Lincoln Electric IM10180 User Manual

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Page 1

Operator’s Manual

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POWER FEED

™

25M NNS

For use with machines having Code Numbers:

12244

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10180 | Issue D ate Nov-13

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Page 2

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.

SAFETY

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.

Page 3

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.

Page 4

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.

cause

Page 5

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

Page 6

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.

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

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

Page 7

TABLE OF CONTENTS

Page

Product Description.........................................................................................................................................7

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

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

Thumb Screw and Metal Tab of Welding Gun .....................................................................A-2

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

Location................................................................................................................................A-3

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

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

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

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

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

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

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

Remote Sense Lead Specification .......................................................................................A-6

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

Typical System Configurations.............................................................................................A-7

________________________________________________________________________________

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

afety Precautions ...............................................................................................................B-1

Graphic Symbols that appear on this Machine or in thi

Definition of Welding Terms .................................................................................................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, 2 Step - 4 Step Trigger Operation and Graphics

Set-Up Feature Menu for Parameters and Definition ........................................B-21 thru B-27

Dual Procedure/Memory Buttons .......................................................................B-28 thru B-30

Internal Controls.................................................................................................................B-31

Cold Feed / Gas Purge Switch, Light Switch, Heater Switch, Pressure Arm Adjustment ..B-32

Rear Controls .....................................................................................................................B-33

________________________________________________________________________________

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

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

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

________________________________________________________________________________

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

________________________________________________________________________________

s Manual

.........................................B-1

....B-5 thru B-20

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

________________________________________________________________________________

Parts Pages ................................................................................................................P-754 Series

_______________________________________________________________________

________

Page 8

GENERAL DESCRIPTION

General Physical Description

The POWER FEED™ 25M NNS 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 NNS 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 NNS 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.

The POWER FEED™ 25M NNS continues Lincoln’s 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 NNS from stray signals and keep the feeder from interfering with other digital equipment.

PRODUCT DESCRIPTIONPOWER FEED™ 25M NNS

General Functional Description

The POWER FEED™ 25M NNS is best suited for applications were quality welds are expected. Combined with a Power Wave power source, the POWER FEED™ 25M NNS 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.

Page 9

INSTALLATIONPOWER FEED™ 25M NNS

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 NNS K2536-6

INPUT AMPERES

500A

FCAW

GEARING

Normal Speed

(factory setting)

WFS RANGE

50 – 800 ipm

(2.5 – 20.3m/min)

WIRE SIZES

.023 – 1/16"

(0.6 – 1.6mm)

WFS RANGE

50 – 800 ipm

(2.5 – 20.3m/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)

IP23

IEC 60974-5

A-1

Page 10

THUMB SCREW AND METAL TAB OF WELDING GUN

INSTALLATIONPOWER FEED™ 25M NNS

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the disconnect switch or fuse box before attempting to connect or disconnect input power lines, output cables or control cables.

• Only qualified personnel should perform this installation.

• Do not touch the wire drive, drive rolls, wire coil or electrode when welding output is ON.

• Wire feeder may be connected to a piece of automatic equipment that may be remotely controlled.

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

• Do not let the electrode or wire spool touch the wire feeder housing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

The metal tab of the welding gun and thumb screw securing the gun are at electrode potential when the welding output is on. Do not touch the metal tab or thumb screw unless input power is turned OFF. Do not allow the metal tab or thumb screw to touch other parts of the wire feeder or to touch part at work potential.(See Figure A.1)

FIGURE A.1

THUMB SCREW

METAL TAB OF THE WELDING GUN

A-2

Page 11

INSTALLATIONPOWER FEED™ 25M NNS

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 NNS 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.

Do not submerge the POWER FEED™ 25M NNS.

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

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

CABLE CONNECTION

There is one connector on the front of the POWER FEED™ 25M

NNS for the gun trigger. (See 2-prong Figure A.2)

Figure A.2

ARCLINK CONTROL CABLES

There is one circular connector on the rear of the POWER FEED™ 25M NNS. Maximum control cable length is 200 ft (61 m). (See Figure A.3)

FIGURE A.3

Function

5-pin ArcLink connector.

(See Figure A.4) 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 B C

67 Electrode Voltage Sense D E

Wiring

ArcLink ArcLink

40VDC

Common

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

HIGH FREQUENCY PROTECTION

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

CAUTION

between components.

Figure A.4

Locate the POWER FEED™ 25M NNS away from radio controlled machinery. The normal operation of the POWER FEED™ 25M

POWER SOURCE

WIRE FEEDER

NNS may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

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

Power Source

Pin Function

A ArcLink B ArcLink C "67" voltage sense D40 VDC E Common

A-3

Wire Feeder

Pin Function

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

Page 12

INSTALLATIONPOWER FEED™ 25M NNS

Electrtrode

Work

El ect r ode

or k

El ec t r ode

or k

Power Sour ce

Coax i al W

el d Cabl e

Wi r e Feeder

WELD CABLE SIZE

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

COAXIAL WELD CABLE

(See Table A.2)

lead extension for best 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.

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

Power Sour c e

or k

El ec t r ode

to form the work lead, one end attached to the power source and the other end to the work piece. See Figure A.5

FIGURE A.5

Coaxial W

el d Cabl e

El ec t r ode

Wi r e Feeder

or k

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

50 to 75 Ft.

(15.2 to 22.9M)

1 1

75 to 100 Ft.

(22.9 to 30.5M)

1/0

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

PERCENT

DUTY

CYCLE

100

40 & 30

30 40 60

100

60 60

100

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

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).

A-4

Page 13

INSTALLATIONPOWER FEED™ 25M NNS

SHIELDING GAS CONNECTION

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.

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

AXIMUM INLET PRESSURE IS

Install the shielding gas supply as follows:

100

PSI

. (6.9

BAR

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 thumb-

screws counter-clockwise to unscrew them from the feed plate.

4. Rotate the triangular lock and remove the drive rolls.

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% CO cylinder, insert regulator adapter between regulator and cylinder

valve. If adapter is equipped with a plastic washer, be sure it is seated for connection to the 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.

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

A-5

Page 14

CONNECT AALL SSENSE LEADS

THE EEND

THE WWELD

CONNECT

WORK

LEAD

THE

BEGINN

THE WWELD

DIRE

TI ON

TRAVEL

INSTALLATIONPOWER FEED™ 25M NNS

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

• Do not wear gloves when threadin

g wire or

changing w ir e spool.

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

REMOTE SENSE LEAD SPECIFICATIONS

Welding with Multiple Arcs: ( See Figure A.6)

Special care must be taken when more than one arc is welding

imultaneously on a single part. Arc blow and arc interference

s 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.6

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

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

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.

1. Squeeze the release bar on the retaining collar and 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.

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.

FIGURE A.6

TI O

AAT TH

F FTH

A-6

Page 15

TYPICAL SYSTEM CONFIGURATIONS

STANDARD FEATURES

Arc Performance

• 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:

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

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

INSTALLATIONPOWER FEED™ 25M NNS

• 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.

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

Extras:

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

• Internal lights for illuminating the wire drive compartment.

A-7

Page 16

POWER FEED™ 25M NNS

OPERATION

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE.

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.

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

INPUT POWER

OFF

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

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

ARC RAYS can burn.

• Wear eye, ear and body protection.

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

SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MANUAL.

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

B-1

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

WARNING OR CAUTION

Page 17

POWER FEED™ 25M NNS

OPERATION

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

• Constant Current

• Constant Voltage

GMAW

• Gas Metal Arc Welding

DUTY CYCLE

The POWER FEED™ 25M NNS 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 NNS may run continuously for 6 minutes and then must sit idle for 4 minutes.

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

B-2

Page 18

POWER FEED™ 25M NNS

RECOMMENDED PROCESSES

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

• FCAW

• SMAW

GTAW (Lift Start only)

•

• Solid wires .025" to 1/16"

• Cored wires .035" to 5/64"

EQUIPMENT LIMITATIONS

• Works only on ArcLink®Power Wave power sources.

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

• 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).

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

RECOMMENDED POWER SOURCES

• Power Wave®355M

• Power Wave

455M

455M/STT

S350

R350

i400

OPERATION

B-3

Page 19

POWER FEED™ 25M NNS

CASE FRONT CONTROLS

(SEE FIGURE B.1)

OPERATION

10. Gun Trigger Connection

1. Left DISPLAY window

Shows WIRE FEED SPEED or AMPERAGE.

2. Left KNOB

Adjusts values in left display.

3. Main display

Shows detailed welding and diagnostic information.

4. Left Button

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

5. Procedure Button

Selects A or B procedure, or gun control.

6. 2-Step/4-Step Button

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

7. Gun Shielding Gas Connections

8. ON/OFF switch

Controls power to the POWER FEED™ 25M NNS.

9. Gun Electrode Connection

FIGURE B.1

11. Right Display window

Shows VOLTAGE or TRIM.

12. Right Knob

Adjusts values in the right display.

13. Thermal

Lights when the drive overheats.

14. Set-Up

Lights when feeder is set-up.

15. Right Button

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

16. Set Knob

Changes the value on the Main display.

17. Memories Buttons

For selection of common procedures.

18. Gun Conduit Connection

B-4

Page 20

ELECTRI C SHOCK can kill.

• Turn the input power OFF at the welding pow er source before installation or

chang-

ing drive rolls and/or guides.

• Do not touch el ectrically live parts.

• When inching with the g

un trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized sever

al seconds after the gun trigger is released.

• Welding power source must be connected to system groun

d per the National Electrical Code or any applicable loca l codes.

• Only qualified personnel should perf

orm maintenance work.

The serviceability of a product or structure utilizing the welding p r o g r a m s is and mus t b e th e so l e r e

s p on s ib i li t y of t he builder/user. Many variables beyond the control of The Li ncoln Electric Company aff

ect the results obtained in applying these

programs. These variables include, but are not limited to,

welding proced ur e, plate ch emistry and temperatu r e , weldmen t design, fabrication methods and service

requirements. The availab le rang e o f a welding p rogr am m ay not be suit able fo r a ll appli cations, and

the build/user is and must be solely responsi-

ble for welding pro gram selection.

POWER FEED™ 25M NNS

OPERATION

8. 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

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

POWER WAVE SYSTEM OPERATION

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.

WARNING

---------------------------------------------------------------------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.

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

B-5

Page 21

POWER FEED™ 25M NNS

WIRE FEED SPEED / AMPS DISPLAY AND KNOB

FIGURE B.2

The left display and knob are used to adjust either wire feed speed or amperage, depending upon the process selected.

While welding, the amps LED lights when amperage is displayed and the wire feed speed LED lights when WFS is displayed.

OPERATION

B-6

Page 22

POWER FEED™ 25M NNS

OPERATION

VOLTAGE / TRIM DISPLAY AND KNOB

The right display and knob control voltage, trim or output depending upon the process selected. Once welding is complete, the display continues to show the welding voltage for 5 seconds.

Process

SMAW (Stick) and GTAW (TIG)

Non-synergic GMAW (MIG) and FCAW (Flux-cored)

Display / Function

Weld Output

Voltage

Description

Rotate clockwise to turn output ON.

Rotate counterclockwise to turn output OFF.

Adjusts the voltage. The display is blank for non-synergic STT modes.

Synergic GMAW (MIG) and FCAW (Flux-cored)

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. The display is blank for synergic STT modes.

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

Voltage

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

• Preset voltage below idealvoltage. (lower bar displayed)

B-7

Page 23

POWER FEED™ 25M NNS

VOLTAGE / TRIM DISPLAY AND KNOB

OPERATION

Process

Pulse GMAW (MIG) and FCAW (Flux-cored)

Display / Function

Trim

Description

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.

Trim .50

Arc Length Short

Trim 1.00

Arc Length Medium

Trim 1.50

Arc Length Long

B-8

Page 24

POWER FEED™ 25M NNS

SELECTING A WELD MODE

Weld modes may be selected by mode number or through a search function.

To select a weld mode:

1. Press the left button until the Weld Mode Menu LED illuminates.

2. Rotate the center knob to select the weld mode.

To enter the search function:

1. Rotate the center knob until “Weld Mode Search” is displayed and then press the right button.

2. Rotate the center knob to select the wire material. Press the right button to accept and the left button to cancel.

3. Rotate the center knob to select the wire size. Press the right button to accept and the left button to cancel.

4. Rotate the center knob to make the final selection about the process, gas type and waveform. Press the right button to accept and the left button to cancel.

OPERATION

B-9

Page 25

POWER FEED™ 25M NNS

OPERATION

WAVE CONTROL

Wave Control is used to adjust the arc for exact preferences. The wave control functions vary for different processes and weld modes.

Process

SMAW (Stick)

GMAW (MIG) and FCAW (Flux-cored)

Wave Control Name

Arc Force

Pinch

Effect / Range

Soft (-10.0) to Crisp (10.0)

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 of organic coated electrodes, particularity 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.

Pinch controls the arc characteristics when short-arc welding.

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.

GMAW-P (Pulsed MIG), Steel and Stainless

Ultimarc

Soft (-10.0) to Stiff (10.0)

Arc Control -10.0 Low Frequency, Wide

Arc Control OFF Medium Frequency and Width

Arc Control +10.0 High Frequency, Focused

For Pulse modes, Arc Control 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.

B-10

Page 26

POWER FEED™ 25M NNS

WAVE CONTROL

OPERATION

Process

GMAW-STT (Surface Tension Transfer

Wave Control Name

Peak Current

Effect / Range

Controls arc length

Description

Peak Current acts similar to an arc pinch control. Peak Current sets the arc length and promotes good fusion. Higher peak current levels will cause the arc to broaden momentarily while increasing arc length. If set too high, globular transfer may occur. Setting it too low may cause instability and wire stubbing. Best practice is to adjust for minimum spatter and puddle agitation.

Peak also affects the shape of the root. When using 100% CO2, the peak current will be higher than when welding with blended shielded gases. A longer arc length is required with CO2 to reduce spatter.

Background current adjusts the overall heat input into the weld. Changing the background current changes the shape of the back bead. 100% CO2 requires less background current than when welding with blended shielding gases.

GTAW (TIG)

Background Current

Tail-out

No wave controls available.

Regulates bead contour

Provides additional power to the arc.

----

Tail out provides additional power without the molten droplet becoming too large. Increase as necessary to add heat input without increasing arc length. Often this results in faster travel speeds. Note that as tail out increases, the peak current and/or background current may need to be reduced.

----

B-11

Page 27

POWER FEED™ 25M NNS

2-St

2- STEP 4- STEP- TRIGGER OPERATION

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. 4Step 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 welding 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

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.

ep Trigger

B-12

Page 28

POWER FEED™ 25M NNS

OPERATION

2-Step T rigger

2-Step Trigger controls the welding sequence in direct response to the trigger. 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.

Example 1: 2-Step Trigger: Simple operation

The simplest trigger operation occurs with a 2-Step trigger and Start and Crater set to OFF.

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 2.0 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.

Trigger Pulled

Arc Established

Trigger Released

B-13

Page 29

POWER FEED™ 25M NNS

Trigger Pulled

Arc Established

Trigger Released

OPERATION

2-Step T rigger

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.

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 2.0 seconds, the power source output and wire feed speed skips to the weld settings.

START: 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.

B-14

Page 30

POWER FEED™ 25M NNS

Trigger Pulled

Arc Established

Trigger Released

OPERATION

2-Step T rigger

Example 3: 2-Step Trigger: Customized Arc Start, Crater and Arc End Aluminum is an example of where start, crater and burnback are commonly used to improve welding performance.

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 2.0 seconds, the power source output and wire feed speed skips to the weld settings.

START & 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: After the crater time expires, the wire feed speed is turned OFF and the machine output continues for the burn-

back time.

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

2-Step trigger: Special considerations

The weld sequence response depends upon when the trigger is pulled and released and whether or not START or CRATER are active.

An example sequence: Pull the trigger to start feed of wire. When arc is established the sequencer will begin START/UPSLOPE. If trigger is released during UPSLOPE and CRATER/DOWNSLOPE is active, the machine will begin CRATER/DOWNSLOPE and sloping down over the CRATER time, regardless of when the trigger release occurred.

If the CRATER is disabled and the trigger is released during START/UPSLOPE, the sequencer will move to the BURNBACK state to end the weld.

B-15

Page 31

POWER FEED™ 25M NNS

OPERATION

4-Step T rigger

4-step trigger allows the operator to release the trigger once an arc has been established. To end the weld, the trigger is pulled and then released again.

Two types of 4-Step Trigger are available. Use the set-up menu to select the desired type of operation.

With current interlock, if the arc goes out for more than 0.5 seconds while the trigger is released, the welding process stops and goes to the idle state.

Without the current interlock, if the arc goes out while the trigger is released, output to the power source remains on and the wire feeder will continue to feed wire.

Example 1: 4-Step Trigger: Trigger Interlock

The 4-Step trigger can be configured as a trigger interlock. Trigger interlock adds to the welder’s 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.

For this sequence,

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. The trigger is released and welding

continues. Welding continues when the trigger is pulled a second time

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.

Trigger Pulled

Arc Established

Trigger Released

Trigger Pulled

Trigger Released

B-16

Page 32

POWER FEED™ 25M NNS

OPERATION

4-Step T rigger

Example 2: 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.

In this sequence,

piece at the run-in WFS. If an arc is not established within 2.0 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. If the trigger is pulled before upslope is complete, WELD is skipped and the sequence jumps to DOWNSLOPE.

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

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

As soon as the trigger is pulled, 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

time.

Trigger Pulled

Arc Established

Trigger Released

Trigger Pulled

Trigger Released

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POWER FEED™ 25M NNS

OPERATION

Spot T rigger

The Spot Trigger may only be selected if the Spot Time has previously been set to a value other than 0.0 (OFF) and the Start and Crater are both OFF.

Spot time causes the welding system to turn on for a fixed time, regardless if the trigger is held for a longer period of time. If the trigger is released before the spot timer is complete, welding stops.

If the Spot Time is set to 0.0 (OFF), the left display will be blank and the right display will show “OFF”. The Spot Time LED from the timer menu will blink twice. After 2.0 seconds, the trigger menu cycles back to the Cold Feed Trigger option.

If Start is not set to OFF, the left display will be blank and the right display will show “On”. The Start LED from the sequence menu will blink twice. After 2.0 seconds, the trigger menu cycles back to the Cold Feed Trigger option.

If Crater is not set to OFF, the left display will be blank and the right display will show “On”. The Crater LED from the sequence menu will blink twice. After 2.0 seconds, the trigger menu cycles back to the Cold Feed Trigger option.

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POWER FEED™ 25M NNS

OPERATION

4-Step T rigger: Special Considerations

The response to the trigger with 4-step trigger active is dependent upon when the trigger is pulled/released and the settings for START and CRATER.

Example 1. Pull the trigger to start feed of wire. When arc is established the sequencer will remain in START until the trigger is released. When the trigger is released, UPSLOPE begins. If trigger is pulled again during UPSLOPE and CRATER/DOWNSLOPE is active, the feeder will begin the DOWNSLOPE, sloping down over the CRATER time, regardless of when the trigger pull occurred.

If the CRATER/DOWNSLOPE state is disabled and the trigger is pulled during UPSLOPE, the sequencer will remain in the UPSLOPE state and continue with the weld. If the fourth step (trigger release) occurs during UPSLOPE, the sequencer will jump to the BURNBACK to end the weld.

Example 2: Pull the trigger to start feed of wire. When arc is established the sequencer will remain in START until the trigger is released. When the trigger is released, UPSLOPE begins and continues into WELD when the START timer is complete. When the trigger is pulled again (step 3) and CRATER/DOWNSLOPE is active, DOWNSLOPE begins and continues until the CRATER timer expires, at which time CRATER will be entered until the trigger is released.

While in DOWNSLOPE, if the trigger is released before the timer expires, the trigger will be ignored and the DOWNSLOPE state will continue until the timer expires, at which point CRATER state will be enabled, check for trigger, and jump to BURNBACK since the trigger has been released.

While in the DOWNSLOPE state and the trigger is released and then pulled again, it will be ignored. During 4-Step operation in DOWNSLOPE, the trigger will always be ignored.

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POWER FEED™ 25M NNS

START OPTIONS

The Start Options available depend upon the process and weld mode selected.

OPERATION

Process

SMAW (Stick)

All GMAW (MIG) and FCAW (Fluxcored)

GTAW (TIG)

END OPTIONS

Start Options

----

Preflow Time

Run-In WFS

Start time, WFS and Volts

----

Effect / Range

----

0 – 25.0 seconds

Auto, OFF, 30 in/min to weld WFS

0 – 10.0 seconds

----

Description

----

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

Use run-in for softer arc starts.

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.

----

The End Options available depend upon the process and weld mode selected.

Process

SMAW (Stick)

All GMAW (MIG) and FCAW (Fluxcored)

GTAW (TIG)

Start Options

----

Spot Timer

Crater Time, WFS and Volts

Burnback Time

Postflow Time

Effect / Range

----

0 – 10.0 seconds

Auto,

0 – 0.25 seconds

0 – 25.0 seconds

Description

Sets the length of time for welding when the trigger is pulled. If the trigger is released before the Spot Timer is complete, welding stops.

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.

Crater is not commonly used with STT processes.

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.

----

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POWER FEED™ 25M NNS

OPERATION

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

DEFINITION

Unsecured Parameters (always adjustable)

Diagnostic Parameters (always read only)

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

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.

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POWER FEED™ 25M NNS

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.

OPERATION

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.

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POWER FEED™ 25M NNS

USER DEFINED PARAMETERS

Parameter Definition

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.

"Feeder Solenoid" = The internal (feeder) MIG solenoid will turn on and off automati-

cally while TIG welding.

"Pwr Src Solenoid" = 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.

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.

OPERATION

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).

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.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.

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POWER FEED™ 25M NNS

USER DEFINED PARAMETERS

Parameter Definition

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.

P.27 Language Select

Selects which language will be displayed on the User Interface. English (Default) Italiano

Deutsch Francais Polski Espanol

OPERATION

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.

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.

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POWER FEED™ 25M NNS

USER DEFINED PARAMETERS

Parameter Definition

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).

OPERATION

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.

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.

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POWER FEED™ 25M NNS

USER DEFINED PARAMETERS

Parameter Definition

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.

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.

OPERATION

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.

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.

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POWER FEED™ 25M NNS

USER DEFINED PARAMETERS

Parameter Definition

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.

OPERATION

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.

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POWER FEED™ 25M NNS

OPERATION

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

GUN B

USER

MEMORIES

ARE COPIED TO

PROCEDURE

MEMORY

(8) USER

MEMORIES

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

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

GUN B

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OPERATION

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

GUN B

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.

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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

WELD MODE

ARC CONTROL

Parameter Name

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.

SET

SETUP

START OPTIONS

END OPTIONS

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

Enable/Disable

Limits: Press

10 seconds

GUN B

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:

200

HI = 200 LOW = 180

WELD WFS

ELD MODE

RC CONTROL

Rotate to

Change

Value.

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.

SET

SETUP

START OPTIONS

END OPTIONS

Press to

select item

to change.

MEMORY 2 LIMITS ENABLE/DISABLE

WELD MODE

ARC CONTROL

START OPTIONS

END OPTIONS

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.

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POWER FEED™ 25M NNS

INTERNAL CONTROLS

OPERATION

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 Adapter 7 Thumb Screw for securing the Gun Adapter

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FCAW GMAW

OPERATION

COLD FEED/GAS PURGE SWITCH

Cold Feed and Gas Purge are combined into a Rocker switch.

To activate Cold Feeding, push and hold the Rocker 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.

Push the Rocker 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.

LIGHT SWITCH

Push the light Rocker switch to illuminate the inside of the POWER FEED™ 25M NNS

COLD FEED/GAS PURGE ROCKER SWITCH

COLD

FEED

GAS

PURGE

LIGHT ROCKER SWITCH

LIGHTS

G7937-2 VM

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

Push the heater switch ON to warm the inside of the POWER FEED™ 25M NNS. The heater is useful for reducing condensation build-up on the spool of wire.

HEATER ROCKER SWITCH

HEATER

OFF

FCAW GMAW

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REAR CONTROLS:

OPERATION

ITEM DESCRIPTION

1 Shielding Gas Inlet

2 ArcLink Cable Connector 3 Electrode Cable

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POWER FEED™ 25M NNS

DRIVE ROLL KITS USED

Drive Roll Kits, Steel wires

KP1505-030S .023-.030 (0.6-0.8mm) KP1505-035S .035 (0.9mm) KP1505-045S .045 (1.2mm) KP1505-052S .052 (1.4mm) KP1505-1/16S 1/16 (1.6mm) KP1505-1 .035,.045 (0.9, 1.2mm) KP1505-2 .040 (1.0mm)

Drive Roll Kits, Cored Wires

KP1505-035C .030-.035" (0.8-0.9mm) KP1505-045C .040-.045" (1.0-1.2mm) KP1505-052C .052" (1.4mm) KP1505-1/16C 1/16" (1.6mm)

Drive Roll Kits, Steel or Cored Wires

KP1505-068 .068-.072" (1.8mm) KP1505-5/64 5/64" (2.0mm) KP1505-3/32 3/32" (2.4mm) KP1505-7/64 7/64" (2.8mm) KP1505-.120 .120" (3.2mm)

ACCESSORIES

Includes: 4 Smooth V groove drive rolls and inner wire guide.

Includes: 4 Knurled drive rolls and inner wire guide.

Drive Roll Kits, Hardfacing Wires

KP1505-7/64C 7/64" (2.8mm)

Drive Roll Kits, Aluminum Wire

KP1507-035A .035" (0.9 mm) KP1507-040A .040" (1.0mm) KP1507-3/64A 3/64" (1.2mm) KP1507-1/16A 1/16" (1.6mm) KP1507-3/32A 3/32" (2.4mm)

K2596-2 Plastic Case

K4405-xx

Heavy Duty ArcLink Control Cable

Includes: 2 Knurled drive rolls, 2 Smooth V groove drive rolls and inner wire guide.

Includes: 4 polished U groove drive rolls, outer wire guide and inner wire guide, pressure door springs, conduit bushing.

Includes: a complete engineered plastic case. Decals and latches

are all preassembled.

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.

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POWER FEED™ 25M NNS

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.

ACCESSORIES

To verify the voltage display:

• Set the welding power source and POWER FEED™ 25M NNS 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 NNS 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 NNS.

To verify the wire feed speed:

• Assemble a .045 (1.2mm) drive roll kit into the

POWER FEED™ 25M NNS.

• 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.

D-1

Page 51

POWER FEED™ 25M NNS

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.

__________________________________________________________________________

TROUBLE SHOOTING

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.

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POWER FEED™ 25M NNS

PROBLEMS

(SYMPTOMS)

Fault Code

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Linc-Net System Error Codes

Description

RECOMMENDED

COURSE OF ACTION

Possible Adjustments

TROUBLE SHOOTING

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

CAUTION

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Page 53

POWER FEED™ 25M NNS

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

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

No shielding gas.

POSSIBLE

CAUSE

Output Problems

1. The POWER FEED™ 25M NNS 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.

TROUBLE SHOOTING

RECOMMENDED

COURSE OF ACTION

1. Turn the POWER FEED™ 25M NNS 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

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Page 54

POWER FEED™ 25M NNS

PROBLEMS

(SYMPTOMS)

Variable or "hunting" arc.

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Output Problems

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. Replace the contact tip.

2. Verify all work and electrode con-

3. Adjust polarity to the recommend-

4. Adjust the gas nozzle and shorten

5. Check gas flow and mixture.

RECOMMENDED

COURSE OF ACTION

nections are tight and that the cables are in good condition. Clean/replace as necessary.

ed procedure. the stickout to 3/8 to 1/2 inches.

Remove or block sources of drafts.

TROUBLE SHOOTING

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. Improper procedures or techniques.

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

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

1. Contact the local authorized Lincoln Field Service Shop.

CAUTION

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POWER FEED™ 25M NNS

DIAGRAMS

F-1

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.

Page 56

POWER FEED™ 25M NNS

DIAGRAMS

17.2

14.8

23.1

12 X 18 In. Ellipse

16 In. Circle

8.7

5.7

14.8

17.2

F-2

Page 57

PARTS LIST FOR

Power Feed

P-754 P-754

™

25M NNS

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 NNS

Page 58

P-754-A

ILLUSTRATION OF SUB-ASSEMBLIES

P-754-A

POWER FEED™25M NNS

Jan-14

Page 59

P-754-A.1P-754-A.1

Power Feed™25M NNS

For Code: 12244

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.

se the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and

U column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

PAGE NO.

CODE NO.

12244 11111

Front Panel Assembly

P-754-C

Control Box Assembly

P-754-D

Spindle & Mast Assembly

P-754-E

Wire Drive Assembly

P-754-F

Case Assembly

P-754-G

POWER FEED

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25M NNS

Jan-14

Page 60

Front Panel Assembly

P-754-CP-754-C

10B

10A

11B

11A

POWER FEED™25M NNS

Jan-14

Page 61

P-754-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

Case Front Assembly, Includes: NSS 1X

1 Case Front G5577-5 1 X 2 Nameplate (G7937) NSS 1X 3 Button Cover, Small S23055-1 12 X 4 Potentiometer Insulation S27401 1 X 5A User Interface P.C. Board S28540-[ ] 1 X 5B Sems Screw T10082-12 4 X 6 Shaft Seal T14034-4 2 X 7 Knob M22778-1 3 X 8 Switch, SPST T10800-71 1 X 9 Cam-Lok Receptacle, Includes: M25112 1 X 9A Conduit Lock Nut T14370-3 1 X 9B Plain Washer S9262-120 1 X 9C Lock Washer E106A-16 1 X 9D 3/8-16 Hex Jam Nut CF000121 1 X 10 Female Connector, Includes T14557-3 1 X 10A Lock Washer T9695-8 1 X 10B 1/2-13 Jam Nut CF000054 1 X 11 Receptacle, Includes: S25449 1 X 11A #6-32 HN CF000054 2 X 11B Lock Washer E106A-13 2 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

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25M NNS

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Control Box Assembly

25A

25B

11D

19A

16A

16C

13A

13B

19E

19B

19C

19H

19F

19G

11B

11C

15A

P-754-DP-754-D

15A

19G

19F

19B

19C

19H

19A

19E

13B

25A

16C

16A

13A

11D

11C

11B

25B

POWER FEED

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25M NNS

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Page 63

P-754-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, Includes: NSS 1X

1 Control Box G5584-8 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 6A Flex Tube T10642-265 1 X 6B Hose Clamp (Not Shown) T13777-8 1 X 7A Spindle & Mast Assembly (G5572-2) See P-754-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 Bus Bar M21006-6 1 X 12A Sleeving (Not Shown) E1159/B-.875-10.00 CS000902 1 X 13 Weld Cable, Includes: M21463-4 1 X 13A Cord Grip Connector S19999 1 X 13B Conduit Lock Nut T14370-3 1 X 13C Cam-Lok Welding Plug (Not Shown) M25115 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 M21501-4 1 X 19 Resistor Bank Asbly, 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

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25M NNS

Jan-14

Page 64

Spindle & Mast Assembly

P-754-EP-754-E

Jan-14

POWER FEED

™

25M NNS

Page 65

P-754-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

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25M NNS

Jan-14

Page 66

Wire Drive Assembly

P-754-FP-754-F

13B

13A

15A

15B

15C

10A

POWER FEED™25M NNS

Jan-14

Page 67

P-754-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: M21079-10 1 X

1 Wire Drive Panel G5569-2 1 X

Feed Plate Assembly, Includes: M19932-8 1 X

2A Idle Arm NSS 1X 2B Adjustment Arm Assembly M20593-3 1 X 2C Self Tapping Screw S9225-102 4 X 2D Set Screw S11604-21 1 X 3 Motor Gearbox Assembly, Includes: L12081-1 1 X 3A Drive Motor NSS 1X 3B Connector, Molex S24018-8 1 X 3C Locking Post (Not Shown) S24019-8 1 X 3D Woodruff Key (Not Shown) S24170-1 1 X 3E Snap Ring (Not Shown) S9776-27 1 X 3F Motor Brush & Brush Cap (Not Shown) S28460 1 X 3G Lock Washer E106A-2 3 X 3H M6 x 1.00 PPHS 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 Wire Guide Assembly (Outer), Includes: KP2071-3 1 X 6A Wire Guide Knob S24396 2 X 7 Ball Housing M18946 1 X 10 Drive Roll Shaft Assembly, Includes: S25638 2 X 10A Twist Lock Ring S25308 2 X 11 Retainer S25403 2 X 12 Plug and Lead Assembly (switch & LEDs) (Not Shown) M22587 1 X 13A LED Lens, Clear S23093-1 2 X 13B O Ring T13483-7 2 X 14 Thread Forming Screw S9225-99 4 X 15A Switch Panel S25706-1 1 X 15B Decal, Switch Panel (G7937-2) (Part of G7937) NSS 1X 15C Thread Forming Screw S9225-99 2 X 16 Rocker Switch T10800-71 2 X 17 Momentary Rocker Switch T10800-76 1 X 18 Plug Button T10397-3 1 X

NSS - Not Sold Separately

POWER FEED

™

25M NNS

Jan-14

Page 68

P-754-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

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 NNS

Jan-14

Page 69

NOTES

POWER FEED™25M NNS

Page 70

Case Assembly

P-754-GP-754-G

12A

POWER FEED

™

25M NNS

Jan-14

Page 71

P-754-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 (G5661-2), Includes: K2596-2 1 X

1 Plastic Case Asbly (G5660) NSS 1X 2 Warning Decal (S20601-2A)(Part of S20601-2) NSS 1X 3 Case Logo Decal S11893-9 1 X 4 Warning Decal (S20601-2B)(Part of S20601-2) NSS 1X 5 Warning Decal S25536-1 1 X 6 Door Logo Decal S11893-8 1 X 7 Decal - Crossed Out Wheeled Bin T13086-201 1 X 8 Plug Button T10397-6 2 X 9 Plug Button T10397-19 2 X 10 Gasket S26924 1 X 11A Insulated Fastener (Not Shown) T15088-2 6 X 11B Thread Forming Screw (Not Shown) S9225-102 2 X 12A Handle Assembly S18170 1 X 12B Plain Washer (Not Shown) S9262-98 2 X 12C Plain Washer (Not Shown) S9262-113 1 X 12D Lock Washer (Not Shown) E106A-2 2 X 12E 1/4-20 x .625 HHCS (Not Shown) CF000013 2 X

NSS - Not Sold Separately

POWER FEED

™

25M NNS

Jan-14

Page 72

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 IM10180 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual