Lincoln Electric IM10077 User Manual

Operator’s Manual

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POWER FEED ™25M

For use with machines having Code Numbers:

11743, 11744

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Date Purchased

Code: (ex: 10859)

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IM10077 | Issue D ate Oct- 13

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AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

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 PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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.

SAFETY

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

FOR ENGINE POWERED EQUIPMENT.

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.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, 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 before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

ii

SAFETY

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet 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 accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

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.

iii

cause

SAFETY

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

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. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes 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.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

iv

SAFETY

ELECTROMAGNETIC

COMPATIBILITY (EMC)

CONFORMANCE

Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

INTRODUCTION

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

INSTALLATION AND USE

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons

according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

ASSESSMENT OF AREA

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a. other supply cables, control cables, signaling and telephone cables;

above, below and adjacent to the welding equipment;

b. radio and television transmitters and receivers;

c. computer and other control equipment;

d. safety critical equipment, e.g., guarding of industrial equipment;

e. the health of the people around, e.g., the use of pacemakers and

hearing aids;

f. equipment used for calibration or measurement

g. the immunity of other equipment in the environment. The user shall

ensure that other equipment being used in the environment is compatible. This may require additional protection measures;

h. the time of day that welding or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

METHODS OF REDUCING EMISSIONS

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructio ns. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic

Compatibility (EMC) product standard for arc welding equipment.”

TABLE OF CONTENTS

Page

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ...............................................................................................................A-2

Location................................................................................................................................A-2

High Frequency Protection...................................................................................................A-2

Arclink Control Cable............................................................................................................A-3

Cable Connections ...............................................................................................................A-3

Weld cable Sizes..................................................................................................................A-4

Coaxial Weld Cable..............................................................................................................A-4

Shielding Gas Connection....................................................................................................A-5

Changing The Drive Motor Gears.................................................................................A-5, A-6

Wire Drive Configuration ......................................................................................................A-7

Procedure to Install Drive Rolls and Wire Guides ................................................................A-7

Remote Sense Lead Specification .......................................................................................A-8

Loading Spools of Wire ........................................................................................................A-8

Typical System Configurations.............................................................................................A-9

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Graphic Symbols that appear on this Machine or in this Manual .........................................B-1

Definition of Welding Terms .................................................................................................B-2

General Description..............................................................................................................B-2

Duty Cycle ............................................................................................................................B-2

Recommended Processes, Equipment Limitations, Recommended Power Sources ..........B-3

Case Front Controls .............................................................................................................B-4

On-Off Switch .......................................................................................................................B-5

Power Wave System Operation ...........................................................................B-6 thru B-22

Set-Up Feature Menu for Parameters and Definition ........................................B-23 thru B-31

Dual Procedure/Memory Buttons .......................................................................B-32 thru B-34

Internal Controls .................................................................................................................B-35

Cold Feed / Gas Purge Switch, Light Switch, Heater Switch, Pressure Arm Adjustment ..B-36

2 Step - 4 Step Trigger Operation and Graphics ................................................B-37 thru B-42

Rear Controls .....................................................................................................................B-43

Flow Meter..........................................................................................................................B-44

________________________________________________________________________________

Accessories ....................................................................................................................Section C

Factory Installed Equipment.................................................................................................C-1

Drive Roll Kits ......................................................................................................................C-1

Common Packages with Accessories Used...........................................................C-2 thru C-3

Installation of Water Cooling Kit ...................................................................................C-4, C-5

Water Cooled Guns..............................................................................................................C-6

________________________________________________________________________________

Maintenance....................................................................................................................Section D

Safety Precautions ...............................................................................................................D-1

Routine Maintenance ...........................................................................................................D-1

Periodic Maintenance...........................................................................................................D-1

Calibration Specification.......................................................................................................D-1

________________________________________________________________________________

Troubleshooting .............................................................................................................Section E

How to Use Troubleshooting Guide .....................................................................................E-1

Error Fault Codes .................................................................................................................E-2

Troubleshooting Guide ...........................................................................................E-3 thru E-4

________________________________________________________________________________

Wiring Diagrams & Dimension Prints ...........................................................................Section F

________________________________________________________________________________

Parts Pages ................................................................................................................P-662 Series

_______________________________________________________________________

________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS –

INPUT VOLTAGE and CURRENT

INPUT VOLTAGE ± 10%

40 VDC

RATED OUTPUT @ 104°F (40°C)

DUTY CYCLE

60% rating

GEARING - WIRE FEED SPEED RANGE-WIRE SIZE

GMAW

POWER FEED™ 25M K2536-4, -5

INPUT AMPERES

4A

INPUT AMPERES

500

FCAW

GEARING

Normal Speed

(factory setting)

Extra torque

WFS RANGE

50 – 800 ipm

(2.5 – 20.3m/min)

30 – 400 ipm

(1.3 – 10.4m/min)

WIRE SIZES

.023 – 1/16"

(0.6 – 1.6mm)

.023 – 1/16"

(0.6 – 1.6mm)

WFS RANGE

50 – 800 ipm

(2.5 – 20.3m/min)

30 – 400 ipm

(1.3 – 10.4m/min)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

14.5 Inches 8.5 Inches 23.5 Inches 35 lbs (368 mm) ( 216 mm) (597 mm) (15.9 kg)

Handle folded down

TEMPERATURE RANGE

OPERATION: -40°F to 122°F (-40°C to 50°C) STORAGE: -40°F to 185°F (-40°C to 85°C)

WIRE SIZES

.030 – 5/64"

(0.8 – 2.0mm)

.030 – 3/32"

(0.8 – 2.4mm)

IP23

IEC 60974-5

POWER FEED™ 25M

A-2

SAFETY PRECAUTIONS

INSTALLATION

HIGH FREQUENCY PROTECTION

A-2

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

• Only qualified personnel should perform maintenance work.

------------------------------------------------------------------------

LOCATION

For best wire feeding performance, place the POWER FEED™ 25M on a stable and dry surface. Keep the wire feeder in a vertical position. Do not operate the wire feeder on an angled surface of more than 15 degrees.

CAUTION

Locate the POWER FEED™ 25M away from radio controlled machinery. The normal operation of the POWER FEED™ 25M may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

------------------------------------------------------------------------

Do not submerge the POWER FEED™ 25M.

The POWER FEED™ 25M is rated IP23 and is suitable for outdoor use.

The handle of the POWER FEED™ 25M is intended for moving the wire feeder about the work place only.

When suspending a wire feeder, insulate the hanging device from the wire feeder enclosure.

POWER FEED™ 25M

A-3

A

B

C

D

E

A

B

C

D

E

A

B

C

D

E

A

B

C

D

E

INSTALLATION

ARCLINK CONTROL CABLES

(See Figure A.3) ArcLink Control Cables are available in two forms:

• K1543-xx series for most indoor or factory installations.

• K2683-xx series for outdoor use or when the equipment is frequently moved.

ArcLink/LincNet control cables are special high quality cables for digital communication. The cables are copper 5 conductor cable in a SO-type rubber jacket. There is one 20 gauge twisted pair for network communications. This pair has an impedance of approximately 120 ohms and a propagation delay per foot of less than 2.1 nanoseconds. There are two 12 gauge conductors that are used to supply 40VDC to the network. The fifth wire is 18 gauge and is used as an electrode sense lead.

A-3

Use of non-standard cables may lead to system shutdowns, poor arc starting and wire feeding problems.

The control cables connect the power source to the wire feeder, and the wire feeder to other wire feeders.

Control cables may be connected end to end to extend their length. Use a maximum of 200 ft. (61.0m) of control cable between components.

Figure A.3

POWER SOURCE

Power Source

Pin Function

A ArcLink B ArcLink C "67" voltage sense D 40 VDC E Common

Pin Function

A ArcLink B ArcLink C "67" voltage sense D 40 VDC E Common

WIRE FEEDER

Wire Feeder

CABLE CONNECTIONS

There are two circular connectors on the front of the POWER FEED™ 25M. (See 5-pin and 12-pin Figure A.1)

FIGURE A.1

Function

A 5-pin trigger connector for pushonly guns.

B

C

D

Dual Procedure Selection

E

A

B 12-pin connector for remote control,

H

A

B

J

K

L

C

D

foot/hand amptrol,

G

M

push-pull guns and

F

ArcLink peripher-

E

als

C

75 Remote potentiometer, common

D

76 Remote potentiometer, wiper

E

77 Remote potentiometer, 5K

F

ArcLink Peripheral Sense

G

H

J K L

M

Wiring

Trigger Not used Common

Common

Trigger

40VDC Common

40VDC +

Pull Motor – Pull Motor +

CANL CANH

There is one circular connector on the rear of the POWER FEED™ 25M. Maximum control cable length is 200 ft (61 m). (See Figure A.2)

FIGURE A.2

Function

5-pin ArcLink connector.

A B C

67 Electrode Voltage Sense D E

Wiring

ArcLink ArcLink

40VDC

Common

POWER FEED™ 25M

A-4

Electrode

Work

El ec t r ode

Wor k

El ec t r ode

W

or k

Power Sour ce

Coax i al W

el d Cabl e

Wi r e Feeder

WELD CABLE SIZE

INSTALLATION

To install:

1. Turn the input power off at the welding power source.

Table A.1 located below are copper cable sizes recommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop.

2. Connect one end of the center lead to the power source electrode connection, and the other end to the wire feeder electrode connection.

3. Connect the outer lead bundle to the power source work connection, and the other end to the work piece. Minimize the length of any work lead extension for best

COAXIAL WELD CABLE

(See Table A.2)

results.

4. Insulate all connections.

Coaxial welding cables are specially designed welding cables for pulse welding or STT™ welding. Coaxial weld cables feature low inductance, allowing fast changes in the weld current. Regular cables have a higher inductance which may distort the pulse or STT™ wave shape. Inductance becomes more severe as the weld cables become longer.

Coaxial cables work best for high performance waveforms and when:

• long cables are present.

• the cables are housed in a metal tray.

Power Sour c e

El ect r ode

A coaxial weld cable is constructed with multiple small leads wrapped around one large lead. The large inner lead connects to the electrode stud on the power source and the electrode connection on the wire feeder. The small leads combine together to form the work lead, one end attached to the power source and the other end to the work piece. See Figure A.5

TABLE A.2

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C)**

COAXIAL CABLE LENGTH

AMPERES

250 300 350

DUTY

CYCLE

100%

60% 60%

0 to 25Ft.

(0 to7.6M)

1 1

1/0

25 to 50Ft.

(7.6 to 15.2M)

1 1

1/0

FIGURE A.5

Coaxial W

(15.2 to 22.9M)

el d Cabl e

50 to 75 Ft.

1 1

--

Wi re Feeder

or k

75 to 100 Ft.

(22.9 to 30.5M)

1

1/0

--

A-4

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

200 200 225 225 250 250 250 250 300 325 350 400 400 500

** 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).

PERCENT

DUTY

CYCLE

60

100

20

40 & 30

30 40 60

100

60

100

60 60

100

60

0 to 50Ft. (0 to15M)

2 2

4 or 5

3 3 2 1 1

1 2/0 1/0 2/0 3/0 2/0

50 to 100Ft.

(15 to 30M)

2 2 3 3 3 2 1 1

1 2/0 1/0 2/0 3/0 2/0

100 to 150 Ft.

(30 to 46M)

2 2 2 2 2 1 1 1

1 2/0 2/0 2/0 3/0 3/0

150 to 200 Ft.

(46 to 61M)

1 1 1 1 1 1 1

1 1/0 2/0 2/0 3/0 3/0 3/0

200 to 250 Ft.

(61 to 76M)

1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 2/0 3/0 3/0 4/0 4/0 4/0

POWER FEED™ 25M

A-5

SHIELDING GAS CONNECTION

INSTALLATION

CHANGING THE DRIVE MOTOR GEAR RATIO

A-5

WARNING

CYLINDER may explode if

damaged.

• Keep cylinder upright and chained to support.

• Keep cylinder away from areas where it may be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live electrical circuits.

• BUILD UP OF SHIELDING GAS MAY HARM HEALTH OR KILL.

• Shut off shielding gas supply when not in use.

• See American National Standard Z-49.1, "Safety in Welding and Cutting” Published by the American Welding Society.

------------------------------------------------------------------------

M

AXIMUM INLET PRESSURE IS

Install the shielding gas supply as follows:

100

PSI

. (6.9

BAR

.)

WARNING

• Turn off input power at the welding power source before installation or changing drive roll and/or wire guides.

• Do not touch electrically live parts such as the wire drive or internal wiring.

• When feeding with the gun trigger, the electrode and wire drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Only qualified personnel should perform this operation.

------------------------------------------------------------------------

Extra Torque Gearing

Feed Force

400

Normal Speed Gearing

WFS

800

1. Secure the cylinder to prevent it from falling.

2. Remove the cylinder cap. Inspect the cylinder valves and regulator for damaged threads, dirt, dust, oil or grease. Remove dust and dirt with a clean cloth. DO

NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Inform your gas supplier

of this condition. Oil or grease in the presence of high pressure oxygen is explosive.

3. Stand to one side away from the outlet and open the cylinder valve for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet.

4. Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. Note: if connecting to 100% CO2cylinder, 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 CO2cylinder.

5. Attach one end of the inlet hose to the outlet fitting of the flow regulator. Attach the other end to the welding system shielding gas inlet. Tighten the union nuts with a wrench.

6. Before opening the cylinder valve, turn the regulator 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 stops moving, open the valve fully.

8. The flow regulator is adjustable. Adjust it to the flow rate recommended for the procedure and process being used before making a weld.

Extra Torque Gearing

Normal Speed Gearing

Tools required:

• 1/4" hex key wrench

• 3/4" open end wrench

• 9/16" socket and ratchet wrench

• 7/16" nut driver

• 5/16" nut driver

• Phillips screw driver

1. Turn power off at the welding power source.

. Remove the spool of electrode from the wire feeder.

2

3. Loosen the thumb screw at the wire drive and remove the welding gun.

4. Remove the outer wire guide, drive rolls and inner wire guide.

5. Use a 7/16" nut driver to remove the gear cover.

6. Use 9/16" socket and ratchet wrench to remove the lower drive roll hub retainer. Remove the lower drive roll hub.

7. With a Phillips screwdriver, remove the screw, washer and collar holding the pinion gear. Remove the pinion gear.

POWER FEED™ 25M

A-6

8. Remove the busbar by unscrewing the bolt using a 3/4" open end wrench.

9. With a 1/4" hex key wrench, loosen the socket head cap screw securing the gun bushing. Remove the gun bushing from the wire drive.

10. With a 5/16" nut driver remove the five screws securing

the wire drive panel. Lift out the wire drive panel and disconnect the molex connections.

11. Using a 5/16" nut driver, remove the four screws secur-

ing the cover.

12. With a Phillips screwdriver, remove the three screws

and lock washers securing the motor. Remove the motor.

13. Place the motor in the new position.

14. Assemble the three screws and lock washer holding the

wire drive motor.

15. Assemble the molex connections and place the wire

drive assembly inside the wire feeder. Route the gas hose through the opening in the wire drive panel.

INSTALLATION

A-6

16. Place the gun bushing in the wire drive and align the

threaded hole in the gun bushing with the hole in the feed plate. With a 1/4" hex key, tighten the socket head cap screw to secure the bushing in the wire drive.

17. Reassemble the busbar and tighten the mounting hard-

ware with a 3/4" open end wrench.

18. Place the new gear on the motor shaft. Secure the gear

to the motor shaft with the collar, washer and screw.

19. Reassemble the lower drive roll hub and lower drive roll

hub retainer.

20. Reassemble the gear cover.

21. Reassemble the inner wire guide, drive rolls and outer

wire guide.

22. Place the welding gun into the gun bushing and secure

with the thumb screw.

23. Restore power. Set the appropriate gear ratio using the

set-up menu.

POWER FEED™ 25M

A-7

INSTALLATION

WIRE DRIVE CONFIGURATION

(See Figure A-6)

Changing the Gun Receiver Bushing

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Only qualified personnel should perform maintenance work.

------------------------------------------------------------------------

Tools required:

• 1/4" hex key wrench. Note: Some gun bushings do not require the use of

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

Loosen the socket head cap screw that holds the

5.

connector bar against the gun bushing.

Important: Do not attempt to completely remove the socket head cap screw.

6. Remove the outer wire guide, and push the gun

bushing out of the wire drive. Because of the precision fit, light tapping may be required to remove the gun bushing.

7. Disconnect the shielding gas hose from the gun

bushing, if required.

FIGURE A-6

A-7

8. Connect the shielding gas hose to the new gun bushing, if required.

9. Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate. Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun bushing and tighten the thumb screw.

PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Only qualified personnel should perform maintenance work.

------------------------------------------------------------------------

1. Turn power off at the welding power source.

2. Release the idle roll pressure arm.

3.

Remove the outer wire guide by turning the knurled thumbscrews counter-clockwise to unscrew them from the feed plate.

4. Rotate the triangular lock and remove the drive

rolls.

GUN RECEIVER BUSHING

CONNECTOR BLOCK

THUMB SCREW

SOCKET HEAD CAP SCREW

OUTER WIRE GUIDE

LOOSEN TIGHTEN

5. Remove the inner wire guide.

6. Insert the new inner wire guide, groove side out,

over the two locating pins in the feed plate.

7. Install a drive roll on each hub assembly secure

with the triangular lock.

8. Install the outer wire guide by aligning it with the

pins and tightening the knurled thumbscrews.

9. Close the idle arm and engage the idle roll pressure

arm. Adjust the pressure appropriately

POWER FEED™ 25M

A-8

CONNECT AALL SSENSE LEADS

THE EEND

O

THE WWELD

CONNECT

A

LL

WORK

LEAD

S

AT

THE BBEG

INN

IN

G

OF

THE

WELD

DIRE

C

TI ON

OF

TRAVEL

INSTALLATION

A-8

REMOTE SENSE LEAD SPECIFICATIONS

Welding with Multiple Arcs: ( See Figure A.7)

Special care must be taken when more than one arc is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. Do not combine all of the work leads into one lead. Performing welding in the direction away from the work leads. Connect all of the work sense leads from each power source to the work piece at the end of the weld, such that they are out of the path of the weld current. See Figure A.7

For the best results when pulse welding, set the wire size and wire feed speed the same for all the arcs. When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.

LOADING SPOOLS OF WIRE

WARNING

• Keep hands, hair, clothing and tools away from rotating equipment.

• Do not wear gloves when threading wire or changing wire spool.

• Only qualified personnel should install, use or service this equipment.

------------------------------------------------------------------------

Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.

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.

Squeeze the release bar on the retaining collar and

1. remove it from the spindle.

2. Place the spindle adapter on the spindle, aligning the spindle brake pin with the hole in the adapter.

3. Place the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool. An indicator mark on the end of the spindle shows the orientation of the brake tab. Be certain the wire feeds off of the spool in the proper direction.

OF

L

TH

W

FIGURE A.7

TI O

A

G

INN

4. Re-install the retaining collar. Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle.

AAT TH

F FTH

POWER FEED™ 25M

A-9

INSTALLATION

A-9

TYPICAL SYSTEM CONFIGURATIONS

Standard Features

Arc Performance

• Push-Pull ready for welding aluminum with Pulse and Pulse-on-Pulse™ waveforms.

• STT™ capable when used with STT™ equipped Power Waves.

• Waveform Control Technology™ for welds with good appearance and low spatter, even when welding nickel alloys.

Wire Drive

Patented 2 roll drive system. MAXTRAC™ technology delivers great feeding because:

• Patent pending drive rolls improve traction on solid wire by up to 20%.

• The precision machined, rigid aluminum alloy frame results in maximum drive roll clamping pressure.

Extras:

• Flowmeter with gas control valve

• Push-Pull ready.

• Remote control / Foot amptrol ready.

• Internal heater for keeping condensation off of the spool of wire.

• Internal lights for illuminating the wire drive compartment.

Options

• Water cooling kit for use with water cooled guns.

• Patented split wire guides fully support the wire and virtually eliminate birdnesting.

• No tools required to change the drive rolls and wire guides.

• Patented dual spring pressure arms have sensitivity for feeding soft wires without crushing them, and have plenty of compression force for feeding solid or stiff wires.

• All gear driven rolls for more feeding force.

• Changeable gun bushings easily accept guns from other manufacturers.

• Brass-to-brass connections between the electrode connection and the gun minimize voltage drop variations, resulting in consistent arc performance all day, every day.

• Powerful, quiet motor with integrated tachometer for accurate WFS regulation.

POWER FEED™ 25M

B-1

OPERATION

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE.

B-1

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

WARNING

• ELECTRIC SHOCK CAN KILL. Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Do not operate with covers, panels or guards removed or open.

• Only qualified personnel should perform maintenance work.

----------------------------------------------------------------------

• FUMES AND GASSES can be dangerous.

• Keep your head out of fumes.

Use ventilation or exhaust to

• remove fumes from breathing zone.

----------------------------------------------------------------------

• WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

U

INPUT POWER

ON

OFF

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

0

1

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

----------------------------------------------------------------------

ARC RAYS can burn.

Wear eye, ear and body protec-

• tion.

----------------------------------------------------------------------

SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE UAL.

----------------------------------------------------------------------

FRONT OF THIS OPERATING MAN-

POWER FEED™ 25M

U

I

2

1

2

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

WARNING OR CAUTION

B-2

OPERATION

B-2

DEFINITION OF WELDING TERMS

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding

process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of

single knob control. The machine will select the correct voltage and amperage based on the wire feed speed (WFS) set by the operator.

WFS

• Wire Feed Speed

CC

• Constant Current

CV

• Constant Voltage

GMAW

• Gas Metal Arc Welding

GMAW-P

• Gas Metal Arc Welding-(Pulse Arc)

GMAW-STT

• Gas Metal Arc Welding-(Surface Tension Transfer)

SMAW

• Shielded Metal Arc Welding

FCAW

• Flux Core Arc Welding

CAG

• Carbon Arc Gouging

GENERAL DESCRIPTION

General Physical Description

The POWER FEED™ 25M is a premium portable wire feeder for use with the Power Wave products. The wire feeder features a 2 roll MAXtrac™ drive coupled to a powerful motor for driving wire through difficult situations. The easy-to-use, user interface provides ready access to all welding modes in the Power Wave. Built in memories are included with the POWER FEED™ 25M and allows quick recall of favorite weld procedures. Two cases are available: an engineered aluminum case with replaceable skids, or an impact resistant polycarbonate plastic case.

The heart of the POWER FEED™ 25M is the MAXtrac™ drive. The patented features on the wire drive offer tool-less changing of the drive rolls and the wire guides for quick spool changes. Plus, the drive can be configured for extra torque when feeding large diameter flux cored electrodes.

The POWER FEED™ 25M continues Lincolnʼs lead role of environmental protection for electronics. P.C. boards are potted in epoxy and electrical connections are protected with dielectric grease. Noise suppression components protect the POWER FEED™ 25M from stray signals and keep the feeder from interfering with other digital equipment.

General Functional Description

The POWER FEED™ 25M is best suited for applications were quality welds are expected. Combined with a Power Wave power source, the POWER FEED™ 25M is great for aluminum, nickel, alloy and other difficult to weld materials. Easy to use controls make it a great feeder for consistent results with mild steel applications too.

DUTY CYCLE

The POWER FEED™ 25M is rated for 500 amps, 60% duty cycle. The duty cycle is based on a 10 minute cycle.

For example, when welding at 500 amps, the POWER FEED™ 25M may run continuously for 6 minutes and then must sit idle for 4 minutes.

POWER FEED™ 25M

B-3

OPERATION

RECOMMENDED PROCESSES

• GMAW (CV, Synergic CV, Pulse, STT™, Power, Pulse on Pulse™, Push-Pull)

• FCAW

• SMAW

• GTAW (Lift Start only)

• Solid wires .025" to 1/16"

• Cored wires .035" to 5/64"

• Cored wires .035" to 3/32" when configured for "extra torque"

EQUIPMENT LIMITATIONS

• Works only on ArcLink®Power Wave power sources.

• Maximum gun length is 25ft.(7.6m) for push-only systems.

• Maximum gun length is 50ft.(15.2m) for push-pull systems.

• A remote control/foot amptrol and a push-pull gun may not be connected to the POWER FEED™ 25M simultaneously.

• Maximum spool size is 12 in. (305 mm) diameter

• Maximum spool weight is 44 lb (20 kg).

• Maximum control cable length is 200 ft (61 m).

• Other gun bushings are required for welding guns that do not have a Magnum (Tweco #2-#4 compatible) back end.

• No more than 2 wire feeders may be connected to one ArcLink power source at a time.

B-3

RECOMMENDED POWER SOURCES

• Power Wave®355M

• Power Wave

®

455M

®

455M/STT

®

655/R

®

S350

®

R350

®

i400

POWER FEED™ 25M

B-4

CASE FRONT CONTROLS

(SEE FIGURE B.1)

OPERATION

15. Thermal

Lights when the drive overheats.

B-4

1. Left DISPLAY window

Shows WIRE FEED SPEED or AMPERAGE.

2. Left KNOB

Adjusts values in left display.

3. Status LED

Illuminates a steady green when communicating to the power source properly.

4. Main display

Shows detailed welding and diagnostic information.

5. Left Button

Changes the Main display to show the Weld Mode or UltimArc.

6. Procedure Button

Selects A or B procedure, or gun control.

7. 2-Step/4-Step Button

Toggles between 2-step and 4-step trigger operation.

8. 5-pin connector

Trigger connector for a push-only gun.

16. Set-Up

Lights when feeder is set-up.

17. Right Button

Changes the Main display to show Start Options or End Options.

18. Set Knob

Changes the value on the Main display.

19. Memories Buttons

For selection of common procedures.

FIGURE B.1

1

2

3

4

5

6

13

14

15

16

17

18

9. ON/OFF switch

Controls power to the POWER FEED™ 25M.

10. 3 Amp Circuit Breaker

Protects the 12-pin accessories

11. 12-pin connector

Connection for push-pull guns, remotes

12. Cover

Covers location for optional water cooling line.

13. Right Display window

Shows VOLTAGE or TRIM.

14. Right Knob

Adjusts values in the right display.

7

9

10

11

12

19

8

POWER FEED™ 25M

B-5

OPERATION

9. ON-OFF SWITCH

The On-Off Switch turns the wire feeder power on and off. It does not control the power to the welding power source.

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

• Only qualified personnel should perform maintenance work.

------------------------------------------------------------------------

B-5

LED condition

Steady green Blinking green.

Blinking green, fast

Blinking green followed by blinking red.

STATUS LED

(See Table B.1)

The status LED indicates system status. Normal operation is a steady green light. Note: During normal power-up, the LED may flash red and/or green as the equipment performs self tests.

TABLE B.1

Definition

System okay. The power source and wire feeder are communicating normally. Occurs during a reset and indicates the power source is identifying each component in the system. This is normal for up to 15 seconds after power-up, or if the system configuration is changed during operation. Indicates that one or more pieces of ArcLink equipment are not mapping properly.

Non-recoverable system fault. If the power source or wire feeder status LED is flashing any combination of red and green, errors are present in the system. Read the error code before the machine is turned off.

Instructions for reading the error code are detailed in the Service Manual. Individual code digits are flashed in red with a long pause between digits. If more than one code is present, the codes will be separated by a green light.

STAT

US

To clear the error, turn the power source OFF, and then back ON to reset. See Troubleshooting Section E.

POWER FEED™ 25M

B-6

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OPERATION

POWER WAVE SYSTEM OPERATION

WARNING

The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selection.

------------------------------------------------------------------------

The steps for operating the Power Wave will vary depending upon the user interface of the welding system. The flexibility of the Power Wave lets the user customize operation for the best performance.

B-6

FIGURE B.2

!

WARNING

!

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3 5 5

E

A V

E R W

P O W

4

3

First, consider the desired welding process and the part to be welded. Choose an electrode material, diameter, shielding gas and process (GMAW, GMAWP, GMAW-STT™, etc.)

Second, find the program in the welding software that best matches the desired welding process. The standard software shipped with the Power Waves encompasses a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales representative.

All adjustments are made on the user interface. Because of the different configuration options your system may not have all of the following adjustments. Regardless of availability, all controls are described below.

SMAW (STICK) WELDING

SMAW is most often used for outdoor construction, pipe welding and general repairs. The wire feeder controls Amperage, Output Control and Arc Force during SMAW welding.

During SMAW welding, the user interface sets the weld parameters and the wire drive remains idle.

2

K2202-1 Power Wave®455M

1 K2203-1 Power Wave

K2823-xx Power Wave

K2230-1 POWER FEED™ 10M, Bench

Model

2 K2234-1

POWER FEED™ 10M Dual, Bench Model

K2536-4, -5 POWER FEED™ 25M

3 K2683-xx Heavy Duty ArcLink Cable

K1543-xx ArcLink Control Cable

4 K1842-xx Weld Power Cable, Lug to Lug

K910-xx Ground Clamp

5 K909-xx Electrode Holder

6 K2176-1 Twist-Mate to Lug Cable Adapter

K960-3 Tweco Style Cam Lock Torch

Adapter

®

455M/STT

®

S350

5

The “Volts”-”Trim” control is used to turn the power Source Output ON or OFF. (See Figure B.3)

SMAW Welding (See Figure B.2)

POWER FEED™ 25M

OPERATION

SMAW (STICK) WELDING

SMAW is most often used for outdoor construction, pipe welding and general repairs. The wire feeder controls Amperage, Output Control and Arc Force during SMAW welding.

During SMAW welding the wire drive remains idle.

BASIC OPERATION

B-7B-7

CC STICK MODES

PROCESS

Stick Soft(7018) Stick Crisp(6010)

EFFECT / RANGE

ARC FORCE

(Soft)-10.0 to (Crisp)+10.0

WFS

AMPS

LESS AMPS

194

+

MORE AMPS

CONTROL OPTIONS

MODE

1 2

WELD MODE

UltimArc™ Control

DESCRIPTION Arc Force adjusts the short circuit current for a soft arc, or for a forceful, driving arc. It helps

to prevent sticking and shorting

electrodes,

of organic

ticularity globular transfer types such as stainless and low hydrogen. Arc Force is especially effective for root pass on pipe with stainless electrode and helps to minimize spatter for certain electrodes and procedure as with low hydrogen, etc.

coated

OUTPUT OFF

2

Stick Crisp

par

-

OUTPUT ON

VOLTS TRIM

0

n

+

START OPTIONS

No arc starting

SMAW

SETUP

START OPTIONS

END OPTIONS

options are

(Stick) welding modes.

END OPTIONS

No arc ending options are active for SMAW

(Stick) welding modes.

active for

NOTE: When a remote control pot such as a K936-1 or -2

Hand Amptrol is connected, and P.17 is setup for Stick/Gouge Remote, the pot value will be shown on the left display, but can only be adjusted to the max workpoint. The max workpoint is set by adjusting the left knob. When the left knob is adjusted, the left display will show the max workpoint setting, and will switch back to show the pot setting when the knob is done being adjusted.

POWER FEED™ 25M

B-8

OPERATION

SET-UP, PHYSICAL, NON-SYNERGIC GMAW AND FCAW WELDING

(See Figure B.4)

B-8

Three non-synergic welding modes are available.

Description Mode Used for: GMAW, Standard CV 5 Best for traditional

MIG welding.

Non-synergic GMAW and FCAW welding mimics the welding controls of traditional welding power sources. Voltage and WFS are set as independent variables.

FIGURE B.4

6

4

2

3

GMAW, Power 40 Specialized GMAW

mode.

FCAW 6 Best for self shield-

ed electrodes like Innershield™.

1

5

K2202-1 Power Wave®455M

®

1 K2203-1 Power Wave

K2823-xx Power Wave K2230-1 K2234-1

POWER FEED™ 10M, Bench Model POWER FEED™ 10M Dual, Bench Model

455M/STT

®

S350

K2536-4, -5 POWER FEED™ 25M

2 KP1696-xx, Drive Roll Kit, 2 Roll Feeder

KP1697-xx KP1505-xx, Drive Roll Kit, 4 Roll Feeder KP1507-xx

3 K1543-xx Digital Control Cable

K2683-xx

4 K1842-xx Weld Power Cable, Lug to Lug

K960-3 Tweco Style Cam Lock Torch

Adapter

K910-xx Ground Clamp

5 See Magnum MIG gun

Literature

6 K586-1 Deluxe Regulator for Mixed

Shielding Gases and Gas Hose

POWER FEED™ 25M

B-9

DISPLAY OPTIONS:

Modes 5 and 6:

OPERATION

Mode 40:

B-9

WFS

MPS

300

25.3

VOLTS

TRIM

USER INTERFACE Operation, Non-Synergic GMAW (MIG) and FCAW (Flux Cored) Welding.

WELD MODE

PROCESS

GMAW, STANDARD CV GMAW, POWER MODE FCAW, STANDARD CV

WELD MODE

5

40

6

WFS

MPS

250

EFFECT / RANGE

Preflow Time

Run-In WFS:

Start Procedure

START OPTIONS

.

DESCRIPTION

Adjusts the flows

and Run-In sets the wire feed speed from the time the trigger is pulled until an arc is established or 2.5 seconds. The Start Procedure controls the WFS and Volts for a specified time at the beginning of the weld. During the start time, the machine will ramp up or down from the Start Procedure to the preset Welding Procedure.

time

shielding

after the trigger is

prior to feeding wire.

that

5.7

pulled

VOLTS

TRIM

gas

WELD MODE

ARC CONTROL

EFFECT / RANGE

PINCH (Soft)-10.0 to (Crisp)+10.

*Wave Control in Power Wave

ULTIMARC*

Pinch controls the arc characte-

-ristics when short-arc welding.

0

5

STD CV MIG

SET

DESCRIPTION

®

355 and 455 machines.

SETUP

START OPTIONS

END OPTIONS

EFFECT / RANGE

Spot Timer

Crater Procedure

Burnback:

Postflow Time

END OPTIONS

DESCRIPTION

Adjust the time welding will continue even if the trigger is still pulled. This option has no effect in 4-Step Trigger Mode.

Crater Procedure controls the WFS and Volts for a specified time at the end of the weld after the trigger is released. During the Crater time, the machine will ramp up or down from the Weld Procedure to the Crater Procedure.

The burnback time is the amount of time that the weld output continues after the wire stops feeding. It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start.

Adjusts the time that shielding gas flows after the welding output turns off.

POWER FEED™ 25M

B-10

OPERATION

GMAW (MIG) SYNERGIC WELDING

Synergic welding allows for easy procedure setting. The WFS and Voltage change together to maintain an optimal arc length. During synergic welding , when the WFS (left) knob is rotated, the voltage is adjusted accordingly to maintain a similar arc length. Set-up, Physical

FIGURE B.5

6

B-10

4

2

K2202-1 Power Wave 455M

1 K2203-1 Power Wave 455M/STT

K2823-xx Power Wave S350 K2230-1 K2234-1 K2536-4, -5 POWER FEED™ 25M

2 KP1696-xx, Drive Roll Kit, 2 Roll Feeder

KP1697-xx KP1505-xx, Drive Roll Kit, 4 Roll Feeder KP1507-xx

3 K1543-xx Digital Control Cable

K2683-xx

4 K1842-xx Weld Power Cable, Lug to Lug

K910-xx Ground Clamp

5 See Magnum

Literature

6 K586-1 Deluxe Regulator for Mixed

3

5

POWER FEED™ 10M, Bench Model POWER FEED™ 10M Dual, Bench Model

®

MIG gun

Shielding Gases and Gas Hose

1

POWER FEED™ 25M

B-11

WFS

AMPS

VOLTS

TRIM

220

26.4

Display Operation

Synergic CV programs feature an ideal voltage best

suited for most procedures. Use this voltage as a starting point and adjust if needed for personal prefer-

OPERATION

SYNERGIC CV VOLTAGE DISPLAY

When the voltage knob is rotated, the display will show an upper or lower bar indicating if the voltage is above or below the ideal voltage.

ences.

• Preset voltage above ideal voltage. (upper bar displayed)

• Preset voltage at ideal voltage. (no bar displayed)

• Preset voltage below ideal voltage. (lower bar displayed)

USER INTERFACE Operation, Synergic GMAW(MIG) Welding

B-11

WELD MODE

ELECTRODE AND GAS

Steel

Steel Stainless Stainless

Aluminum 4043 Aluminum 5356 Metal Core --- --- 81 83

CO

2

Ar(Mix) Ar(Mix)

Ar/He/CO

Ar Ar

2

WIRE SIZE

0.030 0.035 0.045 0.052

--- 10 20 24

94 11 21 25 61 31 41 --63 33 43 ---

--- 148 71 ---

--- 151 75 ---

Steel

10

.035

CV CO2

WELD MODE

ARC CONTROL

EFFECT / RANGE PINCH EFFECT (-10.0 to +10.0)

*Wave Control in Power Wave 355 and 455 machines.

ULTIMARC*

Pinch controls the arc characte-

-ristics when short-arc welding.

SET

DESCRIPTION

®

-

POWER FEED™ 25M

EFFECT / RANGE

Preflow Time

Run-in WFS:

Start Procedure

SETUP

START OPTIONS

END OPTIONS

EFFECT / RANGE

Spot Timer

Burnback:

Crater Procedure

Postflow Time

START OPTIONS

DESCRIPTION

Adjust the time welding will continue even if the trigger is still pulled. This option has no effect in 4-Step Trigger Mode.

The burnback time is the amount of time that the weld output continues after the wire stops feeding. It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start. Crater Procedure controls the WFS and volts for a specified time at the end of the weld after the trigger is released. During the Crater time, the machine will ramp up or down from the Weld Procedure to the Crater Procedure.

Adjusts the time that shielding gas flows after the welding output turns off.

DESCRIPTION

Adjusts the time gas

flows

pulled and Run-In sets the wire feed speed from the time the trigger is pulled until an arc is established or 2.5 seconds. The Start Procedure controls the WFS, Volts at a specified time at the beginning of the weld. During the start time, the machine will ramp up or down from the Start Procedure to the preset Welding Procedure.

that shielding

after the

prior to feeding.

trigger

is

B-12

OPERATION

B-12

STEEL AND STAINLESS SYNERGIC GMAW-P (PULSED MIG) WELDING

Synergic GMAW-P (Pulsed MIG) welding is ideal for low spatter, out of position and reduced heat input applications. During pulse welding, the welding current continuously switches from a low level to a high level and then back again. Each pulse sends a small droplet of molten metal from the wire to the weld puddle.

Pulse welding controls the arc length with 'Trim' instead of voltage. When trim (arc length) is adjusted, the Power Wave automatically recalculates the voltage, current and time of each part of the pulse waveform for the best result. Trim adjusts the arc length and ranges from 0.50 to 1.50. Increasing the trim value increases the arc length, while decreasing the trim value decreases the arc length.

FIGURE B.6

Trim .50

Arc Length Short

Trim 1.00

Arc Length Medium

Trim 1.50

Arc L ength Long

ULTIMARC*

For steel and stainless pulse modes, UltimArc regulates the focus or shape of the arc. UltimArc values greater than 0.0 increase the pulse frequency while decreasing the background current, resulting in a tight, stiff arc best for high speed sheet metal welding. UltimArc values less than 0.0 decrease the pulse frequency while increasing the background current, for a soft arc good for out-of-position welding.

FIGURE B.7

A rc Con trol -10.0

Low F requency, Wi de

A rc Con trol OFF

Med ium Fr equency and Width

Arc Control +10.0

High Frequency , Fo cu sed

*Wave Control in Power Wave® 355 and 455 machines.

POWER FEED™ 25M

B-13

OPERATION

SYNERGIC GMAW-P (PULSED MIG) WELDING

FIGURE B.8

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W A V E 3 5 5

E R

W

P O

B-13

1

2

4

5

6

K2202-1 Power Wave 455M

1 K2203-1 Power Wave 455M/STT

K2823-xx Power Wave S350

K2230-1 POWER FEED™ 10M, Bench Model K2234-1 K2536-4, -5 POWER FEED™ 25M

2 KP1696-xx, Drive Roll Kit, 2 Roll Feeder

KP1697-xx KP1505-xx, Drive Roll Kit, 4 Roll Feeder

KP1507-xx 3 K1543-xx, K2683-xx Digital Control Cable 4 K1796-xx, Coaxial

K960-3 Tweco Style Cam Lock Torch Adapter

5 K910-xx Ground Clamp 6 See Magnum

®

Literature

7 K586-1 Deluxe Regulator for Mixed

POWER FEED™ 10M Dual, Bench Model

Weld Power Cable, Lug to Lug

MIG gun

Shielding Gases and Gas Hose

POWER FEED™ 25M

B-14

OPERATION

DISPLAY OPERATION

B-14

WFS

AMPS

220

Operation, Steel and Stainless GMAW-P (Pulsed MIG) Welding

WELD MODE

ELECTRODE AND

Steel(Crisp) Steel(Soft) Stainless Stainless

Stainless

GAS

Ar(Mix)

Ar/

CO

2

Ar/

CO

2

Ar/He/CO

0.030 0.035 0.045 0.052

2

WIRE SIZE

95 12 22 26

---

14 19 28 66 36 46 --62 32 42 ---

--- 34 44 ---

EFFECT / RANGE

Preflow Time

Run-In

Start Procedure

Steel

12

.035

SETUP

Pulse ArMix

WFS:

VOLTS

1.06

START OPTIONS

DESCRIPTION

Adjusts the time that shielding

gas

flows

and

pulled Run-in sets the wire feed speed from the time the trigger is pulled until an arc is established or 2.5 seconds.

The Start Procedure controls the WFS, Trim at a specified time at the beginning of the weld. During the start time, the machine will ramp up or down from the Start Procedure to the preset Welding Procedure.

TRIM

after

the trigger

prior to feeding wire.

is

WELD MODE

ARC CONTROL

SET

ARC FOCUS

-10.0 (SOFT to

10.0 (STIFF)

*Wave Control in Power Wave 355 and 455 machines.

ULTIMARC*

DESCRIPTION

Arc Focus adjusts the arc from a wide, soft arc good for out of position work to a narrow, stiff arc preferred for faster travel speeds. The pulse frequency is lower with a soft arc and higher with a stiff arc.

®

START OPTIONS

END OPTIONS

EFFECT / RANGE

Spot Timer

Burnback:

Crater Procedure

Postflow Time:

END OPTIONS

FUNCTION

Adjust the time welding will continue even if the trigger is still pulled. This option has no effect in 4-Step Trigger Mode.

The burnback time is the amount of time that the weld output continues after the wire stops feeding. It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start. Crater Procedure controls the WFS and Trim for a specified time at the end of the weld after the trigger is released. During the Crater time, the machine will ramp up or down from the Weld Procedure to the Crater Procedure.

Adjusts the time that shielding gas flows after the welding output turns off.

POWER FEED™ 25M

B-15

OPERATION

B-15

ALUMINUM SYNERGIC GMAW-P (PULSED MIG)AND GMAW-PP (PULSE ON PULSE) WELDING

The POWER FEED™ 25M and Power Wave welding power source combine to readily produce top quality aluminum welds with excellent appearance, little spatter and good bead shape. Push-pull guns are available for consistent feeding when welding a long distance away from the wire feeder.

Pulse-on-Pulse Welding

The Power Wave system offers both traditional pulse and Pulse-on-Pulse™. Pulse-on-Pulse (GMAW-PP) is an exclusive waveform for aluminum welding. Use it to make welds with a "stacked dime" appearance, similar to GTAW welds.

FIGURE B.9

FIGURE B.11

Frequency Modulation = 10

Narrow weld and ripple spacing, fast travel speed.

The pulsing frequency is adjustable. Changing the frequency modulation (or UltimArc) of the waveform changes the ripple spacing. Faster travel speeds may be achieved by using higher values of frequency modulation.

FIGURE B.10

Frequency Modulation = -10

Wide weld and ripple spacing, slow travel speed.

POWER FEED™ 25M

B-16

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la

o r e e t d

o lo r e

m a g n

a a liq u

a m e ra

t

L o re

m ip s

u m d o

lo r s it

a m e t c

on se c

t e tu e r a d

ip i s c in g

e lit

, e d

d ia m

n o n u

m m y n i

b h e u is

m o d tin

c i d u n t u

t

la o re

e t d o

lo r e m

a g n a

a liq u a m

e r a t

L o r e m

ip s u m

d o l o r s

i t a m e

t c o n

s e c te

tu er a d

i p is c in

g

e

lit, e d d

ia m n o

n u m m y n

ib h e

u i sm

o d ti n

c id u n t u

t

l a o re

e t d o lo

r e m a g

n a a liq u

a m e

r a t

L o re

m ip s

u m d o lo

r s it a m

et c o n s

e c te tu

e r a d

ip i sc in

g

e

li t, e d

d ia m

no n u m m

y n ib h

e u is m o

d tin ci

d u n t u

t

l a o r e

e t d o

lo re m

a g n a a

l iq u a m

e r a t

L o

re m ip

s u m

d o lo r s i t am

e t c o n

s e c t

e tu e r

a d ip is c

in g

e l it , e

d d ia m

n o n

u m m y n ib h

e u is m

o d tin

c id u n

t u t

la o re e t d

o lo r e m

a g n

a a liq u a m e

ra t

L o r

e m ip

s u m d o l

o r si t a

m e t c

o n s e c te tu e

r a d ip

i sc in g

e lit, e d

d ia m

n o n u m

m y n ib

h e u is

m o d tin c id

u n t u t

la o

r ee t d o

l o r e m

a g n a a

liq u a m

e r a t

L o r e m

i p s u m

d o lo r

s it a m e

t c o n s e

c te t u

e r a d i p i s c in

g

e l it, e d d ia

m n o n

u m m

y n i b h e

u is m o

d tin c i

d u n t u t

la o re

e t d o l o r

e m a g n

a a li q

u a m e r a

t

L o re m

ip s u

m d o lo

r s i t a m

e t c o n

s e c te t

u e r a d i p

is c in g

e lit

, e d d

ia m n

o n u m

m y n ib h

e u is m

o d tin

c id u n t u t

l a o r e

e t d o lo

re m a

g n a a

liq u a m e

r a t

L o r e m

i p s u

m d o

lo r s i t a

m e t c

o n s

e c te

t u e r a d

i p i s c

in g

e lit

, e d d

ia m

n o n u

m m y n ib

h e u

is m o

d tin

c i d u n

t u t

la o r e

e t d o lo

r e m

a g n

a a li q u a

m e r a

t

L o

r e m ip

s u m d

o lo r s

i t a m

e t c o n s

e c te

t u e r

a d ip

is c i n g

e l it , e

d d ia

m n o n

u m m

y n ib

h e u i s m

o d t in

c i d u

n t u

t

la

o r e e t

d o l o r

e m a g n

a a liq

u a m

e r a t

L

o r e m ip

s u m d

o lo

r s i t

a m e

t c o n s

e c t e

t u e r a

d ip

is c i n

g

e lit,

e d d ia

m n o

n u m

m y n

ib h e

u is m

o d ti

n c i d u

n t u

t

la

o r e

e t d o

lo r e

m a g

n a a

liq u

a m e

r a t

L o r e m

i p s

u m

d o l o

r s it

a m e

t c o

n s e c

te t u e

r a d ip

is c i n

g

e li

t, e d

d ia m

n o

n u m

m y n

ib h

e u i s

m o d tin

c i d

u n t u

t

la o r e

e t d o

lo r e

m a

g n a

a liq u

a m

e r a t

L o re m

i p s u

m d o

lo r s it a m

e t c o n

s e c t e t ue

r a d ip

is c in

g

e

li t , e d d

ia m n

o n u m

m y n ib h

e u is m

o d tin c i d

u n t u

t

la o re

e t d o l o

r e m a

g n a a

l iq u a m e

r a t

L

o re m ip

s u m d

o lo r s

it am

e t c o n se

c t e tu e

r a d ip is c

in g

e lit , e

d d ia

m n o n u

m m y

n ib h e

u is m o

d ti n c id

u n t u t

la

o r e e t d

o lo re

m a g n a

a liq u

a m e

ra t

OPERATION

B-16

ALUMINUM GMAW-P AND GMAW-PP WELDING

Set-up, Physical

Keep the electrode protected by using a spool cover or a feeder which encloses the spool. Use a heater kit with the feeder if available. If high humidity or condensation is present, store the wire in the original packaging when not welding.

FIGURE B.14

7

!

WARNING

!

W

AR

Lo r e m

e

ip li t

su , e

NING

m

lao

d

olo

i

r

a

e

m e

r

t d

sit a

L

n

or

on

o

e

lo

u

m

r

m

e

ip

m

t

li

co

t

su

y n

, e

ag m

nse

d

ib

n

la

d

a

h e

o

ct

o

i

a

r

a

e

lor

liq

et

m

u

e

ism

u

t

u

d

n

si

e

am

L

o

t

r

o

or

a

od

n

a

lor

!

u

er

e

m

d

m

tin

e

ip

e

a

e

m

t c

iscin

t

i

cid

p

lit, e

y n a

sum

o

gn

un

n

i

g

s

b

lao

d

a

ecte

t

h

A

do

d

ut

a

euism ia r

li

e

lo

q

m

tu

e

ua

r

t d

n

e

TT

sit a

r

m

o

od

a

o

n

e l

dip

o

um

tincid

m

L

ra r

e

o

et

i

t

sc

m

r

m

e

con

y n

i

!

m

a

n

un

e

g

ip

A

ib

n

t u

secte l it

a

E

sum

h

, e

aliq

t

e

la

d

u

tue

d

i

VISO

sm

u

o

ia

a

r

N

e

r

l

m

o

m

od e

a

r

e

t d

n

s

dip

tin

r

i

o

t

a

o

a

n

i

t

s

lor

cid

um

P

ci

m

TION

e

n

un

et co

L

m

g

o

t u

y n

r

ag e m

n

t

R

ib

n

se

ipsu

elit, e

a

h

ct

e

a

Lo

liqu

e

u

m

tu

ism

r

la

d

e

E

d

e

am

m

d

o

DE

r

o

ia

od

a

r

ipsu

e

l

er

o

m

lit, e

dipiscin

et

L

r

tin

o

sit a

a

no

d

C

r

m

t

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d

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n

m

d l o

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u

o

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u

m

olor

r

m

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re

g

n

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lit,

e

m

t

m

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ut

t

n

AUCIO

sit a

con

ed

y

L

m

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tin

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re

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p

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a

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sc

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i

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u

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u

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u t

V E 3 5 5

P O W E R W A

W

A R

NI NG

R E MO

T E

P O W E

R

ON

O

F F

1

3

4

2

5

K2368-1 Power Wave®355M

®

1 K2202-1 Power Wave

K2203-1 Power Wave K2230-1 POWER FEED™ 10M, Bench Model

Requires K1634-1 Spool cover

K2234-1

2

POWER FEED™ 10M Dual, Bench Model

Requires K1634-1 Spool cover K2536-4, -5 POWER FEED™ 25M KP1695-xx Drive Roll Kit, 2 Roll Feeder KP1507-xx Drive Roll Kit, 4 Roll Feeder

3 K1543-xx, K2683-xx Digital Control Cable 4 K1796-xx, K2593-xx Coaxial 5 K910-xx Ground Clamp 6 K2447-xx Python Plus Gun, Air cooled

Deluxe Regulator for Mixed

7 K586-1 Shielding Gases

Shielding Gas Hose

455M

®

455M/STT

Weld Power Cable, Lug to Lug

6

POWER FEED™ 25M

B-17

OPERATION

Display Operation

B-17

WFS

AMPS

220

1.06

VOLTS

TRIM

USER INTERFACE Operation, Aluminum GMAW-P (Pulsed MIG) and GMAW-PP (Pulse on Pulse) Welding

WELD MODES

ELECTRODE AND GAS

ALUMINUM 4043 ALUMINUM 4043 ALUMINUM 5356 ALUMINUM 5356

Ar Ar Ar Ar

72

WIRE SIZE

0.035 3/64 1/16

149 72 74

98 99 100 152 76 78 101 102 103

Aluminum 3/64

SETUP

START OPTIONS

EFFECT / RANGE

Preflow Time

WFS:

Run-In

Start Procedure

DESCRIPTION

Adjusts the time that shielding

gas

flows

pulled

and

Run-in sets the wire feed speed from the time the trigger is pulled until an arc is established or 2.5 seconds. The Start Procedure controls the WFS. Trim at a specified time at the beginning of the weld. During the start time, the machine will ramp up or down from the Start Procedure to the preset Welding Procedure.

the trigger is

after

prior to feeding wire.

4043 Pulse Ar

WELD MODE

ARC CONTROL

SET

PULSE FREQUENCY: (Low)-10.0 to (High)+10.0

PULSE-ON-PULSE FREQ.MODULATION

(Low)-10.0 to (High)+10.0

*Wave Control in Power Wave 355 and 455 machines.

ULTIMARC*

DESCRIPTION

For Pulse changes the pulsing frequency. When the frequency changes, the Power Wave system automatically adjusts the background current to maintain a similar heat input into the weld. Low frequencies give more control over the puddle and high frequencies minimize spatter.

For Pulse -On-Pulse modes, Arc controls changes the frequency modulation. The freque-

-ncy modulation controls the spacing of the ripples in the weld. Use low values for slow travel speeds and wide welds, and high values for fast travel speeds and narrower welds.

modes, Arc Control

®

START OPTIONS

END OPTIONS

Postflow Time:

EFFECT / RANGE

END OPTIONS

Spot Timer

Burnback:

Crater Procedure

FUNCTION

Adjust the time welding will continue even if the trigger is still pulled. This option has no effect in 4-Step Trigger Mode.

The burnback time is the amount of time that the weld output continues after the wire stops feeding. It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start. Crater Procedure controls the WFS and Trim for a specified time at the end of the weld after the trigger is released. During the Crater time, the machine will ramp up or down from the Weld Procedure to the Crater Procedure.

Adjusts the time that shielding gas flows after the welding output turns off.

POWER FEED™ 25M

B-18

OPERATION

B-18

GMAW-STT™ WELDING

Surface Tension Transfer, or STT™ welding, is a

break-through process offered exclusively by the Lincoln Electric Company. STT™ is a low heat, low spatter process created with Waveform Control Technology™. STT™ is the process of choice for open root welding, welding on thin materials or welding on parts with poor fit-up. Low spatter, even when using 100% CO in gas and part clean-up.

Several sets of STT™ weld modes are available.

• Non synergic modes provide individual control of peak current, background current and tail-out. Some modes also provide for adjustment of hot start.

• Synergic STT™ modes keep the arc characteristics the same when the wire feed speed is changed.

Note that STT™ is available only with specially equipped Power Wave power sources, like the Power Wave 455M/STT or the Power Wave S350 + STT Module.

2 shielding gas, results in cost savings

FIGURE B.15

8

3

1

2

4

For best results:

• Attach the work sense lead as close as possible to the welding arc.

• Use only solid steel, stainless steel or silicon bronze electrodes.

1 K2203-1 Power Wave 455M/STT

2 K2536-4, -5 POWER FEED™ 25M

3 K1543-xx Digital Control Cable

4

5 K910-xx Ground Clamp 6 K940-xx Sense Lead Kit

7 See Magnum

8 K586-1 Deluxe Regulator for Mixed

6

5

l

K2823-xx + K2902-1 K2230-1 K2234-1

7

Power S350 + STT Module POWER FEED™ 10M, Bench Model POWER FEED™ 10M Dual, Bench Mode

KP1696-xx Drive Roll Kit, 2 Roll Drive KP1505-xx Drive Roll Kit, 4 Roll Drive

K2683-xx Heavy Duty ArcLink Control Cable K1796-xx, K2593-xx

Coaxial Weld Power Cable, Lug to Lug

K960-3 Tweco Style Cam Lock Torch Adapter

®

MIG Gun

Literature

Shielding Gases and Gas Hose

POWER FEED™ 25M

B-19

OPERATION

GMAW-STT™

Waveform Control Technology™ maximizes the

ability to modify the arc for the perfect weld. When STT™ welding, the parameters to control are:

• Wire Feed Speed - sets the deposition rate.

• Peak Current - controls the arc length.

• Background Current - regulates the bead contour.

• Tail-out - provides additional power in the arc.

USER INTERFACE Operation, GMAW-STT™ Welding

WFS

AMPS

220

----

B-19

VOLTS

TRIM

STEEL

109

.035”

STT

WELD MODE

ARC CONTROL

SET

ULTIMARC*

EFFECT / RANGE

PEAK CURRENT

agitation.

BACKGROUND

CURRENT

TAIL OUT

(

STT ll MODES

ONLY)

*Wave Control in Power Wave 355 and 455 machines.

without the molten

Often this results in

DESCRIPTION

Peak Current acts similar to an control. Peak Current

promotes

and current levels will cause momentarily set too high, globular transfer Setting it too low and wire adjust for minimum spatter and

Background Current controls heat input in the

Tail out provides additional

too large. heat input without increasing

Note that current to be reduced.

while increasing arc length. If

stubbing.

Increase as necessary to add

as tail out increases, the peak

and/or background current

sets the arc length

good fusion.

®

the arc to broaden

may cause instability

practice is to

Best

weld.

droplet becoming

faster travel speeds.

pinch

arc

Higher

may occur.

puddle

overall

the

power

arc length.

may need

SETUP

START OPTIONS

END OPTIONS

peak

EFFECT / RANGE

Preflow Time

Run-In

WFS:

Start Procedure

EFFECT / RANGE

Crater Procedure

Burnback:

Postflow Time:

START OPTIONS

Adjusts the time that shielding

gas

pulled and

Run-in sets the wire feed speed from the time the trigger is pulled until an arc is established or 2.5 seconds.

The Start Procedure is not commonly used with STT procedures.

END OPTIONS

Crater is not commonly used in STT weld procedures.

The burnback time is the amount of time that the weld output continues after the wire stops feeding. It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start.

Adjusts the time that shielding gas flows after the welding output turns off.

FUNCTION

flows

after

prior to feeding wire.

FUNCTION

the trigger

is

POWER FEED™ 25M

B-20

OPERATION

PEAK CURRENT (Figure B.16)

Peak current controls the arc length, which also affects the shape of the root. When using 100% CO the peak current will be higher than when welding with blended shielded gases. A longer arc length is required with CO

2 to reduce spatter.

FIGURE B.16

B-20

2,

Peak Current Too Low

Background Current Too Low

Peak Current Optimum

BACKGROUND CURRENT (Figure B.17)

Background current adjusts the overall heat input into the weld. Changing the background current changes the shape of the back bead. 100% CO background current than when welding with blended shielding gases.

FIGURE B.17

Background Current Optimum

2 requires less

Peak Current Too High

Background Current Too High

TAILOUT

Tailout provides additional heat into the weld without increasing the arc length or the droplet size. Higher tailout values improve wetting and may give faster travel speeds.

POWER FEED™ 25M

B-21

OPERATION

GTAW (TIG) WELDING

The POWER FEED™ / Power Wave system is excellent for Touch Start TIG welding.

The system supports TIG torches with or without gas control valves. TIG torches with gas control valves connect directly to the gas flow regulator. For TIG torches without gas control valves, connect the output gas hose on the wire feeder to the TIG torch gas hose.

The wire feeder gas solenoid may be enabled or disabled by parameter P.8 in the set-up menu found in this operations section.

B-21

Touch Start TIG Weld Sequence

TIG torches without built-in Gas Valves.

TIG torches with built-in Gas Valves.

No Foot / Hand Amptrol

1. Adjust the arc amperage with the left knob on the display panel.

2. Turn the right knob on the display panel until the Output Control is ON. Gas will start to flow.

3. Touch the tungsten to the work piece.

4. Lift the tungsten to create an arc and weld.

5. Stop welding by turning the Output Control to OFF, or by pulling away the tungsten from the work.

6. Gas flow will continue for a short time and then shut-off.

1. Adjust the arc amperage with the left knob on the display panel.

2. Turn the right knob on the display panel until the Output Control is ON.

3. Open the gas valve on the TIG torch.

4. Touch the tungsten to the work piece.

5. Lift the tungsten to create an arc and weld.

6. Stop welding by turning the Output Control to OFF, or by pulling away the tungsten from the work.

7. Close the gas valve on the TIG torch.

With Foot / Hand Amptrol

1. Adjust the maximum arc amperage with the left knob on the display panel.

2. Touch the tungsten to the work piece.

3. Press the foot pedal or slide the hand amptrol a slight amount. Gas will start to flow.

4. Lift the tungsten to create an arc.

5. Regulate the arc current with the foot pedal or hand amptrol.

6. Stop welding by releasing the foot pedal or hand amptrol, or by pulling the tungsten away from the work.

7. Gas will continue for a short time and then shut-off.

1. Adjust the maximum arc amperage with the left knob on the display panel.

2. Touch the tungsten to the work piece.

3. Press the foot pedal or slide the hand amptrol a slight amount.

4. Open the gas valve on the TIG torch.

5. Lift the tungsten to create an arc.

6. Regulate the arc current with the foot pedal or hand amptrol.

7. Stop welding by releasing the foot pedal or hand amptrol, or by pulling the tungsten away from the work.

8. Close the gas valve on the TIG torch.

POWER FEED™ 25M

B-22

Lo

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OPERATION

B-22

GTAW (TIG)WELDING (Figure B.17a)

WARNING

Do not connect a high frequency arc starting kit to the Power Feed / Power Wave system.

FIGURE B.17a

8

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Display Operation

Maximum Amperage

WFS

AMPS

220

OFF

USER INTERFACE Operation, GTAW (Touch Start TIG) Welding.

WELD MODE

TOUCH START 3

MODE

START OPTIONS

No Arc starting options are active for Touch Start TIG.

3

SETUP

Touch Start TIG

WELD MODE

ARC CONTROL

ULTIMARC

No Arc Controls are active for Touch Start TIG.

EFFECT DESCRIPTION

Crater Time Function

0 To 10 seconds

SET

END OPTIONS

During the Crater time, the machine will ramp up or down from the Weld Procedure to the Crater Procedure.

START OPTIONS

END OPTIONS

VOLTS

TRIM

K2202-1 Power Wave® 455M 1 K2203-1 Power Wave® 455M/STT K2823-xx Power Wave® S350 K2230-1 POWER FEED™ 10M, Bench Model (requires K2320-1 connector kit) 2 K2234-1 POWER FEED™ 10M Dual, Bench Model (requires K2320-1 connector kit) K2536-4, -5 POWER FEED™ 25M 3 K1543-xx ArcLink Control Cable K2683-xx Heavy Duty ArcLink Control Cable 4 K1842-xx Weld Power Cable, Lug to Lug 5 K910-xx Ground Clamp 6 K1782-xx, K1783-xx PTA-17, PTA-26 TIG torch (shown with valve) 7 K870-xx Foot Amptrol 8 3100211 Harris Argon Flow Regulator

WELD MODE SEARCHING

The Weld Mode Search feature allows the selection of a welding mode based on certain criteria (wire size, process type, etc.).

SEARCHING FOR A WELD MODE

During the search process, pressing the right pushbutton typically acts as a “next” button and the left pushbutton typically acts as a “back” button.

Rotate the control knob then press the right pushbutton to select relevant welding details such as welding process, wire type, wire size, etc.

To search for a mode, turn the control knob until “Weld Mode Search” is displayed. This will appear in between the highest and the lowest weld mode numbers.

Once “Weld Mode Search” is displayed, pressing the right pushbutton labeled “Begin” will start the search process.

When the final selection is made, the Feeder will automatically change to the weld mode found by the Weld Mode Search process.

Earlier products may not have this feature. To activate this feature, a software update may be needed from www.powerwavesoftware.com

POWER FEED™ 25M

B-23

OPERATION

B-23

SETUP MENU FEATURES

The Setup Menu gives access to the Setup Configuration. Stored in the setup configuration are user parameters that generally only need to be set at installation. The parameters are grouped as shown in the following table.

PARAMETER

P.1 through P.99 P.101 through P.199 P.501 through P.599

1. To access the set-up menu, press the right and left

2. After changing a parameter it is necessary to press

3. To exit the set-up menu at any time, press the

DEFINITION

Unsecured Parameters (always adjustable)

Diagnostic Parameters (always read only)

Secured Parameters (only accessible through a p.c. or palm application)

SET-UP FEATURES MENU

(See Figure B.17b)

buttons of the user interface panel simultaneously. Note that the set-up menu cannot be accessed if the system is welding, or if there is a fault (The status LED is not solid green).

Change the value of the blinking parameter by rotating the SET knob.

the Right hand button to save the new setting. Pressing the Left button will cancel the change.

Right and Left buttons of the MSP4 panel simultaneously. Alternately, 1 minute of inactivity will also exit the set-up menu.

Status LED

FIGURE B.17b - SETUP MENU

Left

button

SET Knob

Right

button

Main display

POWER FEED™ 25M

B-24

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.0 Exit Setup Menu

This option is used to exit the setup menu. When P.0 is displayed, press the Left Button to exit the setup menu.

P.1 Wire Feed Speed Units

This option selects which units to use for displaying wire feed speed. English = inches/minute wire feed speed units (default). Metric = meters/minute wire feed speed units.

P.2 Arc Display Mode

This option selects what value will be shown on the upper left display while welding. Amps = The left display shows Amperage while welding (default). WFS = The left display shows Wire Feed Speed while welding.

P.3 Display Options

This setup parameter was previously named "Display Energy"

If the previous software revision had this parameter set to display energy, that selection will remain.

B-24

This option selects the information displayed on the alphanumeric displays while welding. Not all P.3 selections will be available on all machines. In order for each selection to be included in the list, the power source must support that feature. A software update of the power source may be needed to include the features.

Standard Display = The lower displays will continue to show preset information during and after a weld (default). Show Energy = Energy is displayed, along with time in HH:MM:SS format. Show Weld Score = The accumulative weld score result is shown

P.4 Recall Memory with Trigger

This option allows a memory to be recalled by quickly pulling and releasing the gun trigger. To recall a memory, quickly pull and release the trigger the number of times that correspond to the memory number. For example, to recall memory 3, quickly pull and release the trigger 3 times. To recall memory 1, quickly pull and release the trigger the number of user memories plus 1. Memories cannot be recalled while the system is welding.

Disabled = The gun trigger cannot be used to recall user memories (default). Enabled = The gun trigger can be used to recall user memories.

POWER FEED™ 25M

B-25

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.5 Procedure Change Method

This option selects how remote procedure selection (A/B) will be made. For some products the selected procedure can be changed locally at the user interface by pressing the 'A-Gun-B' button. Other products do not have this button and must use a Cross-switch gun or wire into the procedure select input. The following methods can be used to remotely change the selected procedure:

LF45 and C300CE:

Quick Trigger = Allows switching between Procedure A and procedure B while welding with 2-stroke mode. The Cross-switch gun or remote control is required. To operate:

• Select "Procedure A/B" in P.25 to set up parameters for A and B procedures.

• Start the weld by pulling the gun trigger. The system will weld with procedure A settings.

• While welding, quickly release and then pull the gun trigger. The system will switch to procedure B settings. Repeat to switch back to procedure A settings. The procedure can be changed as many times as needed during the weld.

• Release the trigger to stop welding. When the next weld is made, the system will start again with procedure A.

IntegralTrigProc = Allows switching between Procedure A and procedure B while welding with 4-stroke mode. When in 2-step, the system operates identical to the External Switch selection. To operate in 4step:

• Select "Procedure A/B" in P.25 to set up parameters for A and B procedures.

• Start the weld by pulling the gun trigger. The system will weld with procedure A settings.

• While welding, quickly release and then pull the gun trigger. The system will switch to procedure B settings.

• Release the trigger to stop welding. When the next weld is made, the system will start again with procedure A.

B-25

External Switch = Dual Procedure selection may only be performed by the Cross-switch gun or remote control (default).

All Other Products:

External Switch = Dual Procedure selection may only be performed at the memory panel or an external switch (e.g. K683).

Quick Trigger = The selected procedure can be changed remotely by releasing and re-pulling the trigger quickly while welding. This feature is disabled in 4-Step trigger mode. The external procedure switch is disabled. To operate:

• Select "GUN" on the memory panel (for products that have an 'A-Gun-B' button).

• Start the weld by pulling the gun trigger. The system will weld with procedure A settings.

• While welding, quickly release then pull the gun trigger once. The system will switch to procedure B settings. Repeat to switch back to procedure A settings. The procedure can be changed as many times as needed during the weld.

• Release the trigger to stop welding. The system will automatically return to procedure A settings.

IntegralTrigProc = When using a Magnum DS dual-schedule gun (or similar) that incorporates a procedure switch in the gun trigger mechanism. While welding in 2-step, machine operation is identical to the "External Switch" selection. When welding in 4-step, additional logic prevents procedure A from being reselected when the trigger is released at step 2 of the 4-step weld sequence. The machine will always operate in 2-step if a weld is made exclusively in procedure A, regardless of the 2/4 step switch position (this is intended to simplify tack welding when using a dual-schedule gun in 4-step)

.

POWER FEED™ 25M

B-26

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.7 Gun Offset Adjustment

This option adjusts the wire feed speed calibration of the pull motor of a push-pull gun. This should only be performed when other possible corrections do not solve any pushpull feeding problems. An rpm meter is required to perform the pull gun motor offset calibration. To perform the calibration procedure do the following:

1. Release the pressure arm on both the pull and push wire drives.

2. Set the wire feed speed to 200 ipm.

3. Remove wire from the pull wire drive.

4. Hold an rpm meter to the drive roll in the pull gun.

5. Pull the trigger on the push-pull gun.

6. Measure the rpm of the pull motor. The rpm should be between 115 and 125 rpm. If necessary, decrease the calibration setting to slow the pull motor, or increase the calibration setting to speed up the motor.

The calibration range is -30 to +30, with 0 as the default value.

Note: The range was changed to -90 to +90 for the PF25M in WD software S28539-3. Default value remains at 0.

P.8 TIG Gas Control

This option allows control over which gas solenoid actuates while TIG welding. "Valve (manual)" = No MIG solenoid will actuate while TIG welding, gas flow is manually controlled by an external valve. "Solenoid (auto) = This selection only applicable to PWC300. The MIG solenoid will

turn on and off automatically while TIG welding.

"Feeder Solenoid" = No applicable to PWC300. The internal (feeder) MIG solenoid will

turn on and off automatically while TIG welding.

"Pwr Src Solenoid" = Not applicable to PWC300. Any gas solenoid connected to the

power source will turn on and off automatically while TIG welding. This selection will not appear in the list if the power source does not support a gas solenoid.

B-26

Notes: Preflow is not available while TIG welding. Postflow is available - the same

postflow time will be used in MIG and TIG. When machine output on/off is controlled via the upper right knob, gas flow will not start until the tungsten touches the work. Gas flow will continue when the arc is broken until the Postflow time expires. When machine output on/off is controlled via an arc start switch or foot Amptrol, gas will begin flowing when the output is turned on and will continue flowing until the output is turned off and the Postflow time expires.

P.9 Crater Delay

This option is used to skip the Crater sequence when making short tack welds. If the trigger is released before the timer expires, Crater will be bypassed and the weld will end. If the trigger is released after the timer expires, the Crater sequence will function normally (if enabled).

POWER FEED™ 25M

B-27

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.14 Reset Consumable Weight

Use this option to reset the initial weight of the consumable package. Press the Right Button to reset the consumable weight. This option will only appear with systems using Production Monitoring.

P.16 Push-Pull Gun Knob Behavior

This option determines how the potentiometer on the Push/Pull torch will behave.

• Gun Pot Enabled = The welding wire feed speed is always controlled by the potentiometer on the pushpull gun (default). The left front panel knob is only used to adjust Start and Crater wire feed speed.

• Gun Pot Disabled = The wire feed speed is always controlled by the left front panel knob. This setting is useful when the operator wishes to have wire feed speed settings recalled from memories and not have the potentiometer "overwrite" the setting.

• Gun Pot Proc A = When in procedure A, the welding wire feed speed is controlled by the potentiometer on the push-pull gun. When in procedure B, the welding wire feed speed is controlled by the left front panel knob. This setting allows a fixed wire feed speed to be selected in procedure B and not have the potentiometer "overwrite" the setting when the procedure changes.

P.17 Remote Control Type

This setup parameter was previously named "Spool/Push-Pull"

B-27

This option selects the type of analog remote control being used. Digital remote control devices (those with a digital display) are configured automatically. Not all P.17 selections will be available on all machines. When P.17 is used to configure the remote control to function in a specific process, the remote will be ignored in other processes. For example, if P.17 = TIG Amp Control, the remote control will only function when TIG welding - the remote will be ignored in other processes (MIG, stick and gouge). If P.17 is set to Spool Gun or Push-Pull Gun then set to All Mode Remote, the machine will remember prior value of P.17 and will operate a Spool Gun or Push-Pull Gun, depending on the prior value of P.17.

Spool Gun = Use this setting while MIG welding with a spool gun that uses a potentiometer used for wire feed speed control (this setting is backward compatible with "P.17 Gun Selection" = Standard/Spool).

Push-Pull Gun = Use this setting wile MIG welding with a push-pull gun that uses a potentiometer for wire feed speed control (this setting is backward compatible with "P.17 Gun Selection" = PushPull).

TIG Amp Control = Use this setting while TIG welding with a foot or hand current control device (Amptrol). While TIG welding, the upper left knob on the User Interface sets the maximum current obtained when the TIG amp control is at its maximum setting.

Stick/Gouge Rem. = Use this setting while stick welding or gouging with a remote output control device. While stick welding, the upper left knob on the User Interface sets the maximum current obtained when the stick remote is at itʼs maximum setting. While gouging, the upper left knob is disabled and the gouging current is set on the remote control.

All Mode Remote = This setting allows the remote control to function in all weld modes which is how most machines with 6-pin and 7-pin remote control connections operate. This setting was provided so that customers with a mix of Lincoln Electric equipment can have consistent remote control behavior across all of their equipment. (N. American default)

Joystick MIG Gun = Use this setting while MIG welding with a push MIG gun with a joystick control. Stick, TIG and gouge welding currents are set at the User Interface. (European default)

POWER FEED™ 25M

B-28

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.18 Wire Drive Gear Ratio

This option selects the Wire Drive Gear Ratio that will be used. The possible selectable values are read from the Wire Drive on startup. For semi-automatic systems, if the feedhead board has dip switches, this option does not appear in the menu. Gear ratio can be selected using the dip switches.

Note: Changing this value will cause the system to reset.

P.20 Display Trim as Volts Option

This option determines how trim is displayed. False = The trim is displayed in the format defined in the weld set (default). True = All trim values are displayed as a voltage.

Note: This option may not be available on all machines. The power source must support this functionality, or this option will not appear in the menu.

P.22 Arc Start/Loss Error Time

This option can be used to optionally shut off output if an arc is not established, or is lost for a specified amount of time. Error 269 will be displayed if the machine times out. If the value is set to OFF, machine output will not be turned off if an arc is not established nor will output be turned off if an arc is lost. The trigger can be used to hot feed the wire (default). If a value is set, the machine output will shut off if an arc is not established within the specified amount of time after the trigger is pulled or if the trigger remains pulled after an arc is lost. This is disabled while welding in Stick, TIG or Gouge. To prevent nuisance errors, set Arc Start/Loss Error Time to an appropriate value after considering all welding parameters (run-in wire feed speed, weld wire feed speed, electrical stick out, etc). To prevent subsequent changes to Arc Start/Loss Error Time, the setup menu should be locked out by setting Preference Lock = Yes using the Power Wave Manager software.

B-28

P.24 Push Pull Type

Allows operator to choose the Prince option if welding with a Prince Push Pull gun. This gun requires unique settings to run at the correct WFS.

Note: This option may not be available on all machines. The wire drive must support this functionality, or this option will not appear in the menu.

P.27 Language Select

Selects which language will be displayed on the User Interface.

English (Default) Italiano Deutsch Francais

Polski Espanol

P.28 Display Workpoint as Amps Option

This option determines how workpoint is displayed. False = The workpoint is displayed in the format defined in the weld set (default). True = All workpoint values are displayed as an amperage.

Note: This option may not be available on all machines. The power source must support this functionality, or this option will not appear in the menu.

POWER FEED™ 25M

B-29

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.80 Sense From Studs

Use this option for diagnostic purposes only. When power is cycled, this option is automatically reset to False. False = Voltage sensing is automatically determined by the selected weld mode and other machine settings (default). True = Voltage sensing is forced to "studs".

P.81 Electrode Polarity

Used in place of DIP switches for configuration of the electrode sense lead. This option allows selection of the electrode voltage sense polarity. Most GMAW welding procedures use Electrode Positive welding. Most GTAW and some inner shield procedures use Electrode Negative welding.

Positive Electrode Welding (default). Negative Electrode Welding.

This option will only appear in the menu if the feedhead board does not have a dip switch to set the polarity, and the power source does not support auto-hardware sense lead configuration. If this option does not apper in the menu, voltage sense polarity can be selected using the dip switches.

B-29

P.82 Voltage Sense Display

Allows viewing of Voltage Sense Lead Selection to aid in troubleshooting. The configuration is displayed as a text string on the lower display whenever the output is enabled. This parameter is not saved on a power cycle, but will be reset to False.

P.99 Show Test Modes

Most power sources contain weld modes used for calibration and test purposes. By default, the machine does not include test weld modes in the list of weld modes that are available to the operator. To manually select a test weld mode, set this option to "Yes". When the power source is turned off and back on again, the test modes will no longer appear in the mode list. Test weld modes typically require the machine output to be connected to a grid load and cannot be used for welding.

P.100 View Diagnostics

Diagnostics are only used for servicing or troubleshooting the Power Wave system. Select "Yes" to access the diagnostic options in the menu. Additional parameters will now appear in the setup menu (P.101, P.102, etc).

P.101 View Event Logs

Used for viewing all the system event logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired event log to read. Press the Right Button again to enter the selected log. Rotating the Control Knob will scroll through the event log, displaying the log index number, event code and some other data. Press the Left Button to back out to select another log. Press the Left Button again to exit this option.

P.102 View Fatal Logs

Used for viewing all the system fatal logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired fatal log to read. Press the Right Button again to enter that log. Rotating the Control Knob will scroll through the log, displaying the log index number and fatal code. Press the Left Button to back out to select another log. Press the Left Button again to exit this option.

POWER FEED™ 25M

B-30

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.103 View Software Version Information

Used for viewing the software versions for each board in the system. Press the Right Button to enter the option. Rotate Control Knob to select the desired board to read. Press the Right Button again to read the firmware version. Press the Left Button to back out to select another board. Rotate the Control Knob to select another board, or press the Left Button to exit this option.

P.104 View Hardware Version Information

Used for viewing the hardware version for each board in the system. Press the Right Button to enter the option. Rotate Control Knob to select the desired board to read. Press the Right Button again to read the hardware version. Press the Left Button to back out to select another board. Press the Left Button again to exit this option.

P.105 View Welding Software Information

Used for viewing the Weld Set in the Power Source. Press the Right Button to read the Weld Set version. Press the Left Button to back out and exit this option.

P.106 View Ethernet IP Address

Used for viewing the IP address of Ethernet compatible equipment. Press the Right Button to read the IP Address. Press the Left Button to back out and exit this option. The IP address cannot be changed using this option.

B-30

P.107 View Power Source Protocol

Used for viewing the type of power source the feeder is connected to. Press the Right Button to identify the power source as either LincNet or ArcLink. Press the Left Button to back out and exit this option.

P.350 User Interface Group Selection

Used to differentiate multiple PF25M feeders connected to the same power source. Each independent feeder must have a unique selection in order to resolve error 18 problems.

P.500 View Lockout Parameters

Originally used to prevent inadvertent changes of secure setup parameters, P.500 was previously used as a gateway to these parameters. Presently, this option does not exist in any setup menu.

P.501 Encoder Lockout

Locks one or both of the upper knobs (encoders), preventing the operator from changing wire feed speed, amps, volts or trim. The function of each upper knob depends on the selected weld mode. When a constant current weld mode is selected (e.g. Stick, TIG, Gouge), the upper right knob will always function as an on/off switch. This parameter can only be accessed using Power Wave Manager software.

P.502 Memory Change Lockout

Determines if the memories can be overwritten with new contents.

• No = Memories can be saved and limits can be configured (default).

• Yes = Memories cannot be changed - saving is prohibited and limits cannot be re-configured.

This parameter can only be accessed using Power Wave Manager.

POWER FEED™ 25M

B-31

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.503 Memory Button Disable

Disables the specified memory button(s). When a memory is disabled, welding procedures cannot be restored from or saved to that memory. If an attempt is made to save or restore a disabled memory, a message will be displayed on the lower display indicating the memory number is disabled. In multi-head systems, this parameter disables the same memory buttons on both

feed heads. This parameter can only be accessed using Power Wave Manager software.

P.504 Mode Select Panel Lock

Selects between several Mode Select Panel lockout preferences. When a Mode Select Panel selection is locked and an attempt is made to change that parameter, a message will be displayed on the lower display indicating the parameter is locked.

• All MSP Options Unlocked = All adjustable parameters on the Mode Select Panel are

unlocked.

• All MSP Options Locked = All knobs and buttons on the Mode Select Panel are locked.

• Start & End Options Locked = The Start and End parameters on the Mode Select Panel are

locked, all others are unlocked.

• Weld Mode Option Locked = The weld mode cannot be changed from the Mode Select Panel,

all others Mode Select Panel settings are unlocked.

• Wave Control Options Locked = The Wave Control parameters on the Mode Select Panel are

locked, all others are unlocked.

• Start, End, Wave Options Locked = The Start, End and Wave Control parameters on the

Mode Select Panel are locked, all others are unlocked.

• Start, End, Mode Options Locked = The Start, End and Weld Mode Select parameters on the

Mode Select Panel are locked, all others are unlocked.

This parameter can only be accessed using Power Wave Manager software.

B-31

P.505 Setup Menu Lock

Determines if the setup parameters can be modified by the operator without entering a passcode.

• No = The operator can change any set menu parameter without first entering the passcode

even if the passcode is non-zero (default).

• Yes = The operator must enter the passcode (if the passcode is non-zero) in order to change

any setup menu parameters.

This parameter can only be accessed using Power Wave Manager.

P.506 Set User Interface Passcode

Prevents unauthorized changes to the equipment. The default passcode is zero which allows full access. A nonzero passcode will prevent unauthorized:

• changes to memory limits, saving to memory (if P.502 = Yes), changes to setup parameters (if

P.505 = Yes).

This parameter can only be accessed using Power Wave Manager software.

P.509 User Interface Master Lockout

Locks all user interface controls, preventing the operator from making any changes. This parameter can only be accessed using Power Wave Manager software.

POWER FEED™ 25M

B-32

OPERATION

B-32

DUAL PROCEDURE/MEMORY PANEL OPERATION

The Dual Procedure/Memory Panel performs three functions:

• Weld procedure selection

• Memory save and recall

• Limits setting

There are two procedure memories (A and B) and eight user memories (1-8).

Procedure Memory vs. User Memory

Procedure memory is used while welding. Changes to the weld procedure (WFS, voltage, UltimArc™ Controll, etc.) immediately change the contents inside the selected procedure memory.

PROCEDURE

MEMORY

A

GUN B

1

USER

MEMORIES

ARE COPIED TO

PROCEDURE

MEMORY

M

2

3

(8) USER

MEMORIES

M

4

USER MEMORIES

Recall a memory with memory buttons

To recall a user a memory, press one of the six user memory buttons. The memory is recalled when the button is released. Do not hold the button for more than two seconds when recalling a user memory.

Recall a memory with the gun trigger

If desired, memories 1 through 8 can be recalled with the gun trigger. For example, to recall memory 3, quickly pull and release the gun trigger 3 times without welding. To recall memory 1, quickly pull and release the gun trigger 9 times without welding. Note: the wire feeder is factory set with this feature disabled. Use the SETUP menu and change P.4 to enable memory recall with the gun trigger.

Note that memories may be locked with P.C. application software to prevent accidental overwrite of the memories. If an attempt is made to save a memory when memory saving is locked, the message "Memory save is Disabled!" will appear briefly in the MSP4 display.

RECALL:

PRESS

1 SECOND

SAVE:

PRESS

2 SECONDS

5

6

7

8

User memories work by copying the weld procedure from one of the eight memories into either the “A ” or “B” procedure. Weld procedures are saved into the memories only when the operator chooses.

Using Procedure Memories

Procedure memories can be selected by choosing either "A" or "B" procedure directly with the memory panel, or by selecting "GUN" and using a dual procedure gun to select between procedure "A" and "B". When selecting procedures with the gun switch, "A" or "B" will flash to show which procedure is active.

PRESS

TO SELECT

PROCEDURE

A

GUN B

1

M

2

3

M

4

A

GUN B

M

1

5

2

6

3

7

M

4

8

5

6

7

8

POWER FEED™ 25M

B-33

OPERATION

B-33

LIMITS

Limits allow the welder to adjust the welding procedure only within a defined range.

Each user memory may have a different set of limits. For example, memory 1 may limit the WFS to 200 through 300 in/min, and memory 2 may limit the WFS to 275 through 310 in/min, while memory 3 may have no WFS limits.

Parameters are constrained by machine limits, or by setting memory limits. When memory limits are enabled, the parameter will flash whenever an attempt is made to exceed the memory limit value. The parameter will not flash if an attempt is made to exceed the machine limit.

The system machine limits are:

Parameter

Wire Feed Speed

Voltage

Trim

UltimArc

Preflow

Start Time Run-In WFS Crater Time

Burnback Time

Postflow Time

Range

Weld mode and wire

feeder dependent.

Weld mode dependent

0.50 to 1.50

-10.0 to 10.0

0.0 to 25.0

0.0 to 10.0

Off, 30 to 150

0.0 to 10.0

0.00 to 0.25

0.0 to 25.0

Units

in/min

Volts

--

Weld mode dependent

Seconds Seconds

in/min Seconds Seconds Seconds

Set Limits:

Press 5

seconds

A

GUN B

1

5

M

2

6

3

7

M

4

8

To set limits, press the desired memory button 1-8 and hold for 5 seconds. Release the memory button when the LED begins to blink rapidly and the user interface displays "Memory X Set Limits" as shown below.

Memory 2

SETUP

Set Limits

START OPTIONS

END OPTIONS

Limits may be set for:

• Wire Feed Speed/Amperage

• Voltage/Trim

• Arc Control

Weld modes cannot be selected through the Limits Setup menu, and must be chosen and saved to memory before entering the Limits Setup Menu.

SET

If the passcode does not equal zero (0000), enter the passcode now. If the passcode has been forgotten, a p.c. computer application is required to change the passcode.

POWER FEED™ 25M

B-34

OPERATION

If the passcode does not equal zero (0000), enter the passcode now. If the passcode has been forgotten, a p.c. computer application is required to change the passcode.

High Limit

Memory Value

Low Limit

200

HI = 200 LOW = 180 WELD WFS

SETUP

B-34

The memory value must always be less than or equal to the high limit, and greater than or equal to the low limit.

After setting limits, press the memory button with the flashing LED. The display will ask to save or discard the limit changes just made. Press the left user interface for button (YES) to save and enable the limits and exit. Press the right button (NO) to exit and leave limits unchanged.

Enabling/Disabling Limits

WELD MODE

ARC CONTROL

Parameter Name

SET

START OPTIONS

END OPTIONS

If the passcode has been set to zero (0000), SETUP will illuminate on the user interface and the display will show the following:

Four items show on the user interface.

• Memory Value

• High Limit

• Low Limit

• Parameter Name One of these items will flash to indicate which item will change when the user interface encoder is rotated. Press the right button on the user interface to select the item to change.

200

HI = 200 LOW = 180 WELD WFS

SETUP

Enable/Disable

Limits: Press

10 seconds

A

GUN B

1

5

M

2

6

3

7

M

4

8

Limits for each memory may be enabled or disabled by pressing and hold the appropriate memory button for 10 seconds. Release the memory button when the display shows the following:

MEMORY 2 LIMITS

SETUP

ENABLE/DISABLE

WELD MODE

ARC CONTROL

START OPTIONS

END OPTIONS

WELD MODE

ARC CONTROL

Rotate to

Change

Value.

SET

START OPTIONS

END OPTIONS

Press to select item to change.

The Limits Setup menu shows a list of all parameters available for the weld mode stored in the memory chosen. For example, if limits are being set for a stick (SMAW) mode, parameters such as Run-in WFS and Postflow will not appear.

To lock a parameter to a specific value that cannot be changed, set the high and low limits to the same value.

POWER FEED™ 25M

SET

If the passcode does not equal zero, enter the passcode now. If the passcode is zero (0000), SETUP will light and the displays the following:

WELD MODE

ARC CONTROL

ENABLE LIMITS?

Yes No

SET

SETUP

START OPTIONS

END OPTIONS

Press the left button (YES) to enable limits or the right button (NO) to disable limits. Disabling limits does not change any limits values that may have been previously set.

B-35

1

8

7

6

32

4

5

INTERNAL CONTROLS

OPERATION

B-35

ITEM DESCRIPTION

1 Cold Feed / Gas Purge Switch

2 Wire Drive Pressure Arm

3 Internal Light Switch

4 Internal Heater Switch

5 Spindle Brake 6 Gun Bushing 7 Thumb Screw for securing the welding Gun

8 Socket Head Cap Screw for securing the Gun Bushing

POWER FEED™ 25M

B-36

FCAW

GMAW

AL

OPERATION

B-36

COLD FEED/GAS PURGE SWITCH

Cold Feed and Gas Purge are combined into a single spring centered toggle switch.

To activate Cold Feeding, hold the switch in the UP position. The wire drive will feed electrode but neither the power source nor the gas solenoid will be energized. Adjust the speed of cold feeding by rotating the WFS knob. Cold feeding, or "cold inching" the electrode is useful for threading the electrode through the gun.

Hold with toggle switch in the DOWN position to activate Gas Purge and let the shielding gas flow. The gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on. The Gas Purge switch is useful for setting the proper flow rate of shielding gas. Flow meters should always be adjusted while the shielding gas is flowing.

COLD FEED

GAS PURGE

LIGHT SWITCH

ON

Turn on the internal light switch to illuminate the inside of the Power Feed 25M

LIGHT

OFF

PRESSURE ARM ADJUSTMENT

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Do not operate with covers, panels or guards removed or open

• Only qualified personnel should perform maintenance work.

------------------------------------------------------------------------

The pressure arm controls the amount of force the drive rolls exert on the wire. Proper adjustment of pressure arm gives the best welding performance.

Set the pressure arm as follows (See Figure B.18):

Aluminum wires between 1 and 2 Cored wires between 2 and 3 Steel, Stainless wires between 3 and 5

FIGURE B.18

HEATER SWITCH

Turn the heater switch ON to warm the inside of the Power Feed 25M. The heater is useful for reducing condensation build-up on the spool of wire. The heater is thermostatically protected.

HEATER

ON

OFF

1

2

3

4

5

6

AL

FCAW GMAW

POWER FEED™ 25M

B-37

OPERATION

2- STEP 4- STEP- TRIGGER OPERATION

The 2-Step - 4-Step switch changes the function of the gun trigger. 2-Step trigger operation switches the welding output ON-OFF in direct response to the trigger. 4-Step trigger operation provides 'trigger interlock' capability and gives the ability to control the amount of time spent in the arc start and arc crater steps.

Press the push button on the case front to toggle between 2-Step and 4-Step operation.

The 2-Step, 4-Step trigger has no effect when weld- ing with SMAW or CAG procedures.

2-Step Trigger

2-Step trigger operation is the most common. When the gun trigger is pulled, the welding system (power source and wire feeder) cycles through the arc starting sequence and into the main welding parameters. The welding system will continue to weld as long as the gun trigger is activated. Once the trigger is released, the welding system cycles through the arc ending steps

B-37

4-Step Trigger

4-Step trigger operation gives the welder additional control in the welding sequence. 4-Step trigger allows the welder to choose the arc start, weld and arc end time. It may also be set-up to work as a trigger interlock.

POWER FEED™ 25M

B-38

OPERATION

EXAMPLE 1 - 2 STEP TRIGGER: Simple operation

The simplest trigger operation occurs with a 2 Step trigger and the Start, Crater and Burnback functions all set to OFF. (See Figure B.19)

For this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the gun trigger is pulled.

RUN-IN:

After preflow time expires, the power source regulates to the welding output and wire is advanced towards the work piece at the Run-In WFS. If an arc is not established within 1.5 seconds, the wire feed speed will jump to the welding wire feed speed

WELD:

The power source output and the wire feed speed continue at the weld settings for as long as the trigger is pulled.

POSTFLOW:

As soon as the trigger is released, the power source output and the wire feed speed are turned OFF. Shielding gas continues until the post flow timer expires.

B-38

Shie lding Gas

Powe r Source Output

WFS

Wel d

Run-in

On

Off

Pulled

Trigger

Idle Prefl ow

Run-In

1.5 sec max.

FIGURE B.19

2 Step Trigger Start = OFF Crater = OFF Burnback = OFF

Established

Arc

Released

Trigger

Weld Postflow Idle

POWER FEED™ 25M

B-39

OPERATION

B-39

EXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start

and Arc End. Tailoring the arc start and arc end is a common method for reducing spatter and improving weld quality. This can be accomplished with the Start and Burnback functions set to a desired values and Crater set to OFF. (See Figure B.20)

For this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the gun trigger is pulled.

RUN-IN:

After preflow time expires, the power source regulates to the start output and wire is advanced towards the work piece at the Run-In WFS. If an arc is not established within 1.5 seconds, the power source output and wire feed speed skips to the weld settings.

FIGURE B.20

2 Step Trigger Start = ON

Cr ater = OFF B urnback = ON

Pulled

UPSLOPE:

Once the wire touches the work and an arc is established, both the machine output and the wire feed speed ramp to the weld settings throughout the start time. The time period of ramping from the start settings to the weld settings is called UPSLOPE.

WELD:

After upslope, the power source output and the wire feed speed continue at the weld settings.

BURNBACK: As soon as the trigger is released, the wire feed speed is turned OFF and the machine output continues for the burnback time.

POSTFLOW:

Next, the machine output is turned OFF and shielding gas continues until the post flow timer expires.

Rel e as e d

Shieldin Gas

Power Source

Output

WFS

g

Run- in

Weld

St a rt

Weld

Established

Tr i gger

Idle Preflow St r ike Upslope Weld Bur nback Post f low Idle

On

Of f

1.5 sec max .

Of f

Ar c

Start

ti me

Tr i gger

Bur nback Ti me

POWER FEED™ 25M

B-40

OPERATION

B-40

EXAMPLE 3 - 2 STEP TRIGGER: Customized Arc

Start, Crater and Arc End. Sometimes it is advantageous to set specific arc start, crater and arc ending parameters for the ideal weld. Many times when welding aluminum crater control is necessary to make a good weld. This is done by setting Start, Crater and Burnback functions to desired values. (See Figure B.21)

For this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the gun trigger is pulled.

RUN-IN:

After preflow time expires, the power source regulates to the start output and wire is advanced towards the work piece at the Run-In WFS. If an arc is not established within 1.5 seconds, the power source output and wire feed speed skips to the weld settings.

START & UPSLOPE:

As soon as the trigger is released, the wire feed speed and power source output ramp to the crater settings throughout the crater time. The time period of ramping from the weld settings to the crater settings is called DOWNSLOPE.

WELD:

After upslope, the power source output and the wire feed speed continue at the weld settings.

CRATER:

As soon as the trigger is released, the wire feed speed and power source output ramp to the crater settings throughout the crater time. The time period of ramping from the weld settings to the crater settings is called DOWNSLOPE.

CRATER & DOWNSLOPE:

As soon as the trigger is released, the wire feed speed and power source output ramp to the crater settings throughout the crater time. The time period of ramping from the weld settings to the crater settings is called DOWNSLOPE.

BURNBACK:

After the crater time expires, the wire feed speed is turned OFF and the machine output continues for the burnback time.

POSTFLOW:

Next, the machine output is turned OFF and shielding gas continues until the post flow timer expires.

Shielding Gas

Po wer So ur ce

Output

WFS

Weld

Star t

Cr ater

Weld

Cr ater Run-in

FIGURE B.21

2 Step Tri gger St art = ON

Crater = ON Burnback = ON

Tr i gger Pulled

Idle Preflow Stri ke Upslope Weld Bu rnback Postflow Idl e

On

Off

1 .5 sec ma x .

Off

Ar c Est abl i shed

St art t i me

Tr i gger Rel eased

Down slope

Cra ter ti m e

Burnback Ti me

POWER FEED™ 25M

B-41

OPERATION

EXAMPLE 4 – 4 STEP TRIGGER: Trigger Interlock

The 4 step trigger can be configured as a trigger interlock. Trigger interlock adds to the welderʼs comfort when making long welds by allowing the trigger to be released after an initial trigger pull. Welding stops when the trigger is pulled a second time and then released, or if the arc is interrupted. (See Figure B.22)

For this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the gun trigger is pulled.

RUN-IN:

After preflow time expires, the power source regulates to the welding output and wire is advanced towards the work piece at the Run-In WFS. If an arc is not established within 1.5 seconds, the wire feed speed will jump to the welding wire feed speed.

WELD:

The power source output and the wire feed speed continue at the weld settings. Welding continues when the trigger is pulled a second time.

B-41

Shielding Gas

Po wer So ur ce

Out put

POSTFLOW:

As soon as the trigger is released for the second time, the power source output and the wire feed speed are turned OFF. Shielding gas flows until the post flow timer expires.

Pulled

Tr i gger

dle Pr eflow Strike Wel

I

On

Off

We ld

Star t

Cr ater

Off

Es t abl i s hed Ar c

1. 5 s e c ma x.

FIGURE B.22

4 Step Tr i gger St ar t = OFF Crater = OFF Burnback = OFF

Rel eas ed

Tr i gger

Pulled

Tr i gger

d

Rel eas ed

Tr i gger

Bur nback Postflow Idl e

WFS

We ld

Cr ater Run- in

Off

POWER FEED™ 25M

B-42

OPERATION

B-42

EXAMPLE 5 - 4 STEP TRIGGER: Manual control of

Start and Crater times with Burnback ON. The 4 step trigger sequence gives the most flexibility when the Start, Crater and Burnback functions are active. This is a popular choice when welding aluminum because extra heat may be needed during Start and less heat desired during crater. With 4 step trigger, the welder chooses the amount of time to weld at the Start, Weld and Crater settings by using the gun trigger. Burnback reduces the occurrence of wire to sticking into the weld pool at the end of a weld and conditions the end of the wire for the next arc start. ( See Figure B.23)

In this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the gun trigger is pulled.

RUN-IN:

After preflow time expires, the power source regulates to the start output and wire is advanced towards the work piece at the run-inWFS. If an arc is not established within 1.5 seconds, the power source output and wire feed speed skips to the weld settings.

START:

The power source welds at the start WFS and voltage until the trigger is released.

UPSLOPE:

During upslope, the power source output and the wire feed speed ramp to the weld settings throughout the start time. The time period of ramping from the start settings to the weld settings is called UPSLOPE.

WELD:

After upslope, the power source output and the wire feed speed continue at the weld settings.

DOWNSLOPE:

As soon as the trigger is released, the wire feed speed and power source output ramp to the crater settings throughout the crater time. The time period of ramping from the weld settings to the crater settings is called DOWNSLOPE.

CRATER:

During CRATER, the power source continues to supply output at the crater WFS and voltage.

BURNBACK:

When the trigger is released, the wire feed speed is turned OFF and the machine output continues for the burnback time.

POSTFLOW:

Next, the machine output is turned OFF and shielding gas continues until the post flow timer expires.

Shielding Gas

Power Sour ce Output

WFS

Wel d

Star t

Cr ater

Wel d

St ar t Cr ater Strik e

FIGURE B.23

4 Step Trigger St art = ON

Cr at er = ON Bur nb ack = ON

Pul l ed

Tr i gger

Idl e Pr e flow Strike Upslope Weld Bur nback Postflow Idle

On

Off

1.5 sec max.

Off

Est abl i s hed Ar c

Rel eased

Tr i gger

Star t

Pul l ed

Tr i gger

Downs l ope

Cr ater

Rel eas ed

Tr i gger

Burnba ck Ti me

POWER FEED™ 25M

B-43

REAR CONTROLS:

OPERATION

B-43

1

2

ITEM DESCRIPTION

1 Flow Meter

2 Shielding Gas Inlet

3 ArcLink Cable Connector

4 Electrode Cable

3

4

5

5 Cover for Optional Water Line Connector

POWER FEED™ 25M

B-44

e

OPERATION

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 CO brated and is for reference purposes only. 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 conditions may effect the amount of shielding gas required.

When using a wire feeder with a flow meter, adjust the regulator at the shield gas bottle or supply to a flow rate that is higher than the flow rate indicated 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 restriction and may cause errors in the readings at the supply regulator. Set the gas flow rate using the feeder flow meter reading and not the supply regulator reading.

2, Ar, and CO2/Ar blends. It is not cali-

B-44

To achieve maximum flow rate, use a regulator with 30 psi or higher pressure compensation.

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

Ball

Valv

POWER FEED™ 25M

C-1

ACCESSORIES

FACTORY INSTALLED EQUIPMENT

• K1500-2 Gun Receiver Bushing.

DRIVE ROLL KITS USED

• See Parts Pages

K2429-1

K857-2

K2596-2

ArcLink "T" Cable Adapter

Remote Output Control

Plastic Case

C-1

Includes: 1 "T" adapter for

connecting two wire feeders to

one power source.

Includes: 1 remote output con-

trol pendant with a 25ʼ cable. Used most often with SMAW

welding.

Includes: a complete engineered plastic case. Decals and latches

are all preassembled.

K2593-xx

K1796-xx

K1803-1

K1840-xx

K1842-xx

#1 Co-Axial Power Cable

1/0 Co-Axial Power Cable

Work and Feeder Cables Package

Weld Power Cable, Twist-Mate to

Lug

Weld Power Cable, Lug to Lug

Includes: AWG #1 Coaxial weld cable of length "xx". Ends of the weld cable have lug connections.

Use for Pulse or STT™ welding.

Includes: 1/0 Coaxial weld

cable of length "xx". Ends of

the weld cable have lug con-

nections. Use for Pulse or

STT™ welding.

Includes: 1/0 Coaxial weld

cable of length "xx". Ends of

the weld cable have lug con-

nections. Use for Pulse or

STT™ welding.

Includes: Twist-Mate to Lug,

1/0 cable of length "xx".

Includes: Twist-Mate to Lug

2/0 cable 14' (1.2m) long with

Ground Clamp, and Twist-

Mate to Lug 2/0 Cable 9'

(2.7m) long.

POWER FEED™ 25M

C-2

K1543-xx

K2683-xx

ACCESSORIES

Digital Control Cable

Heavy Duty ArcLink Control Cable

C-2

Includes: 5 pin to 5 pin wire

feeder to power source control

cable. Cables may be con-

nected end-to-end to make a

longer cable.

Includes: 5 pin to 5 pin wire feeder power source to control cable. Cables may be connected end-to-end to make a longer cable. The male connector is stainless steel and the female connector is brass. Recommended for outdoor applications.

K910-1

K910-2

K1500-1

K1500-2

Ground Clamp

Gun Receiver Bushing (for guns

with K466-1 Lincoln gun connec-

®

tors; Innershield

Gun Receiver Bushing (for guns

with K466-2, K466-10 Lincoln gun

connectors; Magnum

200/300/400 guns and compatible

with Tweco® #2-#4)

and Subarc

guns)

®

Includes: One 300 Amp

Ground Clamp.

Includes: One 500 Amp

Ground Clamp.

Includes: Gun receiver bush-

ing, set screw and hex key

wrench.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

K1500-3

K1500-4

Gun Receiver Bushing (for guns

with K613-7 Lincoln gun connec-

®

tors; Magnum

patible with Tweco® #5)

Gun Receiver Bushing (for gun

with K466-3 Lincoln gun connec-

tors; compatible with Miller® guns.)

550 guns and com-

POWER FEED™ 25M

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

C-3

K1500-5

ACCESSORIES

Gun Receiver Bushing (compatible

with Oxo® guns.)

C-3

Includes: Gun receiver bushing

with hose nipple, 4 guide tubes,

set screw and hex key wrench.

K489-7

K2339-1

K590-6

K435

Gun Receiver Bushing (for Lincoln

Fast-Mate guns.)

Push-Pull Gun Connection Kit

Water Connection Kit

Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2

in (51 mm) spindles.

Includes: Gun receiver bushing

with trigger connector.

Used with K2211-xx and K2212-

xx Python Guns. Includes: Push-

Pull gun bushing, fittings, valve

removal tool, modified gas

bypass valve and control cable

extension.

Includes: 2 hoses with female quick connectors at each end, 2 male connectors for 3/16" ID hose, 2 male connectors for 1/4" ID hose, and mounting hardware.

Includes: Spindle Adapter made

from 2 coil retainers. (Electrode

not included.)

K468

K659-1

3000290

K586-1

Spindle Adapter, for mounting 8in

(203mm) diameter spools on 2 in

(51 mm) spindles.

Gas Guard Regulator

Adjustable Gas Regulator

Deluxe Adjustable Gas Regulator

POWER FEED™ 25M

Includes: 2 Spindle Adapters,

one for 2" wide spools and the

other for 3" wide spools.

Includes: Gas Guard Regulator

and adjustment key.

Includes: Gas Regulator for

Mixed Gases and 10' (3.0m)

Hose.

Includes: Deluxe Gas Regulator

for Mixed Gases, Adapter for

CO2 and 1

0' (3.0m) Hose.

C-4

ACCESSORIES

C-4

INSTALLATION OF THE K590-6 WATER COOLING KIT

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the disconnect 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 compatible with the water cooler and the gun.

Tools required:

• 3/8" wrench

• 5/16" nut driver

• medium flat bladed screw driver

• cutting tool

1. Turn power off at the welding power source. Remove the screws securing the case to the inner

2. module using a 3/8" wrench. (and a 5/8” wrench for plastic case models).

4. Remove the module from the case by lifting the front of the module approximately .25” (6 mm) and then sliding forward.

5. Use a 5/16” nut driver to remove the screws holding the water cooling cover on the case front of the inner module and on the rear of the case.

6. Install the fitting and hose assembly to the case front. Route the hoses along the bottom of the inner module and out through the cutout of the cover. Slide the module back into the case.

3. Remove the bolts holding the handle to the case with a 5/8” wrench

REMOVE 2 BOLTS AND WASHERS FROM HANDLE

POWER FEED™ 25M

7. Assemble the handle to the inner module and case.

ASSEMBLE BOLTS AND WASHER TO HANDLE

C-5

j

o

e

w

a

s

h

e

r

e

2

0

1

jo

e

w

a

s

h

e

r

e

2

0

1

ACCESSORIES

8. Secure the module to the case with the screws.

9. Install the fittings to the rear of the case.

C-5

Aluminum Case

0

s

a

Plastic Case

10. Slide the hose clamps on to the hoses. Trim the hoses to length so that they lay flat on the case bottom. Slide the hoses on to the fittings on the case rear and secure with the hose clamps.

POWER FEED™ 25M

C-6

WATER COOLED GUNS

ACCESSORIES

C-6

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the disconnect switch before working on this equipment.

• Do not touch electrically hot parts.

• Only qualified personnel should install, use or service this equipment.

-----------------------------------------------------------------------Python Water Cooled Guns

K2212-xx push-pull guns require both the K590-6 water connection kit and the K2339-1 push-pull gun connection kit. The hoses from the water connection kit assemble directly to the push-pull gun bushing as shown below. Secure the conduit from the python gun in the gun bushing by using the thumb screw.

To install the K2339-1 Push-Pull Gun Connection Kit in the POWER FEED™ 25M:

1. Turn power off at the welding power source.

2. Remove the gun from the wire feeder, if attached.

Power

Conduit

Gas

10. Assemble Adapter Fitting to the front of the pushpull bushing. Attach the electrode cable from gun to the adapter fitting.

11. Use the adapter fittings to attach one of the water hoses to the adapter.

12. Attach the other water hose to the water hose of the of push-pull gun using the Hose Nipple.

13. Connect the control cable from the push-pull gun to the 7 pin circular connector on the front of the Power Feed 25M.

3. Loosen the socket head cap screw that holds the connector bar against the gun bushing. Important: Do not attempt to completely remove the socket head cap screw.

4. Remove the outer wire guide, and push the gun bushing out of the wire drive. Because of the precision fit, light tapping may be required to remove the gun bushing.

5. Disconnect the shielding gas hose from the gun bushing, if required.

6. Install Adapter, 5/8” L.H. Fitting to the Push-Pull Bushing.

7. Slide the Push-Pull Bushing into the wire drive.

8. Insert the conduit from the push-pull gun into the push-pull bushing until the conduit is flush to the inner wire guide. Secure the conduit with the thumb screw.

9. Tighten the socket head cap screw to hold the push-pull bushing tightly to the wire drive.

POWER FEED™ 25M

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not operate with covers removed.

• Turn off power source before installing or servicing.

• Do not touch electrically hot parts.

• Turn the input power to the welding power source off at the fuse box before working in the terminal strip.

• Only qualified personnel should install, use or service this equipment.

ROUTINE MAINTENANCE

• Check weld cables, control cables and gas hoses for cuts.

• Clean and tighten all weld terminals.

D-1

To verify the voltage display:

• Set the welding power source and POWER FEED™ 25M to a CV procedure that gives steady "spray" transfer in the arc.

• While a weld is being made, measure the voltage from the feed plate to work with a calibrated volt meter.

• The displayed voltage on the POWER FEED™ 25M should be within 2% of the measured value.

PERIODIC MAINTENANCE

• Motor Brushes:

Inspect the motor brushes every 6 months or every

2.5 million arc starts (whichever comes first). Replace the brushes if they are less than 0.5” (12.7 mm) long.

CALIBRATION SPECIFICATION

All calibrations are factory set on the POWER FEED™ 25M.

To verify the wire feed speed:

• Assemble a .045 (1.2mm) drive roll kit into the POWER FEED™ 25M.

• Load a spool of .045 (1.2mm) electrode and thread the electrode through the wire drive.

• Adjust the wire feed speed to 300 in/min (7.62m/min).

• Press the COLD FEED switch and measure the actual wire feed speed with a calibrated wire feed speed tachometer.

• The measured wire feed speed should be within 2% of the set value.

POWER FEED™ 25M

E-1

TROUBLESHOOTING

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED™ 25M

E-2

PROBLEMS

(SYMPTOMS)

Fault Code

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Linc-Net System Error Codes

Description

RECOMMENDED

COURSE OF ACTION

Possible Adjustments

E-2

Err 006

Err 100

Err 53 Voltage sense loss.

Err 81 Motor overload, long term.

1. The wire feeder has not received a recognition command from the power source.

1. The power source has issued a shutdown command.

ArcLink System Error Codes

1. The wire drive motor has overheated.

1. Verify the power source is operating properly. (Status light steady green.)

2. Check control cable for loose or broken leads.

3. See power source Instruction Manual.

1. Verify the power source is operating properly (Status light steady green.)

2. Check control cable for loose or broken leads.

3. See power source Instruction Manual.

1. Check that the electrode slides easily through the gun and cable.

2. Remove tight bends from the gun and cable.

3. Check that the spindle brake is not too tight.

4. Verify a high quality electrode is being used.

5. Wait for the error to reset and the motor to cool. (approximately 1 minute).

Err 82 Motor overload, short term.

Err 95 Spool gun or pull gun motor

overload.

Err 263 No usable weld modes.

1. The wire drive motor current draw has exceeded limits, usually because the motor is in a locked rotor state.

1. The drive motor in the spool gun or push-pull gun is drawing too much current.

1. The power source does not have any welding programs loaded.

1. Check that motor can turn freely when idle arm is open.

2. Verify that the gears are free of debris and dirt.

1. Check that the wire moves freely through the gun when the gun is straight.

2. Verify the correct size contact tip is installed in the gun.

1. See the power source Instruction Manual for load welding programs.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED™ 25M

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

The feeder does power up - no display, no cold feed.

No shielding gas.

TROUBLESHOOTING

POSSIBLE

CAUSE

Output Problems

1. The POWER FEED™ 25M power switch is OFF.

2. The Power Wave power source is OFF.

3. The circuit breaker for the wire feeder on power source have tripped.

4. The control cable may be loose or damaged.

5. The power switch is damaged.

1. The gas supply is OFF or empty.

2. The gas hose is cut or crushed.

3. Dirt or debris is in the solenoid.

4. There is a loose solenoid connection or the solenoid has failed.

5. The solenoid has failed.

E-3

RECOMMENDED

COURSE OF ACTION

1. Turn the POWER FEED™ 25M power switch ON.

2. Turn ON the Power Wave power source.

3. Reset the circuit breakers.

4. Tighten, repair or replace the control cable.

5. Replace the power switch.

1. Verify the gas supply is ON and flowing.

2. Route the gas hose so it avoids sharp corners and make sure nothing is on top of it. Repair or replace damaged hoses.

3. Apply filtered shop at 80psi to the solenoid to remove dirt.

4. Remove the cover and check that all connections are in good condition.

5. Replace the solenoid.

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

1. The gun cable is kinked and/or twisted.

2. The wire is jammed in the gun and cable.

3. The gun liner is dirty or worn.

4. The electrode is rusty or dirty.

5. The contact tip is partially melted or has spatter.

6. Improper gun liner, tip, drive rolls and/or inner wire guide.

7. Incorrect tension arm pressure on the drive rolls.

8. Worn drive roll.

1. Keep the gun cable as straight as possible. Avoid sharp corners or bends in the cable.

2. Remove the gun from the wire feeder and pull the jammed wire out of the gun and cable.

3. Blow dirt out of the liner with low pressure (40psi or less). Replace the liner if worn.

4. Use only clean electrode. Use quality electrode, like L-50 or L-56 from Lincoln Electric.

5. Replace the contact tip.

6. Verify the proper parts are installed.

7. Adjust the tension arm per the Instruction Manual. Most electrodes feed well at a tension arm setting of "3".

8. Replace the drive rolls if worn or filled with dirt.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED™ 25M

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Wire feed speed consistently operates at the wrong value.

TROUBLESHOOTING

POSSIBLE

CAUSE

Output Problems

1. The wire feeder gear setting is not properly set.

E-4

RECOMMENDED

COURSE OF ACTION

1. Verify the POWER FEED™-15 software setting matches the gear mounted. See the Instruction Manual for setting the gear speed.

Variable or "hunting" arc.

Poor arc starts with sticking or "blast-offs", weld porosity, narrow and ropy looking bead.

The wire feed speed/amperage and voltage/trim display work during preset but show nothing during welding.

1. Wrong size, worn and/or melted contact tip.

2. Worn work cable or poor work connection.

3. Wrong polarity.

4. The gas nozzle is extended beyond the contact tip or the wire stickout is too long.

5. Poor gas shielding on processes requiring gas.

1. Improper procedures or techniques.

1. The software in the POWER FEED™ 25M must be upgraded.

1. Replace the contact tip.

2. Verify all work and electrode connections are tight and that the cables are in good condition. Clean/replace as necessary.

3. Adjust polarity to the recommended procedure.

4. Adjust the gas nozzle and shorten the stickout to 3/8 to 1/2 inches.

5. Check gas flow and mixture. Remove or block sources of drafts.

1. See "Gas Metal Arc Welding Guide". (GS-100).

1. Contact the local authorized Lincoln Field Service Shop.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER FEED™ 25M

F-1

Enhanced Diagram

DIAGRAMS

F-1

POWER FEED™ 25M

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-2

DIMENSION PRINT

Dimensions for Aluminum Case Code 11743

F-2

16.9

13.9

23.21

12 X 18 In. Ellipse

16 In. Circle

8.5

5.4

14.54

16.92

POWER FEED™ 25M

F-3

Dimensions for Plastic Case Code 11744

DIAGRAMS

17.2

14.8

F-3

23.1

12 X 18 In. Ellipse

16 In. Circle

8.7

5.7

14.8

17.2

POWER FEED™ 25M

PARTS LIST FOR

Power Feed

P-662P-662

™

25M

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs ofﬁcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs ofﬁcial Parts Book (BK-34) for the latest pages.

POWER FEED™25M

2

1

4

3

5

P-662-A

ILLUSTRATION OF SUB-ASSEMBLIES

P-662-A

2

POWER FEED™25M

Oct-13

P-662-A.1P-662-A.1

Power Feed™25M

For Codes: 11743 & 11744

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

PAGE NO.

CODE NO.

11743 1 1 1 1 1

11744 11112

1

Front Panel Assembly

P-662-C

2

Control Box Assembly

P-662-D

3

Spindle & Mast Assembly

P-662-E

4

Wire Drive Assembly

P-662-F

5

Case Assembly

P-662-G

POWER FEED

™

25M

Oct-13

Front Panel Assembly

1

2

3

3A

22A

11G

18A

18B

19B

17

12

10

9

8

6

5

23

7A

7B

11A

11B

13A

12A

13B

3A

18A

P-662-CP-662-C

7B

7A

18B

11A

19B

12

13A

10

13B

11G

11B

22A

12A

17

23

POWER FEED™25M

Oct-13

P-662-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Front Panel Assembly (G5635-3), Includes: NSS 1X

1 Case Front G5577-3 1 X 2 Nameplate (L15878-1) (Part of L15878) NSS 1X 3 LED, Lens, Includes: S23093-1 1 X 3A Retaining Ring S23094-1 1 X 4 Plug & Lead Assembly (Not Shown), Includes: S18250-942 1 X 4A LED Panel Mount Assembly (Not Shown) S23740-6 1 X 4B LED, Bicolor (Not Shown) T13657-7H24 1 X 5 Button Cover, Small S23055-1 12 X 6 Potentiometer Insulation S27401 1 X 7A User Interface P.C. Board S28540-[ ] 1 X 7B Sems Screw T10082-12 4 X 8 Shaft Seal T14034-4 2 X 9 Knob T13639-3 3 X 10 Switch, SPST T10800-68 1 X 11 Connector & Lead Assembly, Includes: M22586 1 X 11A Connector (5 Socket) (P4) S12021-66 1 X 11B Connector (12 Socket) (P3) S12021-78 1 X 11C #4-40 x .375 PPNHS (Not Shown) CF000339 4 X 11D Lock Washer (Not Shown) T9695-2 4 X 11E #4-40 HN (Not Shown) CF000002 4 X 11F Self Tapping Screw (Not Shown) S8025-118 2 X 11G Cap - Cable Connector S17062-10 1 X 12 Cap - Cable Connector S17062-12 1 X 12A Self Tapping Screw S8025-76 1 X 13A Water Inlet/Outlet Cover M17894 1 X 13B Self Tapping Screw S9225-99 2 X 17 Warranty Decal S22127-7 1 X 18A Circuit Breaker T12287-8 1 X 18B Sealing Boot S22061-2 1 X 19A Rocker Switch Boot (Not Shown) S28672-1 1 X 19B Boot S18581-2 1 X 20 Thread Forming Screw (Not Shown) S9225-4 2 X 22A Thread Forming Screw S9225-99 1 X 22B #10-24 HLN (Not Shown) T9187-13 1 X 23 Thread Forming Screw S9225-99 1 X

# #

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates.

NSS - Not Sold Separately

POWER FEED

™

25M

Oct-13

Control Box Assembly

7A

7B

3A

3B

1

4

2A

2C

25A

25B

11D

19A

16A

16C

13B

13C

19E

12

10

19B

19C

19H

19F

19G

11B

11C

9

5A

6A

17A

15A

20

17B

17A

17B

2A

P-662-DP-662-D

5A

6A

20

15A

16C

19G

19F

19B

19H

19C

10

19A

19E

7A

2C

12

13C

16A

13B

3A

3B

11D

11C

11B

25A

7B

POWER FEED

™

25M

25B

Oct-13

P-662-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Control Box Assembly (G5634-3), Includes: NSS 1X

1 Control Box G5584-4 1 X 2A Control Box Decal M22570 1 X 2B Mast Decal (Not Shown) M22570-1 1 X 2C Insulation S25126 1 X 3A Wire Drive P.C. Board Assembly S28539-[ ] 1 X 3B #10-24 HLN T9187-13 4 X 4 Decal (L15878-5) (Part of L15878) NSS 1X 5A Gas Flow Meter Assembly S25565-2 1 X 5B Lock Washer (Not Shown) E106A-1 2 X 6A Flex Tube T10642-265 1 X 6B Hose Clamp (Not Shown) T13777-8 2 X 7A Spindle & Mast Assembly (G5572-2) See P-662-E 1 X 7B #10-24 HLN T9187-13 4 X 7C Self Tapping Screw (Not Shown) S9225-99 1 X 9 Insulated Mounting Block M21096 1 X 10 Self Tapping Screw S9225-99 2 X 11A 1/2-13 HN (Not Shown) CF000027 1 X 11B Plain Washer S9262-80 1 X 11C Lock Washer E106A-15 1 X 11D 1/2-13 x 1.5 HHCS CF000052 1 X 12 Terminal Block Lead L12901-1 2 X 13A Weld Cable, Includes: M21463-2 1 X 13B Cord Grip Connector S19999 1 X 13C Conduit Lock Nut T14370-3 1 X 14 Harness (Not Shown) G5599-2 1 X 15A Solenoid Assembly M17294-8 1 X 15B Plain Washer (Not Shown) S9262-149 1 X 15C Conduit Lock Nut (Not Shown) T14370-1 1 X 16A Control Box Panel S26587-7 1 X 16B #10-24 HLN (Not Shown) T9187-13 4 X 16C Cable Connection Assembly M21501 1 X 17A Flex Tube T10642-262 1 X 17B Hose Clamp T13777-8 2 X 19 Resistor Bank Asbly (M21145-1), Includes: NSS 1X 19A Resistor S10404-95 2 X 19B Resistor Bracket M21144-1 1 X 19C Insulating Washer T4479-A 4 X 19D Lock Washer (Not Shown) T9695-1 2 X 19E #10-24 x 5.00 RHS CF000045 2 X 19F Lock Washer E106A-1 2 X 19G #10-24 HN CF000010 2 X 19H Voltage Sense Select P.C. Board M19540-[ ] 1 X 19J Self Tapping Screw (Not Shown) S9225-99 2 X 20 Shielding Gas Filter S28863 1 X 22 Bypass Assembly (Not Shown) S22969-12 1 X 25A Control Box Cover M21011-2 1 X 25B Thread Forming Screw S9225-99 4 X 26 Sems Screw (Not Shown) T10082-12 1 X

#

NSS - Not Sold Separately

POWER FEED

™

25M

Oct-13

P-662-D.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number bracket [ ] have purposely been left blank as to eliminate errors, confusion and updates.

POWER FEED

™

25M

Oct-13

NOTES

POWER FEED™25M

Spindle & Mast Assembly

1

7

8

9

10

11

12

2

3A

3B

15

5

3B

P-662-EP-662-E

3A

10

11

12

15

Oct-13

POWER FEED

™

25M

P-662-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Spindle & Mast Assembly (G5572-2), Includes: NSS 1X

1 Spindle Mast G5571-2 1 X 2 Spindle Shaft M20990-1 1 X 3A Thread Forming Screw S9225-102 2 X 3B External Tooth Lock Washer T9860-6 2 X 5 Bushing T12380-1 3 X 7 Spindle L10560-2 1 X 8 Friction Washer S17435-3 2 X 9 Keyed Washer T12965-2 1 X 10 Compression Spring T11862-14 1 X 11 Thumb Screw T14813-A 1 X 12 Retaining Collar Assembly S23811 1 X 15 Bushing T12380-1 2 X

NSS - Not Sold Separately

POWER FEED

™

25M

Oct-13

Wire Drive Assembly

3A

15

37

12A

21

22

12B

1

26

29

23

3D

3E

20

2B

16A

16B

30A

30B

16C

11A

11B

8

6

6A

7

5A

36

5B

2F

2H

2G

35

4A

4D

32

2C

2D

2E

4C

4B

3A

26

P-662-FP-662-F

30A

3D

3E

30B

29

20

22

23

15

2B

16C

16B

16A

12A

32

21

37

12B

2F

2C

2D

2G

2E

2H

11A

35

11B

4A

6A

4B

4C

4D

36

5A

5B

POWER FEED™25M

Oct-13

P-662-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Wire Drive Assembly, Includes: M21079-7 1 X 1 Wire Drive Panel G5569-2 1 X 2A Feed Plate Assembly, Includes: M19932 1 X 2B Connection Bar M19611-1 1 X 2C Socket Head Cap Screw T9447-112 1 X 2D Plain Washer S9262-167 1 X 2E Retaining Ring S9776-69 1 X 2F Idle Arm NSS 1X 2G Adjustment Arm Assembly M19179-1 1 X 2H Set Screw (Not Shown) S11604-47 1 X 2J Self Tapping Screw (Not Shown) S9225-102 4 X 3 Motor Gearbox Assembly, Includes: L12081-1 1 X 3A Drive Motor NSS 1X 3B Connector, Molex (Not Shown) S24018-8 1 X 3C Locking Post (Not Shown) S24019-8 1 X 3D Woodruff Key S24170-1 1 X 3E Snap Ring S9776-27 1 X 3F Motor Brush & Brush Cap (Not Shown) S28460 1 X 3G Lock Washer (Not Shown) E106A-2 3 X 3H M6 x 1.00 PPHS (Not Shown) T14731-18 3 X 4A Drive Gear M19870 1 X 4B Collar S25414 1 X 4C Lock Washer T4291-A 1 X 4D Metric Screw T14731-47 1 X 5A Cover M19999 1 X 5B Self Tapping Screw S9225-102 1 X 6 Drive Roll Shaft Assembly, Includes: S25638 2 X 6A Twist Lock Ring S25308 2 X 7 Retainer S25403 2 X 8 Wire Guide Assembly (Outer) KP2071-3 1 X 11A Ball Housing M18946 1 X 11B Set Screw S11604-21 1 X 12A Timer Kit Panel S25706 1 X 12B Thread Forming Screw S9225-99 2 X 15 Thread Forming Screw S9225-99 4 X 16A 1/2-13 x 1.00 HHCS CF000021 1 X 16B Lock Washer E106A-15 1 X 16C Plain Washer S9262-80 1 X 20 Decal, Toggle Switch (L15878-4) (Part of L15878) NSS 1X 21 Decal, Light & Heater (L15878-2) (Part of L15878) NSS 1X 22 Decal, Serial Number (L15878-3) (Part of L15878) NSS 1X 23 Decal, Pressure Arm S25890-1 1 X 24 Decal, Maxtrac (Not Shown) S26310 1 X 25 Ground Harness (Not Shown) S26832 1 X 26 Toggle Switch T10800-38 2 X 29 Toggle Switch T10800-49 1 X 30A LED, Lens S23093-1 2 X 30B “O” Ring T13483-7 2 X 31 Plug & Lead Assembly (Not Shown M22587 1 X 32 Gun Adapter S22905-2 1 X 35 Screw Stud T13858 1 X

NSS - Not Sold Separately

POWER FEED

™

25M

Oct-13

P-662-F.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

36 Pinion Gear (Low Speed) M18967-1 1 X 37 Plug Button T10397-3 1 X

2 Roll Kits, 2 Roll Drive

Drive Roll Kits, Steel Wires

KP1696-030S .023-.030 (0.6-0.8mm)

KP1696-035S .035 (0.9mm)

KP1696-045S .045 (1.2mm)

KP1696-052S .052 (1.4mm)

KP1696-1/16S 1/16 (1.6mm)

KP1696-1 .035-.045 (0.9-1.2mm)

KP1696-2 .040 (1.0mm)

Drive Roll Kits, Cored Wires

KP1697-035C .030-.035 (0.8-0.9mm)

KP1697-045C .040-.045 (1.0-1.2mm)

KP1697-052C .052 (1.4mm)

KP1697-1/16C 1/16 (1.6mm)

KP1697-068 .068-.072 (1.7-1.8mm)

KP1697-5/64 5/64 (2.0mm)

Includes: 2 V groove drive

rolls and inner wire guide.

Includes: 2 V Knurled drive

rolls and inner wire guide.

Drive Roll Kits, Aluminum Wire

KP1695-035A .035 (0.9mm)

KP1695-040A .040 (1.0mm)

KP1695-3/64A 3/64 (1.2mm)

KP1695-1/16A 1/16 (1.6mm)

Includes: 2 polished U groove

drive rolls, outer wire guide

and inner wire guide.

POWER FEED

™

25M

Oct-13

NOTES

POWER FEED™25M

Case Assembly

25

24

15

1A

20A

13

20A

17A

10A

10B

10C

23A

15

23B

1

18

3A

16

12

22

2

P-662-GP-662-G

20A

13

17A

20A

15

23A

23B

1A

3A

15

25

24

10C

10A

10B

16

12

22

18

POWER FEED

™

25M

Oct-13

P-662-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Assembly (G5633-1), Includes: NSS 1X•

Case Assembly (G5661-2), Includes: NSS 1•X 1 Case Welded Assembly (M20976) NSS 1X• 1A Plastic Case Asbly (G5660) (Includes item 12) NSS 1•X 2 Door G5556 1 X • 3A Shield & Hinge Assembly M21234 1 X • 3B Rivet (Not Shown) T12584-12 8 X • 10A Skid S20195 4 X • 10B Insulated Fastener T15088 2 X • 10C Torx Button Head Screw S25930-7 14 X • 10D Lock Washer (Not Shown) E106A-2 14 X • 11 Door Decal G6849 1 X • 12 Latch M20977 2 X • 12 Latch M20977-1 2 • X 13 Warning Decal S20601-2A 1 X X 15 Warning Decal S20601-2B 1 X X 16 Warning Decal S25536-1 1 X X 18A Decal (Lincoln Electric) S11893-4 2 X • 18B Door Logo Decal S11893-8 1 • X 18C Case Logo Decal S11893-9 1 • X 22 Decal - Crossed Out Wheeled Bin T13086-201 1 X X 23A Water Inlet/Outlet Cover M17894 1 X • 23B #10-24 x .50 HHCS CF000371 2 X • 24 Plug Button T10397-6 2 • X 25 Plug Button T10397-19 2 • X 15 Gasket S26924 1 • X 17A Thread Forming Screw S9225-102 8 X • 17A Thread Forming Screw S9225-102 2 • X 17B Insulated Fastener (Not Shown) T15088-2 6 • X 20A Handle Assembly S18170 1 X X

As Req

20B Plain Washer (Not Shown) S9262-98

XX 20C Plain Washer (Not Shown) S9262-113 1 X X 20D Lock Washer (Not Shown) E106A-2 2 X X 20E 1/4-20 x .625 HHCS (Not Shown) CF000013 1 X X

#

NSS - Not Sold Separately

POWER FEED

™

25M

Oct-13

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Lincoln Electric IM10077 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual