Lincoln Electric SVM114-C K439 Remote Extension Cable Assembly, K577-1 Rear Handle KIT

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C-5

ACCESSORIES

C-5

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K439 REMOTE EXTENSION CABLE ASSEMBLY

The 50 ft. Extension cable assemblies are used to ex- tend the K432 Remote Control Cable Assembly when longer cable lengths are required.

Multiple K439 Extensions may be used, however, to prevent excessive weld cable voltage drops, the 500 amp max. rating of the K432 should be reduced by at least 50 amps for each K439 Extension used. For example, if three K439 Extensions are used (150 ft total extension), the maximum welding current used should be less than 350 amps.

The K439 Extension cable end with the male pin con- nector connects to the K433 Remote Box and power source per the Instructions included with the K433 kit.

The K439 Extension cable end with the socket pin connector connects to the mating K432 cable end (or next K439 Extension cable end). The electrode cables are connected using the bolt and nut provided with the K439 Extension. Properly insulate the bolted con- nection with electrical tape.

K624-1 42V REMOTE OUTPUT CONTROL MODULE

(For use with K625, K626, K627 Remote Control Cable)

The Module includes a 42V Remote PC board and control cable receptacle which mount and connect inside the LN-25™ control box per the Installation Instructions included with the kit.

NOTE: If the K624-1 42V Remote Output Control Module is installed but the LN-25™ is to be used without the K625, K626 or K627 Remote Control Cable Assembly, then the Remote Board harness plug must be removed from the 16-pin receptacle on the Control Board and the jumper plug (T13498-21) reinstalled.

CABLE

60% DUTY

POWER SOURCE

TYPE

RATING

ELECTRODE

 

 

CONNECTION

 

 

 

K625

500 Amps

Stud Terminal

K626

350 Amps

Stud Terminal

K627

400 Amps

Twist-Mate™

 

 

 

The cable assembly end with the socket pin connector connects to the LN-25™ per the Instructions included with the K624-1 Kit.

The cable assembly end with the male pin connector connects to the power source per the Instructions included with the K624-1 kit.

K444, K444-1 OR K444-2 REMOTE VOLTAGE CONTROL KIT

(Not required if using K431-1 or K624-1 Remote Output Control Kit.

The Remote Voltage Control Kit provides remote (10K ohm rheostat) control of power source output arc voltage level.

K444 connects to power sources with control terminal strip connections for lead numbers 75, 76 and 77.

K444-1connects to power sources with a 6-pin control receptacle.

NOTE: To use a K444-1 with power sources with only a 14-pin control receptacle, a K864 Adapter is required to connect to K444-1 and if using a power source without an output control switch, a K484 Jumper Plug will also be required to jumper the output pilot circuit (2-4).

K444-2connects to power sources with a 14-pin control receptacle and provides a 2-4 jumper to activate power source output.

Installation Instructions are included with the kit.

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K625, K626, K627 REMOTE CONTROL CABLE ASSEMBLY

(Requires K624-1 Remote Output Control Module installed in LN-25™.)

The K625, K626, K627 control cable assemblies include an electrode cable and a 8-conductor control cable:

K577-1 REAR HANDLE KIT

(For LN-25™ model codes above 9383)

The fold-down handle mounts to the rear of the LN25 case per the Installation Instructions (M16567) shipped with the kit.

This handle provides a means to also carry the LN25 in the vertical position, especially convenient for passing the unit through a manhole.

LN-25™

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Contents Semiautomatic Wire Feeder California Proposition 65 Warnings SafetyElectric Shock can kill Fumes and GasesCan be dangerous Welding and Cutting Sparks can Cause fire or explosion Cylinder may explode if damagedIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsCurrentrent InstallationTechnical Specifications LN-25 Wire Feed SpeedPower Source Connection Safety PrecautionsFor GMA GUN and Cables INVERTEC, CV300 and Other Newer Lincoln Power SourcesGUN Cable Connection to Feeder With CV AdapterWork Cable Connection Wire Feed Drive Roll and Guide Tube KitsWeld Cable Connection Electrode Cable ConnectionLN-25 Operation Section Operation Welding CapabilityRead and Understand Entire Section Before Operating Machine LN-25 Instruments Controls Electrode Polarity SwitchWire Feed Mode Switch Wire Speed Dial and Range SwitchRemote ARC Voltage Control Optional GAS Post PRE-FLOW Timers OptionalWork Clip Lead AWGMounting 10 to 30 LB Spools Sequence of OperationLoading Electrode Mounting 22 to 30 LB READI-REELCOILS6OPERATIONB-6 Loading Wire DriveIdle Roll Pressure Setting Grooves READI-REEL Inside Cage WiresMinimum Arc Volts Presetting Wire Feed SpeedSetting Constant Wire Feed Speed CV Mode Setting ARC Sensing Wire Feed Speed CC ModeMaking a Weld Figure B.4 VV CC Wire Speed SettingProcedure AT END of Coil WeldingCylinder may explode if damaged Circuit Protection and Automatic Shutdown Overvoltage ShutdownMotor Overload Shutdown Accessories Section C Accessories SectionTable C.1 AccessoriesLN-25 Option Chart How to use Table C.1Optional Accessories K434-1 GAS Flow Timer KITGAS Solenoid KIT K430-2 for Codes LN-25 Contactor KIT K443-1 for Codes K433 Power Source Remote BOXK432 Remote Control Cable Assembly Remote Output Control Options and Control Cable AssembliesK444, K444-1 or K444-2 Remote Voltage Control KIT K439 Remote Extension Cable AssemblyK625, K626, K627 Remote Control Cable Assembly K624-1 42V Remote Output Control ModuleDIA. Hole Connector Must be Insulated in this AreaTo GUN Switch Connect Leads to Pins a and C Style aMaintenance Section Maintenance Routine MaintenanceAdjusting Speed Sensor Module Calibration of LN-25 Wire Speed Dial LN-25 Theory of Operation Section Figure E.1 Theory of Operation Block DiagramControl Circuit Operation Input Power CircuitTheory of Operation General DescriptionTrigger Circuit Feedback and Control CircuitsLater Models Optional CircuitsContactor GAS SolenoidControl PC Board Fuses Protective Devices CircuitsLN-25 Troubleshooting and Repair Section HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairFeeding Problems Feeding Problems Hall Effect For Codes below 10500 only GAS Solenoid Valve and Solenoid PC Board TestTest Description Materials NeededGAS Solenoid Valve Test ProcedureScrew Wire Reel Retaining Collar Case DoorFigure F.2 Solenoid Leads Troubleshooting and Repair PC Board for K430 GAS Solenoid KIT GAS Solenoid Valve and Solenoid PC Board Test512 624A 621 J11LN-25 For Codes Above 10500 only GAS Solenoid Valve and Control PC Board TestFigure F.5 Control BOX Cover Removal For Codes Above 10500 onlyFigure F.6. Solenoid Leads Solenoid LeadsControl PC Board Solenoid Circuitry Test Figure F.7. Applied Voltage Polarity667 555 691 621 500 512 690 G3425LN-25 Hall Effect Module Test Hall Effect Module Test G2196 539 541 500539 G1757 Figure F.11 Control PC Board Codes Above LN-25 Wire Drive Motor Test Drive Motor Lead IN-LINE Connector Hall Effect Module Contactor & Contactor PC Board Test Contactor & Contactor PC Board Test Contactor Test ProcedureContactor Coil Leads S2096328TROUBLESHOOTING and Repair F-28 Contactor PC Board Test667 J14 LN-25 Tools Required Contactor PC Board ReplacementRepair Procedure Contactor PC Board Replacement33TROUBLESHOOTING and Repair F-33 Figure F.17 Control PC Board Replacement Figure F.21. Control PC Board Codes 9812 and below Control PC Board ReplacementJ14 Figure F.22. Plug Locations for L12253- Control BoardFigure F.24. Control Board Replacement PC Board Screw For Codes below Contactor ReplacementContactor Replacement 40TROUBLESHOOTING and Repair F-40For Codes Above Figure F.26 Phillips Head Screwdriver Wrench Pliers GAS Solenoid Present ReplacementPurge Switch Leads Solenoid Plug J11 GAS Solenoid Valve AND/OR Solenoid PC Board ifFigure F.29. Solenoid Assembly Wiring Codes 9812 and below Figure F.31. GAS Solenoid Assembly for Earlier Codes Phillips Head Screwdriver Wrench Slot Head Screwdriver Mylar Insulation Electrode Cable 48TROUBLESHOOTING and Repair F-48Drive Motor and Gearbox Replacement and Access to Hall Effect ModuleG1757 Figure F.34. Drive Motor Replacement Retest After Repair LN-25 Table of Contents Electrical Diagrams Section Electrical DiagramsOptional 42 Volt Remote Output Control Wiring Diagram Above Code 11140 G4679Wiring Diagram Code 10556 Thru 10500 L10925 Wiring Diagram Code 10100 Thru 10500 L9644 Wiring Diagram below Code 9900 L7545 LN-25 Across the ARC Model Schematic Complete Machine Codes Above 11140 G5366Schematic Complete Machine below Code 9900 only G1833 Schematic Control PC BD Above Code 11140 G4616-5 Schematic Control PC BD Code 10556 Thru 10558 G3424-3 Schematic Control PC BD Code 10100 Thru 10500 G2194 PC Board Assembly Control Abovr Code 11140 L12253-3 L12253L12253-3 G3425 PC Board Assembly Control Code 10556 Thru 10558 G3425-3PC Board Assembly Control Code 10100 Thru 10500 G2196-1 LN-25 Control PC Board Assembly Control below Code 9900 G1757-6Contactor Schematic Contactor PC BD Above Code 10500 M10965Schematic Contactor PC BD Code 10100 Thru 10500 M17621 Electrical Diagrams Electrical Diagrams L10863 PC Board Assembly Contactor Above Code 10500 L10863-1PC Board Assembly Contactor Code 10100 Thru 10500 L9670-1 PC Board Assembly Contactor below Code 9900 L9185-2