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)
Serial: (ex: U1060512345)
IM10077 | Issue D ate Oct- 13
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THANK YOU FOR SELECTING
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
PIN
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
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.
PIN
A
B
C
67 Electrode Voltage Sense
D
E
Wiring
ArcLink
ArcLink
40VDC
Common
POWER FEED™ 25M
A-4
Electrode
Work
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
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
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
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
• Power Wave
• Power Wave
• Power Wave
• Power Wave
• 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
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3 5 5
E
A V
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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
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
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
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