Lincoln Electric IM10180 User Manual
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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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.
i
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.
2
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.
3
cause
SAFETY
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures will
not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society (see address
above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in
Cylinders,” available
from the Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Welding Safety
Interactive Web Guide
for mobile devices
4
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.
5
The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.
METHODS OF REDUCING EMISSIONS
Mains Supply
Welding equipment should be connected to the mains supply
according to the manufacturer’s recommendations. If interference
occurs, it may be necessary to take additional precautions such as
filtering of the mains supply. Consideration should be given to
shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding should be
connected to the welding power source so that good electrical contact
is maintained between the conduit and the welding power source
enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to
the manufacturer’s recommendations. All access and service doors
and covers should be closed and properly fastened when the welding
equipment is in operation. The welding equipment should not be
modified in any way except for those changes and adjustments
covered in the manufacturers instructio ns. In particular, the spark
gaps of arc striking and stabilizing devices should be adjusted and
maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be
positioned close together, running at or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and
adjacent to it should be considered. However, metallic components
bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the
electrode at the same time. The operator should be insulated from all
such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not
connected to earth because of its size and position, e.g., ships hull or
building steelwork, a connection bonding the workpiece to earth may
reduce emissions in some, but not all instances. Care should be taken
to prevent the earthing of the work piece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary,
the connection of the workpiece to earth should be made by a direct
connection to the work piece, but in some countries where direct
connection is not permitted, the bonding should be achieved by
suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in
the surrounding area may alleviate problems of interference.
Screening of the entire welding installation may be considered for
special applications.
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic
Compatibility (EMC) product standard for arc welding equipment.”
TABLE OF CONTENTS
Page
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
S
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
_______________________________________________________________________
________
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.
7
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
4A
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
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
INSTALLATIONPOWER FEED™ 25M NNS
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
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.
PIN
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
INSTALLATIONPOWER FEED™ 25M NNS
Electrtrode
Work
Work
El ect r ode
W
or k
El ec t r ode
W
or k
Power Sour ce
Coax i al W
el d Cabl e
Wi r e Feeder
WELD CABLE SIZE
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
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
60
100
20
40 & 30
30
40
60
100
60
100
60
60
100
60
0 to 50Ft.
(0 to15M)
2
2
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
50 to 100Ft.
(15 to 30M)
2
2
3
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
100 to 150 Ft.
(30 to 46M)
2
2
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
150 to 200 Ft.
(46 to 61M)
1
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
200 to 250 Ft.
(61 to 76M)
1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
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
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.
----------------------------------------------------------------------
M
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
2
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
CONNECT AALL SSENSE
LEADS
THE EEND
O
THE WWELD
CONNECT
A
LL
WORK
LEAD
S
AT
THE
BEGINN
IN
G
OF
THE WWELD
DIRE
C
TI ON
OF
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.
OF
B
TH
OF
L
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
A
A
G
AAT TH
F FTH
A-6
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
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
ON
OFF
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
INPUT POWER
DIRECT CURRENT
U
U
0
1
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
U
I
I
2
1
2
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVE
GROUND
WARNING OR
CAUTION
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
CC
• Constant Current
CV
• 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
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
• Power Wave
• Power Wave
• Power Wave
• Power Wave
®
455M
®
455M/STT
®
S350
®
R350
®
i400
OPERATION
B-3
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
1
2
11
12
3
13
4
14
15
5
6
16
17
7
18
8
9
10
B-4
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
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
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
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