IM_PEAK IM_PEAK 74 P0[0] P4[0] 63 CUR_SENSE CUR_SENSE

CC_SENSE CC_SENSE 3 P0[1] P4[1] 11 GAS_PURGE GAS_PURGE
IM_AVE IM_AVE 77 P0[2] P4[2] 64 TRIG_INLK_2_STEP TRIG_INLK_2_STEP
35V_SENSE 35V_SENSE 99 P0[3] P4[3] 10 CV_CC CV_CC
13V_SENSE 13V_SENSE 79 P0[4] P4[4] 66 COLD_FEED COLD_FEED
WFS_POT 97 P0[5] P4[5] 9

WFS_POT
ARCV_SENSE ARCV_SENSE 81 P0[6] P4[6] 67 LED LED
BURNBACK BURNBACK 95 P0[7] P4[7] 8
DATA DATA 44 P1[0] P5[0] 52 THERMAL_LED
SCLK SCLK 30 P1[1] P5[1] 23 LED[1]
SPIBUS TACH_IN TACH_IN 45 P1[2] P5[2] 53 STATUS_LED
PWM_MOTR PWM_MOTR 29 P1[3] P5[3] 22
PWM_CONT PWM_CONT 46 P1[4] P5[4] 54 GAS_ON_OFF
PWM_SOL PWM_SOL 28 P1[5] P5[5] 21 GAS_FLOW
SPI_MOSI 47 P1[6] P5[6] 55
SPI_SCLK 24 P1[7] P5[7] 20
68 P2[0] P6[0] 86 RXD RXD
POLARITY_SENSE POLARITY_SENSE 7 P2[1] P6[1] 87 TXD TXD
69 P2[2] P6[2] 88
6 P2[3] P6[3] 89
TRIGGER TRIGGER 70 P2[4] P6[4] 90 OUT_2_4 OUT_2_4
5 P2[5] P6[5] 91
BRAKE BRAKE 72 P2[6] P6[6] 92
MISO MISO 4 P2[7] X3 CONFIG[0..3]
P6[7] 93
CS1 56 P3[0] P7[0] 43 CONFIG[0]
CS2 19 P3[1] P7[1] 42 CONFIG[1]
CS3 57 P3[2] P7[2] 41 CONFIG[2]
SS 18 P3[3] P7[3] 40 CONFIG[3]
58 P3[4] P7[4] 39
17 P3[5] P7[5] 38
59 P3[6] P7[6] 37
16 P3[7] P7[7] 36
XRES XRES 62 XRES NC51 51
1 NC1 NC60 60
2 NC2 NC61 61
12 NC12 NC71 71
13 NC13 NC73 73
25 NC25 NC75 75
26 NC26 NC76 76
27 NC27 NC78 78
31 NC31 NC80 80
33 NC33 NC94 94
35 NC35 NC96 96
48 NC48 NC98 98
49 NC49 NC100 100
50 NC50
CY8C29866
LAST NO. USED

GENERAL INFORMATION R- _
ELECTRICAL SYMBOLS PER E1537 _ SEE PAGE 1
C-
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)

D- _
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS
DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
PSOC EARTH GROUND CONNECTION
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: JPZ 9/24/2009 DOCUMENT DOCUMENT
REFERENCE:
COMPONENTS OR CIRCUITRY OF CONTROLS
MATERIAL APPROVAL
DISPOSITION: NA DATE:
--------- PROJECT
9-12-2008 NUMBER: CRM39801 G 4745-1H0 A
lN-25™ prO
RIN 8 R36 RS232_RX RS232_RX

RXD DIN 11 TXD 200
RXD MAX3221 0.1uF 50V TXD
9 ROUT C2- 6
RS232_TX RS232_TX C25
R19 13 DOUT C2+ 5
200
10 INVALID X2 V- 7
12 FORCEON V+ 3 50V
0.1uF
+5V R37 16 FORCEOFF C1- 4
3.32K C29
C1+ 2
0.1W
EN 1
C27 C26
0.1uF 0.1uF
50V 50V
GND
LAST NO. USED

ELECTRICAL SYMBOLS PER E1537 C- _ SEE PAGE 1

D- _
SUPPLY VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
RS232 EARTH GROUND CONNECTION
REFERENCE:
MATERIAL
--------- APPROVAL
DISPOSITION: NA DATE: 9-12-2008 PROJECT
NUMBER: CRM39801 G 4745-1H0 A
lN-25™ prO
+15V
2
D50
3 0.2A +5V
30V
1
2
-15V D18
3 0.2A
30V
ELECTRODE R180 R175 R176 R177 1
221K 221K 221K 221K GND
1
D51 3
2 0.2A R184 POLARITY_SENSE
X6 R182 70V 2.21K
1 2 C70
3.32K
R181
3 33074ADT 221K 0.1uF
50V
GND
WORK R174 R173 R179 R178 GND

221K 221K 221K 221K
R170 METER_COMP
+15V 20K
0.1W +15V
2 1
D14 D52 3 2
0.2A 3 0.2A R172 9
6 70V 10K D19
30V R183 X6 0.2A
X6 7 2 C71 0.1W 8 3 30V
R171
1 33074ADT 3.32K 475 0.1uF 10 33074ADT
5 50V 1
-15V GND
-15V
GND
LAST NO. USED

C-

D- _
SUPPLY VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
ARC VOLTS READ EARTH GROUND CONNECTION
REFERENCE:
MATERIAL APPROVAL
--------- PROJECT
9-12-2008 NUMBER: CRM39801 G 4745-1H0 A
lN-25™ prO
D28
3A
600V
IN X5 OUT 15VDC_SUPPLY 15VDC_SUPPLY
78M15
R114
C2 2K GND
82uF
35V C3
220uF
25V
R115
2K
624 624 T1-10 GND

D46 T1 10
3A
10 0.5W
10 0.5W
10 0.5W
10 0.5W
600V 5VSPI_SUPPLY
R138
R137
R136
R135
9 5VSPI_SUPPLY
5.1K 5.1K 58P6091 L1
R13
10uH
R11
5W 5W T1-9 T1 1.02A
R117
1 100
10 0.5W
10 0.5W
10 0.5W
10 0.5W
R143
R142
R140
R141
D48 C12 C5
15A 0.0033uF 220uF
600V 630V 2 25V
D43
1A
R116
600V D27 100
3A C4
40V 0.001F
D39 35V
3
Q8 1A
33.2 20A 400V
R130 600V GND
D47
3A
R127
600V DZ16 4 2K
22.1K 18V D33
0.063W 0.5W 1A C6 C56
R128 600V 82uF 0.1uF
C19 35V 50V
2.21K 0.063W
R126
0.1uF 8 2K
630V VREF R129 D41
7 VCC 4 DZ18 GND
R119
RT/CT 3.01K 1A
6 OUT 2 0.1W 400V D40 3.3V
X10 VFB R121 1A 0.5W IN OUT
5 GND 1 X9 NEG15V_SUPPLY
100K 0.063W
COMP 1K 332 400V
2843BD1 3 C59 0.063W R151 79M15
R122
CS 150pF D38
DZ5 100V 1A
17V 3.32K R152 400V
5W 0.063W DZ11
2 332 15V R220
R131
R120
D29 3.01K 3W 100 LED1
C7 0.2A C60 C61 0.1W
220uF 3 30V 100pF 0.0047uF IN X12 OUT 5.0VDC_SUPPLY
25V 100V 50V
R194
R200
R202
R192
R193
R196
R195
R198
R197
R199
1 1 1 1 1 1 1 1 1 1 1 7805
DZ10 C10 C9
15V 82uF GND 82uF
3W 35V 35V D34
1A
600V
T1-5 15V_ISO
GND 5 D34-C
6 T1
58P6091 C62 C74
0.1uF 82uF DZ19
50V 35V 18V
0.5W
ISO
15V_ISO_COM
R223
2.67K
D36 D37
15A 30A
600V 600V
D45 667 MOTOR_SUPPLY
8A MOTOR_SUPPLY
10 0.5W
10 0.5W
10 0.5W
10 0.5W
1000V C14 C8 5.1K
R224
R164
R169
R168
R165
2.67K
R14
35VDC_SUPPLY 470uF 470uF 5W
T2 1 4 350V 350V
3 6 T2 C17
0.012F
TX06101B TX06101B 50V
10 0.5W
10 0.5W
10 0.5W
10 0.5W
R167
R166
R163
R162
C16 GND
R139
301 0.0033uF
630V
GND
D42
1A
400V
1 VS1 VS8 8 Q10
2 IN 47A
OUT7 7 R227 600V 1A/FR
DZ12 4 GND4 X14
OUT6 6 15 400V X11
43V R222 T1-7 8 78L05A 1 5V_ISO2 5V_ISO2
1W MIC4452YM GND5 5 7 IN OUT
15 D35 GND C11
8 T1 C64 1uF
58P6091 1uF 2 3 6 7 35V
DZ6 D56 DZ17 35V
30V 0.5A 18V
GND 30V 0.5W 3.92K COM_ISO2 COM_ISO2
R12
3W 1W
22.1K 0.1W
R161
DZ7 2.21K 0.063W
30V VREF 8 R160
3W 7 VCC RT/CT 4
6 OUT X13 VFB 2 R148
OVERVOLTAGE 5 GND 1
100K 0.063W
DZ8 COMP 1K
SHUTDOWN 30V 2843BD1 3 C68 0.063W
R159
113 - 126VDC CS 150pF

3W 100V 3.32K
0.063W
R147
C20 2 R149 301
180uF 0.1W
350V D44
3 0.2A C67 C69 +5V
30V 100pF 0.0047uF
1 100V 50V
R204
R203
R206
R205
R208
R207
R209
R201
R210
C13 1 1 1 1 1 1 1 1 1 R211 1
C18
R150
1uF 1K DZ9 82uF

63V 3.3V 35V
3W
R111
4.75K
0.063W
VM_LIM
GND GND Q6
R112 0.5A GENERAL INFORMATION LAST NO. USED
33.2K 40V R- _
0.063W ELECTRICAL SYMBOLS PER E1537 _ SEE PAGE 1
C-
C57
R113
39.2K CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)

0.1W 0.022uF RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- _
50V DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
SUPPLY VOLTAGE NET
COMMON CONNECTION
GND
FRAME CONNECTION
POWER SUPPLY EARTH GROUND CONNECTION
REFERENCE:
MATERIAL APPROVAL
--------- PROJECT
XX-XX-XXXXNUMBER: CRM39801 G 4745-1H0 A
lN-25™ prO
sChEmaTiC - lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 1
+5V +15V_ISO
TACHOMETER +15V +5V +VM
RED 9 J4 2 1
D30
1A/FR
R101
D32 4.75K
R230
0.063W 0.2A GND 0.063W 1K 400V PWM
30V
R97
10K Q5
10K 4 2 47A
0.063W 3 9 6 3 X7-8 R110 Q5-G 600V
BLUE 7 J4 R98 R99 10 X8 8 TACH TACH_IN PSOC PWM_MOTR 5 X8
HC132 1 X8
HC132 R230-R231 100
100 HC132 X7 Vb 7
C58 DZ14
R231
100pF 2 +5V 12 HIN HO 8 C53 C75 1K 18V
100V Q7
R225
0.1uF 82uF
BLACK 10 J4 GAS ON/OFF 3 J2 R43
D7
3 0.2A 3.32K
0.1W
12
11 0.115A 13 SD 50V 35V 0.5W 541
(BLK)
70V 13 X8 R100 60V 14 LIN Vs 6 R102 J4-1 J4 1
GND 2.21K GAS_ON_OFF HC132 100 D31
0.1W 1 GAS_ON_OFF LO 1 15 1A/FR
2113 400V
C31 GND GND D26 BRAKE
0.1uF 3A Q9 MOTOR
R44
+15V 1K ISO 26A
0.1W 50V 26.7K 600V
BRAKE R118 600V
0.1W 150
6 J6 +5V R105 GND
J4 2
7 J6 GND DZ15
18V
539
(WH)
8 J6 IM_AVE IM_AVE R85 X6
13 1K 26.7K 0.5W
VAVE = 0.331*IAVE 14 0.063W 0.1W
2 2 2 26.7K R84 R83
D17 1 D22 1 D16 1 2 1 2 1 +5V +5V C46 0.1W 33074ADT 12
-15V 0.2A 0.2A 0.2A D20 D21 0.1uF
30V 30V 30V 0.2A 0.2A GND 50V 4.75K D24 C44 0.05
R87
30V 30V
R9
2 0.063W 1A/FR 0.1uF 5W
3 3 3 2 400V 50V
3 3 D23
D25 3 0.2A
R104
CUR_SENSE 5 J6 R77 CUR_SENSE 3 0.2A 20K 30V
30V 0.1W GND
4.75K 1
GAS_PURGE 1 J6 R93 GAS_PURGE VIM_PEAK = ((+5V - (IPK*RS))*R2.67/(R2.67+R20+RS))
1 2.67K GND
4.75K + (IPK*RS) 0.063W +35V
IM_PEAK
TRIG_INLK_2_STEP 3 J6 R89 TRIG_INLK_2_STEP IM_PEAK
15AMPS = 1.25VDC
R103
4.75K J4 3
C55
CV_CC 4 J6 R92 CV_CC 330pF D13 D12
4.75K 100V 1A/FR 1A/FR J4 8 SOL
2 J6
COLD_FEED R79 COLD_FEED 400V 400V

4.75K 2K 2K GND J4 4
2K 2K 2K HIGH TORQUE
0.1W 0.1W 0.1W 0.1W 0.1W 8 J2 R21 CONFIG[0]
C41 C48 C42 C50 C49 1K 0.063W
R76
R88
R78
R90
R91
0.1uF 0.1uF 0.1uF
50V 50V 50V 0.1uF 0.1uF 9 J2 R22 CONFIG[1] CONT
50V 50V Q3
+5V 1K 0.063W 47A J4 5
PWM_SOL SOLENOID_DRIVE R57 55V
L3 7 J2 R20 CONFIG[3] 200 Q2
600 OHMS GND 1K 0.063W CONTACTOR_DRIVE 47A
6 J4 PWM_CONT
+5V
R59 55V
C73 +5V 200
2 +5V POWER BRAZER
0.1uF
R56
R58
50V D8 2 10K 10K
CW 3 0.2A 4 J2 D1 R153 667
0.063W 0.063W
PSOC
GND 30V 0.2A
475 3 30V 100K
1
WFS 12 J4 GND WFS
10K
R155
POT R39 R40 WFS_POT 1 100K GND
10K
0.1W C30 +15V_ISO CC_SENSE GND 38.2V = 5.00V 667
CC_SENSE
R38
100K 0.1uF R33 +5V

0.1W 50V +VM +35V +15V -15V +5V +5SPI 1K
R156
ISO 0.063W C65 150K
11 J4
R145
R154
0.1uF 82.5K 47.5K 2
50V 0.1W 0.1W
15V_ISO 15V_ISO_COM D3
GND MOTOR_SUPPLY 3 0.2A
30V
1 J5
R157
667 667 GND 1 150K ARC SENSE
INPUT POWER 667 35VDC_SUPPLY
621 8 J5 15VDC_SUPPLY ARCV_SENSE ARC_VSENSE R29
GND
155.0V = 5.00V
POWER_SUPPLY
1K
NEG15V_SUPPLY POLARITY_SENSE 0.063W C66
R146
GND 5.0VDC_SUPPLY LED 0.1uF 10K +5SPI
LED 50V 0.063W
7 J5 ELECTRODE ELECTRODE TRIGGER
STATUS_LED
LED[1]
THERMAL_LED
5VSPI_SUPPLY OUT_2_4
C15 624 OUT_2_4 J6 14
0.05uF POLARITY_SENSE POLARITY_SENSE 5V_ISO2 COM_ISO2 VM_LIM DUAL_P_TRIGGER
35V_SENSE GND
600V +5V
6 J5 WORK METER_COMP METER_COMP R94 J6 11
WORK 15 J6 J6 16 +15V +5V L2
600 OHMS J2 200 J6 13
+15V 2 R96
R217
R218
R219
R216
ARC VOLTS READ 2 100 100 100 100
5 J5 4.75K 5V_ISO2 COM_ISO2 D4 C72 0.1W 0.1W 0.1W 0.1W Q13 R95
200 J6 12
R80
R4 0.1W 3 0.2A 0.1uF 0.115A Q12

30V 200
9 J6 50V 60V
622A R5 R3 0.115A
R30
47.5K 1 60V Q14
121 121 500 TRIGGER 0.1W CW 0.115A
TRIGGER 1W 1W GND 60V
+5V DUAL_P_TRIGGER V13_VSENSE 475
R8 332 13V_SENSE BURNBACK J2 BB
10K
10 J6 Q4 R28 R27 5
R214
R213
R212
500A R6 R7 R82 0.5A POT 10K 10K 10K
C22 10K 0.063W 0.063W 0.063W
121 121 500 40V C21 0.1W +15V
1W 1W 0.1uF
R48
R26
50V 16.5K 0.1uF 100K
C43 0.1W DATA J3 50V 0.1W
221 4.75K DATA
R81
5.1V 0.1uF R106 4 DATA

R2
3W 50V 0.1W 0.1W 200 J2 1

DZ3 SCLK SCLK R107 J3 3 SCLK GND GND
R144
R191
GND 200 1.82K 1.82K
XRES XRES R108 J3 2 XRES GND
GND SPIBUS OUTPUT2 J5
R13 332 200 R15 4
DUAL_P_TRIGGER 10 J2 R16 R17 R10 Q1
0.5A +5V OCI1 OCI1 20
R226
R109
121 121 40V 10K 10K 1 4 5W
1W 1W 500 0.063W 0.063W J3 +5V 5 TP1
DZ1 C1 RXD TXD GAS_FLOW 7 S
150V
221
R1
5.1V 0.1uF 80J

3W 50V 0.1W 2 2 6
+5V J5 3
+5SPI GND D5
0.2A OUTPUT4 +5V
+15V +5SPI 3 30V Q11
GND 8 J3 PROGRAMMING 1
0.115A
60V 2 +35V
1 J1 2 1
2
D55 1 2 D53 1 1 J3 RS232_RX RS232_RX RXD GND D2 3
R215
D10 0.2A 0.2A 10K 0.2A +35V SUPPLY
2 J1 0.2A 30V 30V GND R25 R24 J2 6 GAS FLOW 0.063W 30V VOLTAGE
30V 5 J3 RS232_TX RS232_TX TXD 100 100
ENABLE SENSE
R42
3 3 1 26.7K
0.1W 0.1W
3 6 J3 GND GND
4 J1 R185 R188 CS1 RS232 +35V_SENSE R32 45.2V = 5.00V
332 100 0.1W GND 1K
5 J1 R186 R189 CS2 0.063W C23
3.32K
R31
332 100 0.1W 0.1uF
50V 0.063W
3 J1 /SS_P R69 R67 SS
332 100 0.1W
6 J1 R187 R190 CS3 +15V +15V GND
332 100 0.1W +5V +5V
9 J1 MOSI_P R51 R49 SPI_MOSI
LAST NO. USED
332 100 0.1W GENERAL INFORMATION 232 DZ- 19 Q- 14
8 J1 SCK_P SPI_SCLK R-
R68 R66 ELECTRICAL SYMBOLS PER E1537 C- 73
L- 3 T- 2
332 100 0.1W 4 TP- 1
3 3 3 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED) LED- 1

3 +5V +5SPI Vcc RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 56 OCI- 1 X- 14
+5SPI 11 14 15
D9 D6 D54 Vcc 82 32 83 14 C54 C45 X6 DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
SUPPLY VOLTAGE NET
0.2A 0.2A Vdd 0.1uF
0.2A C28 C38 AVDD VDD SMP 0.1uF X7
2 30V 1 2 30V 1 2 30V 1 C52 C51
X8 0.1uF X2 0.1uF X3 C33 50V 2113
50V 33074ADT POWER SUPPLY SOURCE POINT
0.1uF X7 0.1uF 50V 50V CY8C29866 0.1uF
5 50V 50V MAX3221 VSS 50V GND 11
COMMON CONNECTION
VCC 2113 HC132 2
R34
4.75K Vss GND 15 34 65 84 85 FRAME CONNECTION

475 0.1W 475 LVC1G14GW 7 14
0.1W 0.1W GND 15 MAIN EARTH GROUND CONNECTION
7 J1 MISO_P R35 R50 2 A X1 Y 4 MISO
C24
22pF DZ13 NC GND C34
GND -15V PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
50V 5.1V 0.1uF GND
0.5W 1 3 50V
GND SINCE COMPONENTS OR CIRCUITRY ON A
10 J1 WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: APM 9/3/2010 DOCUMENT DOCUMENT
GND
DIAGRAM MAY NOT SHOW THE EXACT ENGINEER: APM SUBJECT:
REFERENCE:
GND
NUMBER: CRM40617 G 4783-1C0 A
MATERIAL APPROVAL
HAVING A COMMON CODE NUMBER. APPROVED: DRS DISPOSITION: NA DATE:
--------- 10-23-2009 PROJECT
lN-25™ prO
sChEmaTiC- lN-25 prO CONTrOl pC BOarD - CODEs 11620, 11621, 11716, 11717, 11746, 11747 (G4783-1) pG 2
IM_PEAK IM_PEAK 74 P0[0] P4[0] 63 CUR_SENSE CUR_SENSE

CC_SENSE CC_SENSE 3 P0[1] P4[1] 11 GAS_PURGE GAS_PURGE
IM_AVE IM_AVE 77 P0[2] P4[2] 64 TRIG_INLK_2_STEP TRIG_INLK_2_STEP
35V_SENSE 35V_SENSE 99 P0[3] P4[3] 10 CV_CC CV_CC
13V_SENSE 13V_SENSE 79 P0[4] P4[4] 66 COLD_FEED COLD_FEED
WFS_POT WFS_POT 97 P0[5] P4[5] 9

ARCV_SENSE ARCV_SENSE 81 P0[6] P4[6] 67 LED LED
BURNBACK BURNBACK 95 P0[7] P4[7] 8
DATA DATA 44 P1[0] P5[0] 52 THERMAL_LED
SCLK SCLK 30 P1[1] P5[1] 23 LED[1]
SPIBUS TACH_IN 45 P1[2] STATUS_LED
TACH_IN P5[2] 53
PWM_MOTR PWM_MOTR 29 P1[3] P5[3] 22 GAS_ON_OFF
PWM_CONT PWM_CONT 46 P1[4] P5[4] 54
PWM_SOL PWM_SOL 28 P1[5] P5[5] 21 GAS_FLOW
SPI_MOSI 47 P1[6] P5[6] 55
SPI_SCLK 24 P1[7] P5[7] 20 RXD
68 P2[0] P6[0] 86 RXD
POLARITY_SENSE POLARITY_SENSE 7 P2[1] P6[1] 87 TXD TXD
69 P2[2] P6[2] 88
6 P2[3] P6[3] 89
TRIGGER TRIGGER 70 P2[4] P6[4] 90 OUT_2_4 OUT_2_4
5 P2[5] P6[5] 91
BRAKE BRAKE 72 P2[6] P6[6] 92
MISO MISO 4 P2[7] X3 P6[7] 93 CONFIG[0]
CS1 56 P3[0] P7[0] 43 CONFIG[0]
CS2 19 P3[1] P7[1] 42 CONFIG[1] CONFIG[1]
CS3 57 P3[2] P7[2] 41 DUAL_P_TRIGGER
SS 18 P3[3] P7[3] 40 CONFIG[3] DUAL_P_TRIGGER
58 P3[4] P7[4] 39
17 P3[5] P7[5] 38 CONFIG[3]
59 P3[6] P7[6] 37
16 P3[7] P7[7] 36
XRES XRES 62 XRES NC51 51
1 NC1 NC60 60
2 NC2 NC61 61
12 NC12 NC71 71
13 NC13 NC73 73
25 NC25 NC75 75
26 NC26 NC76 76
27 NC27 NC78 78
31 NC31 NC80 80
33 NC33 NC94 94
35 NC35 NC96 96
48 NC48 NC98 98
49 NC49 NC100 100
50 NC50
CY8C29866
LAST NO. USED

ELECTRICAL SYMBOLS PER E1537 SEE PAGE 1
C- _

D- _
SUPPLY VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
PSOC EARTH GROUND CONNECTION
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: APM 9/2/2010 DOCUMENT DOCUMENT
REFERENCE:
MATERIAL APPROVAL
--------- 10-23-2009 PROJECT
lN-25™ prO
RIN 8 R36 RS232_RX RS232_RX

RXD DIN 11 TXD 200
RXD MAX3221 0.1uF 50V TXD
9 ROUT C2- 6
RS232_TX RS232_TX C25
R19 13 DOUT C2+ 5
200
10 INVALID X2 V- 7
12 FORCEON V+ 3 50V
0.1uF
+5V R37 16 FORCEOFF C1- 4
3.32K C29
C1+ 2
0.1W
EN 1
C27 C26
0.1uF 0.1uF
50V 50V
GND
LAST NO. USED

C-

D- _
SUPPLY VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
RS232 EARTH GROUND CONNECTION
REFERENCE:
HAVING A COMMON CODE NUMBER. APPROVED: DRS
MATERIAL APPROVAL
--------- PROJECT
10-23-2009 NUMBER: CRM40617 G 4783-1C0 A
lN-25™ prO
+15V
2
D50 +5V
3 0.2A
30V
1 2
D18
-15V 3 0.2A
30V
ELECTRODE R180 R175 R176 R177 1
1 GND
221K 221K 221K 221K
D51 3
0.2A R184 POLARITY_SENSE
70V 2.21K
2 2
X6 R182 C70
R181
1 221K 0.1uF
33074ADT 3.32K 50V
3
GND
WORK R174 R173 R179 R178 GND

221K 221K 221K 221K
R170 METER_COMP
+15V 20K
0.1W +15V
2 1
D14 D52 3 2
0.2A 3 0.2A R172 9
6 70V 10K D19
30V R183 X6 0.2A
X6 7 2 C71 0.1W 8 3 30V
R171
1 33074ADT 3.32K 475 0.1uF 10 33074ADT
5 50V 1
-15V GND
-15V
GND
LAST NO. USED

C-

D- _
SUPPLY VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
ARC VOLTS READ EARTH GROUND CONNECTION
REFERENCE:
HAVING A COMMON CODE NUMBER. APPROVED: DRS
MATERIAL APPROVAL
--------- PROJECT
10-23-2009 NUMBER: CRM40617 G 4783-1C0 A
lN-25™ prO
D28
3A
600V
IN X5 OUT 15VDC_SUPPLY 15VDC_SUPPLY
78M15
R114
C2 2K GND
82uF
35V C3
220uF
25V
R115
2K
624 624 GND

D46 T1 10
3A
10 0.5W
10 0.5W
10 0.5W
10 0.5W
600V 5VSPI_SUPPLY
R138
R137
R136
R135
9 5VSPI_SUPPLY
58P6091 L1
3K 10uH
R11
10W T1 1.02A
R117
D48 1 100
15A
10 0.5W
10 0.5W
10 0.5W
10 0.5W
600V T1-9
R143
R142
R140
R141
C12 C5
0.0033uF 220uF
630V 2 25V
D43
1A
R116
600V D27 100
3A C4
40V 0.001F
D39 35V
3
Q8 1A
33.2 20A 400V
R130 600V GND
D47
3A
R127
600V DZ16 4 2K
22.1K 18V D33
0.063W 0.5W 1A C6 C56
600V
R128 82uF 0.1uF

C19 35V 50V
2.21K 0.063W
R126
0.1uF 8 2K
630V VREF R129 D41
7 VCC 4 DZ18 GND
R119
RT/CT 3.01K 1A
6 OUT 2 0.1W 400V D40 3.3V
X10 VFB R121 1A 0.5W IN OUT
5 GND 1 X9 NEG15V_SUPPLY
100K 0.063W
COMP 1K 332 400V
2843BD1 3 C59 0.063W R151 79M15
R122
CS 150pF D38
DZ5 100V 1A
17V 3.32K R152 400V
5W 0.063W DZ11
2 332 15V R220
R131
R120
D29 3.01K 3W 100 LED1
C7 0.2A C60 C61 0.1W
220uF 3 30V 100pF 0.0047uF IN X12 OUT 5.0VDC_SUPPLY
25V 100V 50V
R194
R200
R202
R192
R193
R196
R195
R198
R197
R199
1 1 1 1 1 1 1 1 1 1 1 7805
DZ10 C10 C9
15V 82uF GND 82uF
3W 35V 35V 1A
T1-5 600V
5 15V_ISO 15V_ISO
GND 6 T1 D34
58P6091 C62 C74
0.1uF 82uF DZ19
50V 35V 18V
0.5W
ISO 15V_ISO_COM
D36
15A
600V R41
2.2 C8
5W 0.0015uF
10 0.5W
10 0.5W
10 0.5W
10 0.5W
2000V B1
R164
R169
R168
R165
35VDC_SUPPLY
R223
2.67K 1 4 35VDC_SUPPLY
T2 T2 D45 C17 D37
3 6 8A 0.012F 30A
TX06101B TX06101B 1000V 50V 600V
3K 3K
10 0.5W
10 0.5W
10 0.5W
10 0.5W
R23
667
R18
10W 10W 667 MOTOR_SUPPLY
R167
R166
R163
R162
C16 MOTOR_SUPPLY
D42
R224
2.67K 1A 0.0033uF
400V 630V GND 5.1K
R14
5W
B2
R53
15K
R139
301 1 VS1 Q10

VS8 8 47A
2 IN OUT7 7 R227 600V GND
4 GND4 X14 OUT6 6 15 1A/FR
R222 400V X11
DZ12 MIC4452YM GND5 5 T1-7 D35-C 8 78L05A 1 5V_ISO2 5V_ISO2
43V 15 7 IN OUT
R52
15K 1W D35 C11

GND
D56 DZ17 8 T1 C64 1uF
0.5A 1uF 2 3 6 7 35V
GND 18V 3.92K 58P6091 35V
30V 0.5W
R12
DZ6 1W COM_ISO2 COM_ISO2
56V 28K 0.1W
3W R161
R47
15K
2.67K 0.1W
VREF 8 R160
DZ7 7 VCC RT/CT 4
30V 6 OUT 2
3W X13 VFB R148
5 GND 1
100K 0.063W
COMP 1K
C68 0.063W
R46
15K 2843BD1 3
R159
OVERVOLTAGE CS 150pF
SHUTDOWN DZ8 100V
126 - 146VDC 30V 3.32K
3W 0.063W
R147
Q15 C20 2 R149 301
25A 470uF 0.1W
250V 350V D44
3 0.2A C67 C69 +5V
30V 100pF 0.0047uF
1 100V 50V
R204
R203
R206
R205
R208
R207
R209
R201
R210
R211
C13 C18 1 1 1 1 1 1 1 1 1 1
R150
R45
1.5K 1uF 1K DZ9 82uF

0.1W 63V 3.3V 35V
3W
R111
4.75K
0.063W
VM_LIM
LAST NO. USED
GND GND GENERAL INFORMATION R- _
R112 Q6
0.5A ELECTRICAL SYMBOLS PER E1537 SEE PAGE 1
C- _
33.2K 40V CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)

0.063W RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- _
C57
R113
39.2K DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
0.1W 0.022uF SUPPLY VOLTAGE NET
50V POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
GND
POWER SUPPLY EARTH GROUND CONNECTION
REFERENCE:
MATERIAL APPROVAL
--------- 10-23-2009 PROJECT
lN-25™ prO
sChEmaTiC - mOTOr FilTEr pC BOarD - CODE 11746, 11747 (s27505-1)
D1
40A
1600V
1 J61 J61 3
L1
470uH C1 C2
11.4A 470uF 470uF

350V 350V
2 J61 J61 4
GND
LAST NO. USED

ELECTRICAL SYMBOLS PER E1537 C- _
D- _
SUPPLY VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION

PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION EQUIPMENT TYPE: LN-25 PRO PAGE 01 OF 01
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: WDW 10-30-2008 DOCUMENT DOCUMENT
DIAGRAM MAY NOT SHOW THE EXACT ENGINEER: APM REFERENCE:
SUBJECT: SCHEMATIC, MOTOR FILTER PCB NUMBER: REVISION:
HAVING A COMMON CODE NUMBER. APPROVED: --------- MATERIAL APPROVAL
DISPOSITION: NA DATE: ------- PROJECT
NUMBER: 5021492 S 27505-1B0 A.01
lN-25™ prO
sChEmaTiC - K2330 TimEr KiT pC BOarD - all CODEs (m21341-1)
+15V
+5V
5V
2K
R9
R18
D8 2K
J60 1A/FR GAS_ON_OFF
8 R11 400V
GAS FLOW ENABLE 2.21K
1 P0[5] P0[4] 7 100 ms 100 ms 100 ms 100 ms
2 P0[3] Q1
D9 X2 P0[2] 6 195mA
1A/FR 3 P1[1]
400V C10 P1[0] 5 60V b d
0.022uF
R13
12.1K CY8C27143 J60
50V R10 7
33.2K 100 GAS ON/OFF
R8
R17
4.75K
R12
4.75K COM D7 D6
1A/FR 1A/FR
+5V 400V 400V
COM
COM COM
Power_Detect COM COM +15V
CW
R15 R16
R3
Postflow
10K 100K 1K +15V
C11 +5V
C12 D10 D11
R14
0.1uF 100K 1A/FR 1A/FR
50V 0.1uF +5V
50V 400V 400V D3
1A/FR
D4 400V
1A/FR
+5V COM COM 400V
J60 IN OUT
3 X1
+15V L2 7805
180
100 MHz GND C5
CW C4 82uF
Preflow R6 R7 C6
R1
0.1uF 35V
10K 100K 1K 50V 22uF
63V
+5V J60
C1 100K C3 D1 D2
R5
1A/FR 1A/FR 6
0.1uF 0.1uF
50V 50V 400V 400V +5V COM
CW
J60
5
R2
COM COM 10K B/B VIPER
Power_Detect J60
R19 8 1
13.7K +15V Vdd COM
X2 C9 COM
0.1uF LAST NO. USED
J60 CY8C27143 50V GENERAL INFORMATION R- 19 Q- 1
2 Vss
L3 4 ELECTRICAL SYMBOLS PER E1537 C- 12 X- 2
D5
180 1A/FR CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
D- 11 L- 3
100 MHz C7 400V RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS
0.1uF C8 DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)
50V 4.7uF SUPPLY VOLTAGE NET
35V COM POWER SUPPLY SOURCE POINT
+5V COMMON CONNECTION
COM FRAME CONNECTION

EARTH GROUND CONNECTION
J60
4 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
L1 TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
180
100 MHz
C2 PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: LN-25 PRO & LF-72 PAGE 01 OF 01
0.1uF WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: MFN M20337 DOCUMENT DOCUMENT
50V ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT ENGINEER: MFN DO NOT SUBJECT: SCHEMATIC, TIMER PCB NUMBER: REVISION:
SCALE THIS
3/27/2007 NUMBER: 5021492-A M 21341-1B0 A.01
COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL APPROVAL PROJECT
COM APPROVED:
HAVING A COMMON CODE NUMBER. DRAWING
PLOTTING DELIMITER - DON’T DELETE
lN-25™ prO

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LN-25™ PRO WIRE FEEDER

Safety Depends on You

Lincoln arc welding and cutting

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

CALIFORNIA PROPOSITION 65 WARNINGS

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

idler by pushing on the throttle control rods

ELECTRIC SHOCK can kill. ARC RAYS can burn.

• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

welding procedure and application involved. Worker expo-

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 cause fire or if damaged.

electrically “hot” parts to touch a cylinder.

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

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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

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

RETURN TO MAIN MENU

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

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

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

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-557

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

High Frequency Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Wire Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Changing The Gun Receiver Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Procedure To Install Drive Rolls and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Pressure Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Loading Spools of Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Gun Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Power Source to LN-25™ PRO Cable Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7/A-8

MACHINES COVERED IN THIS MANUAL

TECHNICAL SPECIFICATIONS – LN-25™ PRO (K2613-1, -2, -5, and -7)

INPUT VOLTAGE and CURRENT

RATED OUTPUT @ 104°F (40°C)

60% rating 450

GEARING - WIRE FEED SPEED RANGE-WIRE SIzE

WFS RANGE WIRE SIzES WFS RANGE WIRE SIzES

14.8 Inches 8.7 Inches 22.2 Inches 36 lbs

Do not submerge the LN-25™ PRO.

350 60 1/0 1/0 2/0 2/0 3/0

2. Remove the cylinder cap. Inspect the cylinder valves

and regulator for damaged threads, dirt, dust, oil or

5. Attach one end of the inlet hose to the outlet fitting of

7. Standing to one side, open the cylinder valve slowly a

WARNING 8. The flow regulator is adjustable. Adjust it to the flow

• Keep cylinder upright and WIRE DRIVE CONFIGURATION

American Welding Society.

Tools required: PROCEDURE TO INSTALL DRIVE ROLLS