Lincoln Electric IM761 User Manual

POWER FEED 15M

R

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For use with machines having Code Number : 10940

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.

IM761

September, 2005

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

NRTL/C

OPERATOR’S MANUAL

Copyright © 2005 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

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 Above For Diesel Engines

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.

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

The Above For Gasoline Engines

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.

____________________________________________________

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.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

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.

___________________________________________________

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.

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.

Mar ‘95

ii

SAFETY

ii

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.

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 below Threshold Limit Values (TLV)
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.

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
between the 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.

3.j. Also see Items 6.c. and 8.

5.b.

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

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. 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.e. Also see item 1.b.

vapors

Mar ‘95

to

iii

SAFETY

iii

WELDING 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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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.

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

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

vv

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

vi

TABLE OF CONTENTS

Page

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

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

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

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

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

Digital Welding System Components ...................................................................................A-2

Control Cable Connection ....................................................................................................A-3

Weld Cable Size and Table..................................................................................................A-3

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

Electrode Polarity .................................................................................................................A-4

Shielding Gas Connection....................................................................................................A-4

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

Wire Drive Configuration ......................................................................................................A-6

Procedure to Install Drive Rolls and Wire Guides ................................................................A-6

Remote Sense Lead Specification .......................................................................................A-7

________________________________________________________________________________

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

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

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

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

General Description..............................................................................................................B-3

Duty Cycle ............................................................................................................................B-3

Recommended Processes ...................................................................................................B-3

Processes Limitations ..........................................................................................................B-3

Equipment Limitations ..........................................................................................................B-3

Making a Weld with Waveform Technology Power Sources................................................B-4

General Welding Adjustments..............................................................................................B-4

1. WFS/AMPS ...............................................................................................................B-4

2. Volts/Trim ..................................................................................................................B-4

3. Welding Mode ...........................................................................................................B-4

4. Arc Control ................................................................................................................B-4

Constant Voltage (CV) Welding ...........................................................................................B-5

Pulse Welding ......................................................................................................................B-5

STT Synergic Welding..........................................................................................................B-6

Case Front Controls .............................................................................................B-7 thru B-10

Extended Features Menu ...................................................................................................B-11

Internal Controls .................................................................................................................B-12

Cold Feed/Gas Purge Switch......................................................................................B-12

Idle Roll Pressure Setting............................................................................................B-12

Flow Meter..........................................................................................................................B-13

2 Step - 4 Step Trigger Operation and Graphics ................................................B-14 thru B-18

________________________________________________________________________________

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

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

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

Common Packages with Accessories Used.........................................................................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,E-3

Troubleshooting Guide ...........................................................................................E-4 thru E-5

________________________________________________________________________________

vi

Wiring Diagram & Dimension Prints .............................................................................Section F

________________________________________________________________________________

Parts Pages .............................................................................................................................P484

_______________________________________________________________________

________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS –

INPUT VOLTAGE and CURRENT

MODEL

K2196-1

Domestic

DUTY CYCLE

35% rating
60% rating

100% rating

ELECTRODE DIAMETERS and SPEED RANGE

PROCESS

GMAW

GMAW-Pulsed

GMAW-STT

FCAW

FCAW- Gas Shielded

ELECTRODE DIAMETER RANGE

.023 - .052"

(0.6 -1.3 mm)

.023 - .052"

(0.6 -1.3 mm)

.023 - .052"

(0.6 -1.3 mm)

0.035 - 5/64"

(0.9mm - 2.0 mm)

0.035 - 5/64"

(0.9mm - 2.0 mm)

POWER FEED 15M K2196-1

INPUT VOLTAGE ± 10%

40 VDC

OUTPUT RANGE (AMPERES)

up to 500 Amps

INPUT AMPERES

5A

WIRE FEED SPEED RANGE

50 - 700 ipm (1.3 - 17.8

m/min)

PHYSICAL DIMENSIONS

MODEL

K2196-1

Domestic

HEIGHT WIDTH DEPTH WEIGHT

12 Inches 9 Inches 23.3 Inches 34 lbs
(305 mm) ( 229 mm) (590 mm) (15.5 kg)

TEMPERATURE RANGE

OPERATION: -14° F to 140° F (- 10° C to 60oC)
STORAGE: - 40° F to 185° F (- 40° C to 85oC)

POWER FEED 15M

A-2

Digital Control Cable

Work
Cable

Electrode Cable

Power Sou rc e

Wire Feeder

+

-

Welding Gun

Shielding
Gas Hose

Shielding
Gas Hose

Digital Control Cable

Work
Connection

Coaxial Weld Cable

Power Sourc e

Wire Feeder

+

-

Welding Gun

SAFETY PRECAUTIONS

INSTALLATION

HIGH FREQUENCY PROTECTION

A-2

WARNING

ELECTRIC SHOCK CAN KILL.

• ONLY QUALIFIED PERSONNEL
SHOULD PERFORM THIS
INSTALLATION.

• Turn off input power to the power

source at the disconnect switch or

fuse box before working on this
equipment. Turn off the input power to any other
equipment connected to the welding system at
the disconnect switch or fuse box before
working on the equipment.

• Do not touch electrically hot parts.

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

LOCATION

The Power Feed 15M has an IP23 rating, suitable for
outdoor use.

The Power Feed 15M should be positioned upright on
a horizontal surface. Do not submerge the Power
Feed 15M in water. The best practice is to keep the
wire feeder in a dry environment. When working
outdoors in severe wet weather, place the Power Feed
15M with the door facing up.

CAUTION

Locate the Power Feed 15M away from radio con­trolled machinery. The normal operation of the
Power Feed 15M may adversely affect the operation
of RF controlled equipment, which may result in
bodily injury or damage to the equipment.

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

CONNECTION DIAGRAMS

CV Welding: Figure A.1

Pulse Welding or STT Welding: Figure A.2

POWER FEED 15M

A-3

Po

wer

Source

A

B

C

D

E

W

ireFeeder

A

B

C

D

E

A

B

C

D

E

CONTROL CABLE CONNECTION:

INSTALLATION

WELD CABLE SIZE

A-3

Digital Control Cable: Figure A.3

Power Source

Pin Function

A Digital I/O
B Digital I/O
C "67" voltage sense
D 40 VDC
E 40 VDC

Wire Feeder

Pin Function

A Digital I/O
B Digital I/O
C "67" voltage sense
D 40 VDC
E 40 VDC

Welding Gun/Wire Feeder Trigger Connector
Wire Feeder: Figure A.4

Wire Feede r

n

i

g Gun

Weld

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.

WIRE FEEDER

Pin Function

A Gun Trigger
B ­C Common
D Dual Procedure
E Common

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

AMPRERES

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

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables

larger than recommended, or cables rated higher than 167°F(75°C).

PERCENT

DUTY

CYCLE

60

100

20

40 & 30

30
40
60

100

60

100

60
60

100

60

0 to 50Ft.
(0 to15M)

2
2

4 or 5

3
3
2
1
1

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

50 to 100Ft.

(15 to 30M)

2
2
3
3
3
2
1
1

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

POWER FEED 15M

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

A-4

Electrode

Work

Work

ElectrodeElectrode

WWorkork

ElectrodeElectrode

W

Workork

Power SourcePower Source

Coaxial WCoaxial Weld Cableeld Cable

Wire FeederWire Feeder

INSTALLATION

COAXIAL WELD CABLE

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 waveshape. Inductance
becomes more severe as the weld cables become longer.

A-4

SHIELDING GAS CONNECTION

WARNING

CYLINDER may explode if

damaged.

• Keep cylinder upright and
chained to support.

Coaxial weld cables are recommended for all pulse and STT
welding, especially when the total weld cable length (elec­trode cable + work cable) exceeds 50 feet (7.6m)

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

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

A coaxial weld cable is constructed by 8 small leads
wrapped around one large lead. The large inner lead con­nects to the electrode stud on the power source and the
electrode connection on the wire feeder. The small leads
combine together to form the work lead, one end attached to
the power source and the other end to the work piece. See
Figure A.5

FIGURE A.5

• 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.

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

Install the shielding gas supply as follows:

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 con-

dition. 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.

ELECTRODE POLARITY

CAUTION

When changing the electrode polarity, the weld cables must be
changed at the power source studs and the DIP switch inside the
Power Feed 15M must be properly set. Operation with the DIP

switch in the wrong position will cause erratic arc performance.

The Power Feed 15M is factory set for Electrode Positive weld­ing. Most welding procedures use Electrode Positive welding.
Some Innershield procedures may use Electrode Negative
welding.

To change the DIP switch iside the Power Feed 15M electrode
polarity:

1. Turn off power at the welding power source.

2. Remove the rear access panel on the wire drive.

3. Locate DIP switches on the Wire Drive Board.

4. Set DIP switch #7 to the desired polarity.
DIP Switch #7 Position Polarity

4. Attach the flow regulator to the cylinder valve and tighten
the union nut(s) securely with a wrench. Note: if connect­ing to 100% CO2 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 CO2 cylinder.

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.

ON (Up) - (negative) polarity
OFF (Down) + (positive) polarity

5. Assemble the rear access panel to the wire drive.

6. Restore power.

POWER FEED 15M

A-5

Low Speed
High T orque
Gear

High Speed
Low T orque
Gear

INSTALLATION

CHANGING THE DRIVE MOTOR GEAR RATIO

WARNING

A-5

11. Use a 5/16" nut driver to remove the four screws

and washers holding the insulated panel to the
sheet metal bracket.

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

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

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

• Only qualified personnel should perform this
operation.

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

Tools required:

• 1/4" hex key wrench

• 3/4" socket and ratchet wrench

• 9/16" socket and ratchet wrench

• 7/16" nut driver

• 5/16" nut driver

• Phillips screw driver

1. Remove the spool of electrode from the wire feeder.

2. Loosen the thumb screw at the wire drive and remove the

welding gun. Take the tension off the drive rollers and
open the tension handle.

12. Lift the wire drive assembly partially out of the wire
feeder. With a Phillips screw driver, remove the
three screws and lock washers securing the
motor. Remove the motor.

13. Place the motor in the new position.

14. Assemble the three screws and lock washers
holding the wire drive motor.

15. Place the wire drive assembly inside the wire
feeder. With a 5/16" nut driver, assemble the four
screws and lock washers to hold the insulating
panel to the sheet metal bracket.

16. With a 7/16" nut driver, replace the bolt at the top
securing the wire drive insulated panel to the
sheet metal case.

17) Move DIP switch #8 on the Feed head board to
the appropriate position.

Gear Select DIP Switch #8 Setting Range

High Speed ON 50 – 700 ipm
Low Speed OFF 50 – 400 ipm

18. Reassemble the cover assembly protecting the
display board with a 5/16" nut driver.

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

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

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

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

7. Remove the electrode lead by unscrewing the bolt using
a 3/4" socket and ratchet wrench.

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

9. With a 5/16" nut driver remove the screws securing the
cover assembly protecting the display board. Lift out the
cover assembly enough so it does not overlap the wire
drive.

10. Use a 7/16" nut driver to remove the bolt at the top

securing the wire drive insulated panel to the sheet
metal case.

POWER FEED 15M

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

20. Reassemble the electrode and tighten the mount­ing hardware with a 3/4" socket and ratchet
wrench.

21. Place the new gear on the motor shaft. Secure the
gear to the motor shaft with the collar, washer and
screw.

22. Reassemble the lower drive roll hub and lower
drive roll hub retainer.

23. Reassemble the gear cover.

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

25. Place the welding gun into the gun bushing and
secure with the thumb screw.

A-6

G

E

WIRE DRIVE CONFIGURATION

(See Figure A-6)

Changing the Gun Receiver Bushing

INSTALLATION

10. Tighten the socket head cap screw.

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

A-6

WARNING

ELECTRIC SHOCK can kill.

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

• Do not touch electrically live parts.

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

• Only qualified personnel should perform mainte­nance work.

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

Tools required:

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

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.

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

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

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

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

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

FIGURE A-6

THUMB SCREW

UN RECEIVER BUSHING

OUTER WIRE GUID

PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES

WARNING

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

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

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

• Only qualified personnel should perform this
operation.

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

1. Release the idle roll pressure arm.

2. Remove the outer wire guide by turning the knurled

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

3. Rotate the triangular shaped drive roll retaining

mechanism to unlock the drive rolls and remove the
drive rolls.

4. Remove the inner wire guide.

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

over the two locating pins in the feed plate.

6. Install a drive roll on each hub assembly and lock

by rotating the triangular drive roll retaining mecha­nism.

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

pins and tightening the knurled thumbscrews.

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

arm. Adjust the pressure appropriately.

CONNECTOR BLOCK

SOCKET HEAD
CAP SCREW

LOOSEN TIGHTEN

POWER FEED 15M

A-7

CONNECT A LL SENSE
LEADS AT THE END
OF THE WELD

CONNECT A

LL

WORK LEAD

S AT

THE BEGINN

ING

OF

THE WELD

DIRE

CTION

OF

TRAVEL

INSTALLATION

REMOTE SENSE LEAD SPECIFICATIONS

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

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

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

FIGURE A.7

A-7

POWER FEED 15M

B-1

OPERATION

B-1

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..

• Do not touch electrically live part or electrode
with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

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

• 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

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

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

U

U

U

I

I

0

1

2

1

2

OPEN CIRCUIT
VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

POWER FEED 15M

B-2

OPERATION

B-2

DEFINITION OF WELDING TERMS

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding

process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of

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

WFS

• Wire Feed Speed

CC

• Constant Current

CV

• Constant Voltage

GMAW

• Gas Metal Arc welding

GMAW-STT

• Gas Metal Arc welding-(Surface Tension Transfer)

SMAW

• Shielded Metal Arc welding

FCAW

• Flux Core Arc Welding

CAC

• Carbon Arc Cutting

CAG

• Carbon Arc Gouging

GMAW-P

• Gas Metal Arc welding-(Pulse Arc)

POWER FEED 15M

B-3

OPERATION

GENERAL DESCRIPTION

The Power Feed 15M is a portable wire feeder for
customers seeking high end arc performance all
packed in a rugged stainless steel case. The stainless
steel case provides protection from corrosion, heat
and rough handling. The heart of the Power Feed­15M is a rugged two roll, two speed wire drive capable
of driving electrode under the most demanding condi­tions. Shielding gas flow is easily regulated with a
built-in, standard flow meter that includes a flow con­trol valve.

The Power Feed 15M runs with the Power Wave
power sources. "Dual boot" software programmed into
the Power Feed 15M operates with both ArcLink and
LincNet Power Waves. Customers may transport the
feeder between one vintage of power source and the
other without having to set any special switches.

A Mode Select Panel-3 type panel is permanently
mounted to the case front of the Power Feed 15M.
The panel allows the operator to customize many
weld parameters, including preflow and postflow
times, start and crater procedures, burnback, and
many more.

B-3

RECOMMENDED PROCESSES

The Power Feed 15M is best suited for alloy elec­trodes, out-of-position work, root welding and general
fabrication.

• GMAW

• GMAW-Pulse

• GMAW-STT

• FCAW

• SMAW

PROCESS LIMITATIONS

The Power Feed 15M is not suitable for:

• SAW

• CAG

• GTAW

EQUIPMENT LIMITATIONS

• The Power Feed 15M does not operate with the
Power Wave 450.

• The Power Feed 15M does not operate with any
analog based power sources (CV-xxx machines,
DC-xxx machines, etc.)

• Electrode spool size must not exceed 8" diameter.

• K435 spindle adapters ("pie pans") for Innershield

electrode do not fit in the Power Feed 15M.

An ON/OFF switch on the case front controls power to
the feeder.

DUTY CYCLE

The Power Feed 15M is rated for 500 amps, 60% duty
cycle and 350 amps, 100% duty. The duty cycle is
based on a 10 minute cycle.

For example, when welding at 500 amps, the Power
Feed 15M may run continuously for 6 minutes and
then must be shut off for 4 minutes.

POWER FEED 15M

B-4

OPERATION

MAKING A WELD WITH WAVEFORM
TECHNOLOGY POWER SOURCES

B-4

GENERAL WELDING ADJUSTMENTS

1. WFS / AMPS:

WARNING

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

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

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

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

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

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

In synergic welding modes (synergic CV, pulse
GMAW, STT or power mode) WFS (wire feed speed)
is the dominant control parameter, controlling all other
variables. The user adjusts WFS according to factors
such as weld size, penetration requirements, heat
input, etc. The power source then uses the WFS set­ting to adjust its output characteristics (output voltage,
output current) according to pre-programmed settings.
In non-synergic modes, the WFS control behaves
more like a conventional CV power source where
WFS and voltage are independent adjustments.
Therefore to maintain the arc characteristics, the oper­ator must adjust the voltage to compensate for any
changes made to the WFS.

2. VOLTS / TRIM:

In constant voltage modes (synergic CV, standard
CV) the control adjusts the welding voltage.

In pulse synergic welding modes (pulse GMAW only)
the user can change the Trim setting to adjust the arc
length. It is adjustable from 0.500 to 1.500. A Trim set­ting of 1.000 is a good starting point for most condi­tions.

In STT modes, the user can adjust the Trim setting to
change the overall heat input to the weld.

3. WELDING MODE:

May be selected by name (CV/MIG, CC/Stick Crisp,
Gouge, etc.) or by a mode number (10, 24, 71, etc.).
Selecting a welding mode determines the output char­acteristics of the power source.

4. ARC CONTROL:

Also known as Inductance or wave control. Allows
operator to vary the arc characteristics from "soft" to
"harsh" in all weld modes. It is adjustable from -10.0 to
+10.0, with a nominal setting of 0.0. Also varies induc­tance in CV, in pulse modes, changes pulsing fre­quency and background current.

POWER FEED 15M

B-5

Arc

Arc Control 0.00

Control +10.

0

Wave Control -10.0

Current

Amps

Amps

TTime

ime

CC

Arc

ontrol 0.0

C

Arc

ontrol +10.0

C

Arc

ontrol +10.0

Arc

Control -10.0

Arc

Control -10.0

Current

Current

Amps

Amps

TTime

ime

CONSTANT VOLTAGE (CV) WELDING

(See figure B.1)

OPERATION

PULSE WELDING

(See figure B..2)

B-5

• Synergic CV:

Synergic welding allows for easy procedure setting. The
WFS and Voltage change together to maintain optimal arc
length.

Pulse welding procedures are set by controlling an over­all "arc length" variable. When pulse welding, the arc
voltage is highly dependent upon the waveform. The
peak current, back ground current, rise time, fall time
and pulse frequency all affect the voltage. The exact

When synergic welding and the WFS (right) knob is rotated,
the WFS is adjusted accordingly to control deposition rate.
The voltage changes too, to maintain a similar arc length.

voltage for a given wire feed speed can only be predict­ed when all the pulsing waveform parameters are
known. Using a preset voltage becomes impractical, and
instead the arc length is set by adjusting "trim".

Trim adjusts the arc length and ranges from 0.50 to

1.50, with a nominal value of 1.00. Higher trim values
increase the arc length, while lower trim values
decrease the arc length.

Change WFS to change deposition rate.
When the Voltage (left) knob is rotated, the voltage is adjust­ed accordingly to control the arc length.

Most pulse welding programs are synergic. As the wire
feed speed is adjusted, the power source will automati­cally recalculate the waveform parameters to maintain
similar arc properties.

Power Wave power sources utilize "adaptive control" to
compensate for changes in electrical stick-out while
welding. (Electrical stick-out is the distance from the
contact tip to the work piece.) Power Wave waveforms
are optimized for a 0.75" (19mm) stick-out. The adaptive

Change Voltage to change Arc length.

behavior supports a range of stickouts from 0.50"
(13mm) to 1.25" (32mm). At very low or high wire feed

• Non Synergic CV:

speeds, the adaptive range may be less due to reaching
physical limitations of the welding process.

This type of CV mode behaves more like a conventional CV
power source. WFS and Voltage are independent adjust­ments. Therefore to maintain the arc characteristics, the oper­ator must adjust the voltage to compensate for any changes
made to the WFS.

Arc Control in pulse programs usually adjusts the focus
or shape of the arc. Arc Control 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. Arc Control values less than

• All CV Modes:

0.0 decrease the pulse frequency while increasing the
background current, for a soft arc good for out-of-posi-

Arc Control adjusts the inductance of the waveshape. (This

tion welding.

adjustment is often referred to as "pinch". Inductance is
inversely proportional pinch.) Increasing Arc Control greater
than 0.0 results in a crisper, colder arc while decreasing the
Arc Control to less than 0.0 provides a softer, hotter arc.

CURRENT WAVE FORM

FIGURE B.2

CURRENT WAVE FORM (CV)

FIGURE B.1

POWER FEED 15M

B-6

rim 1.00

T

rim 1.50

Trim 0.50

Current

Time

Trim 1.50

Trim 1.00

Trim 0.50

HEAT
INPUT

CArc ontrol

0.0

Arc

Control +10.0

C

Arc

ontrol -10.0

Time

Current

ARC
LENGTH

OPERATION

STT SYNERGIC WELDING

The Figures B.3 and B.3a is the waveshape of current
for the process. They are not drawn to scale, and are
intended only for the purpose of showing how the vari­ables effect the waveform.

FIGURE B.3

Trim in the STT mode changes the heat input by
adjusting the tailout and background portion of the
waveform. For open root processes, the tailout is
fixed, and the trim affects only the background level.
Trim values greater than 1.0 add more energy to the
weld and make the weld puddle hotter; trim values
less than 1.0 reduce energy to the weld A nominal
value of 1.0 will work for most applications.

B-6

FIGURE B.3a

Arc control adjusts the arc length in the STT mode.
This is accomplished by changing the peak portion of
the current waveform. An arc control value of +10.0
maximizes the arc length by increasing the peak cur­rent, while a arc control of -10.0 minimizes the arc
length by decreasing the peak current. The nominal
value is "OFF" (0.0), and should work for most appli­cations.

POWER FEED 15M

B-7

LED’S

OPERATION

CASE FRONT CONTROLS (See Figure B.3b)

1. WIRE FEED SPEED/AMMETER DISPLAY-This

meter displays either the wire feed speed or current
value (Amps) depending upon the status of the wire
feeder and the power source. Written below the dis­play is "WFS" and "Amps". A LED light illuminates
the units of the value displayed on the meter.

• Prior to CV welding, the meter displays the desired
preset WFS value.

• During welding, the meter displays the actual
amperage.

• After welding, the meter holds the actual current
value for 5 seconds. The display blinks to indicate
the Power Feed 15M is in the "Hold" period. If the
Wire Feed Speed knob is adjusted while in the
"Hold" period, the Power Feed 15M will revert to
the "Prior to welding" display described above.

B-7

The voltage display shows the actual average arc volt­age during the welding.

After welding, the meter holds the actual average arc
voltage for 5 seconds. During this time, the display
flashes to indicate the product name is in the "Hold"
period. Output adjustment while in the "Hold" period
results in the "prior to operation" characteristics
described above.

The voltage is calibrated to ±2% over a range of 10 to
45 volts.

4. VOLTAGE / TRIM KNOB- The Voltage / Trim knob
is rotated to adjust the ideal voltage / trim for each
personal welding mode process used.

FIGURE B.3b

The default wire feed speed units are inches/minute
and can be changed to meters/minute by entering
the "Extended Feature Menu" during power-up. The
wire feed speed is calibrated to within ±2%. Refer to
the power source manual for calibration specifica­tions of the ammeter.

2. WIRE FEED SPEED KNOB

knob that adjusts of the rate of feeding electrode.

3. VOLTAGE / TRIM DISPLAY

meter displays either the voltage or trim value,
depending upon the status of the wire feeder and
the power source.

Weld Process
Nonsynergic CV
Synergic CV
Synergic CV-Pulse

Synergic CV-STT

Nonsynergic Power

Displays the preset Voltage value
Displays the preset Voltage value.
Displays the preset Trim value from 0.50 to 1.50, with 1.00 as the default. Trim adjusts the arc length
for Pulse programs. Lower the trim value to decrease the arc length, and raise the trim value to
increase the arc length. A trim value of 1.00 is a setting for most conditions.

• Adjusts the background current of the STT waveform. Used to modify the heat input.

• Linc Net Power Sources: Displays the background current as a value from 0.50 to 1.50, with 1.00

as the default. Lower the trim value to decrease the heat input, and raise the trim value to increase
the heat input. A trim value of 1.00 is a good setting for most conditions.

• Arc Link Power Sources: Displays the background current in amps. Lower the background current
to decrease the heat input and raise the background current to increase the heat input.

Displays the preset CP value from 0 to 20. The Power mode is best for thin sheet metal and aluminum
applications.

-The Wire Feed Speed

-The voltage/trim

Voltage / Trim Display prior to operation

1
2

5

6

10

3

4

7

8

9

11

POWER FEED 15M

B-8

P r E

F L o

OPERATION

Synergic CV Voltage Display

Synergic CV programs feature an ideal voltage best
suited for most procedures. Use this voltage as a
starting point for the weld procedure and adjust if
needed for personal preferences.

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

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

B-8

MSP-3 Multi-Process Panel

The center portion of the Power Feed-15M front case
enables selection of weld modes and fine tuning of
weld parameters within each weld mode. Preflow,
Postflow, Run In, Arc Control, Burnback, Postflow,
Crater and Spot are all adjustable with the SET and
SELECT toggle switches and 3 digit display.

6. SELECT toggle switch- Toggles through the 8
adjustable welding parameters detailed above the
switch. A red LED is located next to each welding
parameter and is illuminated when the parameter is
active.

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

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

5. STATUS LED-The status LED indicates system
status. Normal operation is a steady green light.

Note: During normal power-up, the LED may flash red
and/or green as the equipment performs self tests.

Light

Condition

Steady Green

Blinking
Green

Alternating
Green and
Red

System OK. Power source communicating normal­ly with wire feeder and its components.

Occurs during a reset and indicates the
power source is identifying each component
in the system. This is normal for the first 10
seconds after power-up, or if the system con­figuration is changed during operation.

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

before the machine is turned off.

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

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

Meaning

7. DISPLAY METER- Shows the active value of the

weld parameter.

8. SET toggle switch- changes the value of the
active weld parameter shown in the display meter.

Weld Mode

The Weld Mode selection is enabled by toggling the
SELECT toggle switch until the LED next to WELD
MODE is lit. The present mode number will be dis­played. Toggling the SET toggle switch up or down
will increase or decrease the WELD MODE number.
The weld mode on the display will become the active
weld mode after 2 seconds of SET toggle switch inac­tivity.

The last active weld mode is saved at power down
and will is automatically selected upon the next power
up of the feeder.

Preflow

The Preflow setting adjusts the amount of time the
shielding gas flows after the trigger is pulled and prior
to wire feeding and arc strike. Preflow times can be
adjusted from 0 to 2.5 seconds in 0.1 second incre­ments.

To adjust the Preflow time, toggle the SELECT toggle
switch until the LED next to PREFLOW/POSTFLOW
is lit. The display will read:

The present Preflow time will be displayed.Toggle the
SET toggle switch up or down to change the Preflow
time to a new value.

Steady Red

Blinking Red

Non recoverable hardware fault. Generally
indicates a problem with the cables connect­ing the wire feeder to the power source.

Not applicable.

POWER FEED 15M

B-9

P

o

S

F L o

POSTFLOW

The Postflow setting adjusts the amount of time the
shielding gas flows after the trigger is released and
welding current is turned off. Postflow times can be
adjusted from 0 to 10.0 seconds in 0.1 second incre­ments.

To adjust the Postflow time, toggle the SELECT toggle
switch until the LED next to PREFLOW/POSTFLOW is
lit. Then toggle the SELECT toggle switch once more
until the display reads:

The present Postflow time will be displayed. Toggle the
SET toggle switch up or down to change the Postflow
time to a new value.

Run In

The Run In function sets the wire feed speed from the
time when the trigger is pulled until the time an arc is
established. The Run In speed is independent of the
welding or start wire feed speed.

To change the Run In speed, toggle the SELECT tog­gle switch until the LED next to Run In is lit. The display
will show the present Run In speed. Toggle the SET
toggle switch up and down to change the Run In speed
to a new value. Do not use the left Knob,WIRE FEED
SPEED Knob. The WIRE FEED SPEED Knob adjusts
welding wire feed speed, not Run In wire feed speed.

Run In speed is adjustable from 50 to 150 ipm (1.27 to

3.81 m/min).

OPERATION

B-9

Arc Control

Arc Control is a generic control that allows fine tuning
the waveform. The function of Arc Control depends
on the active weld process.

To change the Arc Control values, toggle the
SELECT toggle switch until the LED next to ARC
CONTROL is flashing. Then use the SET toggle
switch to raise or lower the arc control setting to the
new value.

The Arc Control value ranges from -10.0 to 10.0 in
increments of 0.1, with "OFF" being the midpoint,
equivalent to 0.0.

Weld Process

CV

GMAW-Pulse

GMAW-STT

Power

Arc Control regulates the pinch effect for
synergic and nonsynergic GMAW and
FCAW weld programs. A low Arc Control
value gives a soft arc best for welding with
Argon blend shielding gases. A high Arc
Control value gives a crisp arc suitable for
welding with FCAW and CO
gases. Most self shielded electrodes work
well with Arc Control value "5".

Arc Control regulates the pulse frequency.
Lower the Arc Control value for a lower
pulse frequency, and raise the Arc Control
value for a higher frequency.

Arc Control regulates the background cur­rent of the STT waveform.

Arc Control regulates pinch.

Arc Control Function

shielding

2

The default value for Run In is OFF (Run In wire feed
speed = Welding wire feed speed.)

Start

The Start function sets the wire feed speed and voltage
at the beginning of the weld for a specified time period
prior to initiation of the preset values for WFS and
Volts. The start timer begins at arc strike and the WFS
and Volts settings will ramp up/down from the start
WFS and Volts values to the Weld mode WFS and
Volts values over the time selected.

To change the Start function values, toggle the
SELECT toggle switch until the LED next to START is
flashing. Rotate the WIRE FEED SPEED Knob to
adjust the Start WFS and rotate the VOLTAGE / TRIM
KNOB to adjust the Start Volts / Trim. Change the Start
time by toggling the SET toggle switch up and down to
a new value.

The Start time is adjustable from 0 to 0.50 seconds in

0.01 second increments.
The default Start time is OFF (0 seconds)

POWER FEED 15M

B-10

OPERATION

B-10

Crater

The Crater function sets an endpoint WFS and
Voltage to achieve over a specified time period. At
the end of the weld when the trigger is released, the
crater time begins and the WFS and Voltage values
ramp from the welding WFS and Voltage to the crater
WFS and Voltage.

To change the Crater function values, toggle the
SELECT toggle switch until the LED next to Crater is
flashing. Rotate the WIRE FEED SPEED Knob to
adjust the Crater WFS and rotate the VOLTAGE /
TRIM KNOB to adjust the Crater Volts/Trim. Change
the Crater time by toggling the SET toggle switch up
and down to a new value.

The Crater time is adjustable from 0 to 10.0 seconds
in 0.1 second increments.

The default Crater time is OFF (0 seconds).

Burnback

The Burnback function continues current flow for a
specified time period at the end of the weld after wire
feeding has stopped. Burnback is used to prevent the
electrode from sticking in the weld puddle and to con­dition the end of the electrode for the next arc start.

Spot

The Spot function is useful when making many short,
repetitive welds. When the Spot function is active, the
power source will weld for a set time after the trigger
has been pulled and an arc established. Once the
Spot time expires, the power source will continue to
the Crater function and Burnback function, if active.
The trigger must be released and pulled again to
make another weld and repeat the Spot cycle.

To change the Spot time, toggle the SELECT toggle
switch until the LED next to Spot is lit. The display will
show the present Spot time. Toggle the SET toggle
switch up and down to set a new Spot time.

The default Spot time is "OFF" (0.0 seconds.)
The Spot time is adjustable from 0.0 to 10.0 seconds

in 0.1 second increments.

To change the Burnback function value, toggle the
SELECT toggle switch until the LED next to Burnback
is lit. The display will show the present Burnback
time. Toggle the SET toggle switch up and down to
set a new Burnback time.

The default Burnback time is "OFF" (0.0 seconds.)
The Burnback time is adjustable from 0.0 to 0.25 sec-

onds in 0.01 second increments.

POWER FEED 15M

B-11

Us er Pr efe ren ce

Setting

WFS AM PS

VOLTS

TRIM

OPERATION

EXTENDED FEATURES MENU

The Extended Features Menu gives access to the set­up configuration. Stored in the set-up configuration
are user preferences that rarely change, like calibra­tion test modes or wire feed speed units.

To access the Extended Features Menu, turn power
OFF to the feeder and then hold the SELECT switch
in the up position. Continue to hold while the Power
Feed 15M powers up. Release the SELECT switch
when the display shows the first user preference that
may be changed.

FIGURE B.4

WFS/AMPS knob

The left display shows the User Preference number
and is changed with the WFS/AMPS knob. The right
display shows the present setting and is changed with
the VOLTS/TRIM knob.

Rotate the WFS/AMPS knob to the desired User
Preference. User Preferences for the Power Feed
15M are:

P0 On = Enter the Extended Features Menu

Off = Exit the Extended Features Menu

P1 On = m/min wire feed speed units

Off = In/min wire feed speed units (default)

VOLTS/TRIM knob

B-11

The stall factor controls the torque of the wire drive
inside the Power Feed 15M when using a push-pull
gun. The Power Feed 15M is factory set to generate
enough torque for pushing the electrode but not so
much as to cause bird nesting. Check for other feed­ing problems before adjusting the stall factor.

Default value for the stall factor is 25, with a range of
5 - 35.

To change the stall factor:

• Use the VOLTS/TRIM knob to adjust the stall factor.
Increasing the stall factor raises the motor torque
and decreasing the stall factor lowers the motor
torque. Do not increase the stall factor more than
necessary. A high stall factor may increase the
occurrence of bird nesting and a low stall factor may
cause the wire to burn back to the tip.

P514 Adjust pull gun offset.
The push-pull gun offset calibration adjusts the wire

feed speed calibration of the pull motor. The proce­dure should only be performed when other possible
corrections do not solve the push-pull feeding prob­lems. A rpm meter is required to perform the pull gun
motor offset calibration.

To perform the calibration procedure:

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

• Remove wire from the pull wire drive.

• Hold the rpm meter to the drive roll in the pull gun.

• Pull the trigger on the push-pull gun.

• Measure the rpm of the pull motor. The rpm should

be between 115 and 125 rpm. If necessary,
decrease the calibration setting to slow the pull
motor, or increase the calibration setting to speed
up the motor. The calibration range is -30 to +30,
with 0 as the default value.

P2 On = The left display shows Amperage while

welding .
Off = The left display shows Wire Feed Speed
while welding. (default).

P101 On = All weld modes and test modes are

accessible. The test modes allow for calibra­tion of the power supply. When wire feeder
power is turned off, User Preference P101 will
revert back to the "Off" and only the weld
modes will be available.
Off = Only weld modes are accessible
(default).

P513 Adjust the stall factor for a push-pull gun.

POWER FEED 15M

B-12

GND-B

GND-A

SPINDLE
BRAKE

2 STEP / 4 STEP
TRIGGER

COLD FEED /
GAS PURGE

FLOWMETER

PRESSURE
ARM

COLD FEED

GAS PURGE

ALUMINUM

OU TE R S H IE L D

METAL SHIELD
INN ERS HIE LD

STEEL

STAINLE SS

CORED WIRES

SOLID WIRES

6

1

3

2

5

4

OPERATION

INTERNAL CONTROLS (Figure B.5)

COLD FEED/GAS PURGE SWITCH

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

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

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

B-12

• 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.

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

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.
sure arm as follows (See Figure B.5a):

Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6

FIGURE B-5a

Set the pres-

IDLE ROLL PRESSURE SETTING

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.

FIGURE B.5

POWER FEED 15M

B-13

OPERATION

FLOW METER

The flowmeter shows the flow rate of shielding gas
and has a valve to adjust the flow. The flow meter is
calibrated for CO2, Ar, and CO2/Ar blends. The middle
of the ball indicates the flow rate of shielding gas.

Adjust the flow rate by turning the valve at the bottom
of the meter. Most weld procedures require 25-40 scfh
(11.8 - 18.9 lpm) for sufficient shielding gas coverage.
Gun angle, nozzle diameter, joint configuration and
wind conditions may effect the amount of shielding
gas required.

SCFH Liter/Min.

10 4.7
20 9.4
30 14.2
40 18.9
50 23.6
60 28.3
70 33.1
80 37.8

B-13

POWER FEED 15M

B-14

OPERATION

B-14

2 STEP - 4 STEP - TRIGGER OPERATION

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

Place the toggle switch in the DOWN
position for 2 Step operation and in the
UP position for 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.

-STEP

4

2-

STEP

EXAMPLE 1 - 2 STEP TRIGGER: Simple operation
The simplest trigger operation occurs with a 2 Step
trigger and the Start, Crater and Burnback functions
all set to OFF. (See Figure B.6)

For this sequence,

PREFLOW:

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

STRIKE:

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

WELD:

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

POSTFLOW:

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

• 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.

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

Pulled

Established

Shie ldin g
Gas

Powe r
Source
Output

WFS

Wel d

Wel d

Run-in

Trigger

Idle Preflow Strike Weld Postflow Idle

On

Off

Off

Off

Arc

1.5 sec max.

FIGURE B.6

Released

Trigger

POWER FEED 15M

B-15

Shieldi n

g

Gas

Idle Preflow Strike Upslope Weld Burnback Postflow Idle

WFS

On

Off

Run-in

Off

Weld

Off

Weld

Arc

Established

Trigger

Pulled

Trigger

Released

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

1.5 s ec max.

Sta rt

Start

time

Burnback Time

Pow er
Source
Output

OPERATION

B-15

EXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start

and Arc End. Tailoring the arc start and arc end is a
common method for reducing spatter and improving
weld quality. This can be accomplished with the Start
and Burnback functions set to a desired values and
Crater set to OFF. (See Figure B.7)

For this sequence,

PREFLOW:

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

STRIKE:

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

FIGURE B.7

UPSLOPE:

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

WELD:

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

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

POSTFLOW:

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

POWER FEED 15M

B-16

Shielding
Gas

Idle Pr eflow S tr ik e U pslo pe Weld B ur nbac k Post flow Idle

WFS

On

Off

Run -in

Off

Weld

Off

Weld

Arc Established

Trigger Pulled

Trigger Released

2 Step Trigger
Start = ON

Crat er = ON
Burnback = ON

1 .5 sec ma x .

Start

Start time

Burnback Time

Do wnslop e

Crat er

Cr a ter ti me

Power
Source

Output

Crater

OPERATION

B-16

EXAMPLE 3 - 2 STEP TRIGGER: Customize Arc

Start, Crater and Arc End. Sometimes it is advanta­geous to set specific arc start, crater and arc ending
parameters for the ideal weld. Many times when
welding aluminum crater control is necessary to make
a good weld. This is done by setting Start, Crater
and Burnback functions to desired values. (See
Figure B.8)

For this sequence,

PREFLOW:

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

STRIKE:

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

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.

CRATER:

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

BURNBACK:

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

POSTFLOW:

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

FIGURE B.8

POWER FEED 15M

B-17

Shielding
Gas

I

dle Preflo w Strike Wel

d

Burnb ack Postflow Idle

WFS

On

Off

Ru n-in

Off

We l d

Off

We l d

Arc

Established

Trigger

Pulled

Trigger

Released

4 St

ep Trigger
Start = OFF
Crater = OFF
Burnback = OF F

1. 5 s e c ma x .

Start

Cra ter

Power
Source

Output

Crat er

Trigger

Pulled

T

rig

g

e

r

R

e

le

a

s

e

d

OPERATION

EXAMPLE 4 – 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. (See Figure B.9)

For this sequence,

PREFLOW:

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

STRIKE:

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

WELD:

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

B-17

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.

FIGURE B.9

POWER FEED 15M

B-18

Shielding
Gas

Idle Preflow Strike Upsl ope Weld Burnback Postflow Idle

WFS

On

Of f

Stri ke

Of f

Wel d

Of f

Wel d

Arc

Established

Trigger

Pulled

Trigger

Released

4 Step Trigger
Start = ON

Crat er = ON
Burnback = ON

1.5 sec max .

Start

Bur nba ck Time

Down slope

Crat er

Po we r
So urce
Out put

Crat er

Start

Trigger

Pulled

Crat er

Trigger

Released

St a r t

OPERATION

EXAMPLE 5 - 4 STEP TRIGGER: Manual control of

Start and Crater times with Burnback ON. The 4 step
trigger sequence gives the most flexibility when the
Start, Crater and Burnback functions are active. This
is a popular choice when welding aluminum because
extra heat may be needed during Start and less heat
desired during crater. With 4 step trigger, the welder
chooses the amount of time to weld at the Start, Weld
and Crater settings by using the gun trigger. Burnback
reduces the occurrence of wire to sticking into the
weld pool at the end of a weld and conditions the end
of the wire for the next arc start. ( See Figure B.10)

In this sequence,

PREFLOW:

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

STRIKE:

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

START:

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

B-18

UPSLOPE:

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

WELD:

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

DOWNSLOPE:

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

CRATER:

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

BURNBACK:

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

POSTFLOW:

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

FIGURE B.10

POWER FEED 15M

C-1

ACCESSORIES

FACTORY INSTALLED EQUIPMENT

• K1500-2 Gun Receiver Bushing.

DRIVE ROLL KITS USED

• Drive Roll Kits (Includes drive rolls and inner wire guide
necessary to feed the identified wire size and type).

C-1

WIRE TYPE

Steel Wires:

Cored Wires:

Aluminum Wires:

ELECTRODE SIZE

.023-.030 (0.6-0.8mm)

.035 (0.9mm)
.045 (1.2mm)
.052 (1.4mm)
1/16 (1.6mm)

.035,.045 (0.9, 1.2mm)

.040 (1.0mm)
.030-.035" (0.8-0.9mm)
.040-.045" (1.0-1.2mm)

.052" (1.4mm)
1/16" (1.6mm)

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

5/64" (2.0mm)

.035" (0.9 mm)

.040" (1.0mm)
3/64" (1.2mm)
1/16" (1.6mm)
3/32" (2.4mm)

KP KIT

KP1696-030S
KP1696-035S
KP1696-045S
KP1696-052S

KP1696-1/16S

KP2307-6

KP2307-7
KP1697-035C
KP1697-045C
KP1697-052C

KP1697-1/16C

KP1697-068

KP1697-5/64

KP1695-035A
KP1695-040A

KP1695-3/64A
KP1695-1/16A
KP1695-3/32A

COMMON PACKAGES WITH ACCES­SORIES USED

Includes: 2 V groove
drive rolls and inner

wire guide.

Includes: 2 polished
U groove drive rolls,
outer wire guide and
inner wire guide.

GMAW Pulse Welding System:

• K2196-1 Power Feed 15M

• K2176-1 Twist mate to lug adapter

• K1796-xx Coaxial weld cables

• K1543-xx Digital Control Cables

• K2152-x Power Wave 355

• K470-2 Magnum 300 MIG Gun

• KP1696-035S .035" Drive roll kit

GMAW STT Welding System:

• K2196-1 Power Feed 15M

• K1796-xx Coaxial weld cables

• K1543-xx Digital Control Cables

• K1518-x Power Wave 455 STT

• K470-2 Magnum 300 MIG Gun

• KP1696-045S .045" Drive roll kit

POWER FEED 15M

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not operate with covers
removed.

• Turn off power source before
installing or servicing.

• Do not touch electrically hot
parts.

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

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

ROUTINE MAINTENANCE

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

• Clean and tighten all weld terminals.

D-1

PERIODIC MAINTENANCE

• Clean drive rolls and inner wire guide and replace if
worn.

• Blow out or vacuum the inside of the feeder.

CALIBRATION SPECIFICATION

All calibrations are factory set on the Power Feed 15M.
To verify the wire feed speed:

• Assemble a .045 (1.2mm) drive roll kit into the
Power Feed 15M.

• 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 INCH 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.

To verify the voltage display:

• Set the welding power source and Power Feed 15M
to a CV procedure that gives steady "spray" transfer
in the arc.

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

• The displayed voltage on the Power Feed 15M
should be within 2% of the measured value.

POWER FEED 15M

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

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

Step 1. LOCATE PROBLEM (SYMPTOM).

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

Step 2. POSSIBLE CAUSE.

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

Step 3. RECOMMENDED COURSE OF ACTION

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

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

CAUTION

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

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

POWER FEED 15M

E-2

Err 006

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Fault Code

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

Linc-Net System Error Codes

Description

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

E-2

RECOMMENDED

COURSE OF ACTION

Possible Adjustments

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.

Err 100

Err 31 Primary overcurrent.

Err 32 Capacitor bank "A"

under voltage.

Err 33 Capacitor bank "B"

under voltage.

Err 34 Capacitor bank "A"

overvoltage.

Err 35 Capacitor bank "B"

overvoltage.

Err 41 Long term secondary

overcurrent.

1. The power source has issued a
shutdown command.

ArcLink System Error Codes

1. The power source has exceeded
input current limits.

2. See the power source Instruction
Manual.

1. The power source input power
may be wired incorrectly.

1. The power source input power

may be wired incorrectly.

1. The power source input power
may be wired incorrectly.

1. The power source input power
may be wired incorrectly.

1. The power source has exceeded
the output current limits.

2. See the 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. Adjust the welding procedure to
reduce the current draw. The
welding procedure may exceed
the capacity of the power source.

1. Verify the power source reconnect
panel wiring matches the input
power.

2. See the power source Instruction
Manual.

1. Verify the power source reconnect
panel wiring matches the input
power.

2. See the power source Instruction
Manual.

1. Verify the power source reconnect
panel wiring matches the input
power.

2. See the power source Instruction
Manual.

1. Verify the power source reconnect
panel wiring matches the input
power.

2. See the power source Instruction
Manual.

1. Adjust the welding procedure to
reduce the current draw. The
welding procedure may exceed
the capacity of the power source.

CAUTION

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

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

POWER FEED 15M

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Fault Code

Err 43 Capacitors are out of balance

Err 44 Main CPU problem.

Err 53 Voltage sense loss.

Err 54 Short term secondary over-

current.

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

ArcLink System Error Codes

Description

E-3

RECOMMENDED

COURSE OF ACTION

Possible Adjustments

1. Verify the power source reconnect
panel wiring matches the input
power.

2. See the power source Instruction

Manual.

1. Verify the ground connection to
the power source is wired correct­ly.

2. See the power source Instruction

Manual.

Err 81 Motor overload, long term.

Err 82 Motor overload, short term.

Err 95 Spool gun or pull gun motor

overload.

Err 263 No usable weld modes.

1. The wire drive motor has over­heated.

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

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

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

1. Check that 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).

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

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

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

POWER FEED 15M

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

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

No shielding gas.

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

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

Output Problems

1. The Power Feed 15M 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.

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.

E-4

RECOMMENDED

COURSE OF ACTION

1. Turn the Power Feed 15M 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.

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

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

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

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

5. Replace the contact tip.

6. Verify the proper parts are
installed.

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

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

CAUTION

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

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

POWER FEED 15M

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Variable or "hunting" arc.

Poor arc starts with sticking or
"blast-offs", weld porosity, narrow
and ropy looking bead.
The wire feed speed/amperage and
voltage/trim display work during pre­set but show nothing during welding.

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

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. Improper procedures or tech­niques.

1. The software in the Power Feed
15M must be upgraded.

E-5

RECOMMENDED

COURSE OF ACTION

1. Replace the contact tip.

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

3. Adjust polarity to the recommend­ed procedure.

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

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

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

1. Contact the local authorized
Lincoln Field Service Shop.

CAUTION

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

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

POWER FEED 15M

F-1

POWER FEED 15M

L11822

A.04

J1, J34, J86

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

J81,J82

6

5

10

1

3

4

1

2

J85,J87

9

8

16

1

4

613

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE

B - BLACK

R - RED

U - BLUE

J2,J84

5

4

8

1

2

1

3

4

J82

2

1

6

3

4

5

J83

2

1

3

4

J81

2

1

6

3

4

5

J84

8

7

J88

2

1

6

3

4

5

2
16

3

4

5

J85

8

7

10
9

14

11

12

13

1

6

15

2
16

3

4

5

J86

8

7

10
9

2
16

3

4

5

CONTROL P.C. BOARD

8

7

10
9

14

11

12

13

1

6

15

-

+

552

553

GAS

SOLENOID

563

561

562

559

512A

558

559

512A

COLD INCH/

GAS PURGE

S1

554

556

FEED

MOTOR /

GEARBOX

TACH.

PLATE

1

4

3

2

6

5

WB

R

R

B

U

U

J4

512

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE

B - BLACK

R - RED

U - BLUE

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE

B - BLACK

R - RED

U - BLUE

J87

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE

B - BLACK

W - WHITE

R - RED

U - BLUE

CABLE CONNECTION

INPUT ELECTRODE

320V, 150J

320V, 150J

.0047/.005 mF,

1400VDC

1M W

8

7

MOV ASBLY

J1,J83,J88

GND-A

POWER

W

B

R

U

B

B

DISPLAY

P.C. BOARD

FLEX

SPI FLEX CIRCUIT CONNECTION DETAIL

DISPLAY

BOARD

MSP III

BOARD

WIRE DRIVE

BOARD

J34

123456789

10

FLEX

J341

1234567

8

MSP III BOARD

544

541

541A

545

546

541A

547

541

544

545

546

547

SW1

SET

SWITCH

SW2

SELECT

SWITCH

LINC-NET

INPUT

RECEPTACLE

ABCDE

SHIELDED CABLE

POS

835

553

552

551

550

813

812

811

814A

811

81267814

813

L6

L7

814

814A

551

550

562

561

J1

2

1

6

3

4

5

VOLTAGE SENSE

SELECT P.C. BOARD

J2

2

1

FLEX

POS

BRIDGE

DIODE

835

AC

AC

563

558

W

B511

3307 3309

3310

3311

3312

515B

RED / GREEN

STATUS LED

W B

2

3

1

3311

512

3312

VOLTAGE

ENCODER

2

3

1

3307

3309

3310

WIRE FEED

SPEED

ENCODER

515B

511

67

67A

J1

2

1

A

D

C

B

E

555

P3

556

TRIGGER

CONNECTOR

TRIGGER

INPUT

DUAL

PROCEDURE

INPUT

555

L5

GND-B

568

2 STEP/ 4 STEP

67B

67B

L3

L4

L2

554

S2

566

565

565

566

568

P5

S3

P7

P6

L8

814B

GND-D

(CASE)

GND-C

(CONTROL BOX)

GND-D

814B

554A

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..

POWER FEED 15M

F-2

DIMENSION PRINT

F-2

POWER FEED 15M

NOTES

POWER FEED 15M

NOTES

POWER FEED 15M

NOTES

POWER FEED 15M

NOTES

POWER FEED 15M

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com