Lincoln Electric IM892-C User Manual

IM892-C

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POWER FEED

For use with machines having Code Number : 11313, 11456, 11557, 11714, 11715

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 o n y o u r part . D O NOT

INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOU T
READING T H I S MA N U A L AND
THE SAFE T Y PR E C AUTIONS
CONTAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

™

25M

March, 2010

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

IP23

IEC 60974-5

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

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

i

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 f uel near an o pen 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 i t may b e nec ess ary t o remove sa fety

gu a r d s to pe r f o rm re q u i r e d ma i n t e n a n c e . Re m o v e
guards only when necessary and replace them when the
ma i n t e n a n c e r e q u i r i n g t h e i r re m o v a l 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. Elect ric curre nt f lowing thro ugh any condu ctor causes
localized Electr ic and Mag ne tic Fields (EMF). Welding
current creates EMF fields aro und we lding cables and
welding machines

2.b. EM F fie lds m ay interfe re wi th some pace mak ers , 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. Nev er co il the elect rode lead ar oun d your bo dy.

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 clot hing. Wear dr y, hole-fre e

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
mu s t 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,
electrod e re el , we lding head, nozzl e or s em iautomati c
welding gun are also electrically “hot”.

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

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

3.f.

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

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

3.h. Never si mul tane ous ly to uch el ect rically “ hot ” p art s 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.

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
fume s an d gases . When welding, ke ep
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

we l d i n g with electrode s w h ich require speci a l
ve n t ilation such as stainless or hard facing (see
instruc tions on con tainer or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum­st a n ces, outdoors, a respirato r may be require d .
Additional precautions are also required when welding
on galvanized steel.

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

5.c.

Do not weld in locations near chlorinated hydrocarbon
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.d. Shielding gases used for arc welding can displace air and

caus e inj ury or death . Alw ays use e nou gh ventila tio n,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t e r i a l safety d a t a sheet ( M S D S ) and f o l l o w you r
employer’s safety practices. MSDS forms are available from
yo u r we l d i n g di s tributor o r fr om t h e ma n u f a cturer.

5.f. Also see item 1.b.

Jan ‘09

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Re m e m b e r th a t weldin g sparks and ho t
materials from welding can easily go through small cracks
an d o peni n gs to adj a cent ar eas. Av o id wel d ing nea r
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 Z 49.1) and the ope rating info rmation for t he
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
Co n t a i n e r s a n d Pi p i n g T h a t Ha v e H e l d Ha zardous
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 possibi lity of the welding current passi ng
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.

the we lding spar ks from s tar ting a fi re.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Us e on l y c o m p r e s s e d g a s cy l i nders
containing the correct shielding gas for the
pr o c e s s used an d pr o p e r l y oper a t i n g
re g u l a t o r s d e s i g n ed f o r t h e g a s a n d

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Al way s kee p cyl ind ers i n an up right positio n sec ure ly
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. Rea d and fo l low th e inst ruct ions o n c ompr ess e d 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 equip me nt in accordanc e 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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

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 co urt-circuit accidenta l peut pro vo quer 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, net toyage 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. Proté ger l’a utre pe rsonn el travai llant à p roxim ité au

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

4. Des go ut te s de laitier en fusion so nt 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

TThhaannkk YYoouu

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

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

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

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

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

CUSTOMER ASSISTANCE POLICY

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_________________________________________________________________________

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

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

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

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

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

Electrode Polarity .................................................................................................................A-5

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

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

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

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

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

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

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

________________________________________________________________________________

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

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

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

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

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

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

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

Case Front Controls.......................................................................................................B-4,B-5

On-Off Switch .......................................................................................................................B-6

Making a Weld with Waveform Technology Power Sources ................................B-7 thru B-24

Set-Up Feature Menu for Parameters and Definition ........................................B-25 thru B-32

Procedure/Memory Panel Operation ..................................................................B-33 thru B-35

Dual Procedure/Memory Operation....................................................................B-36 thru B-38

Internal Controls .......................................................................................................B-39, B-40

Cold Feed / Gas Purge Switch, Light Switch, Heater Switch, Pressure Arm Adjustment ..B-41

2 Step - 4 Step Trigger Operation and Graphics ................................................B-42 thru B-47

Rear Controls .....................................................................................................................B-48

Flow Meter..........................................................................................................................B-49

Operation On Lincnet Power Sources................................................................................B-49

________________________________________________________________________________

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

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

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

Common Packages with Accessories Used...........................................................C-2 thru C-4

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

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

________________________________________________________________________________

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

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

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

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

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

________________________________________________________________________________

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

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

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

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

________________________________________________________________________________

vi

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

________________________________________________________________________________

Parts Pages ................................................................................................................P-534 Series

_______________________________________________________________________

________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS –

INPUT VOLTAGE and CURRENT

INPUT VOLTAGE ± 10%

40 VDC

RATED OUTPUT @ 104°F (40°C)

DUTY CYCLE

60% rating

100% rating

GEARING - WIRE FEED SPEED RANGE-WIRE SIZE

GMAW

POWER FEED™ 25M K2536-1, -2, -3

INPUT AMPERES

4A

INPUT AMPERES

500
400

FCAW

GEARING

Normal Speed

(factory setting)

Extra torque

WFS RANGE

50 – 800 ipm

(2.5 – 20.3m/min)

30 – 400 ipm

(1.3 – 10.4m/min)

WIRE SIZES

.023 – 1/16"

(0.6 – 1.6mm)

.023 – 1/16"

(0.6 – 1.6mm)

WFS RANGE

50 – 800 ipm

(2.5 – 20.3m/min)

30 – 400 ipm

(1.3 – 10.4m/min)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

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

Handle folded down Memory Panel Closed

TEMPERATURE RANGE

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

WIRE SIZES

.030 – 5/64"

(0.8 – 2.0mm)

.030 – 3/32"

(0.8 – 2.4mm)

POWER FEED™ 25M

A-2
SAFETY PRECAUTIONS

INSTALLATION

HIGH FREQUENCY PROTECTION

A-2

WARNING

ELECTRIC SHOCK CAN KILL.

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

• Do not touch electrically live parts.

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

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

• Only qualified personnel should perform mainte­nance work.

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

LOCATION

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

CAUTION

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

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

Do not submerge the POWER FEED™ 25M.

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

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

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

POWER FEED™ 25M

A-3

A

A

BB

CC

D

D

EE

AA

BB

CC

DD

EE

P

OWER SOURCE

WIRE FEEDER

AA

BB

CC

DD

EE

AA

BB

CC

DD

EE

AA

BB

CC

DD

FF

EE

AA

BB

GG

CC

DD

FF

EE

INSTALLATION

ARCLINK CONTROL CABLES

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

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

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

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

CABLE CONNECTIONS

There are three circular connectors on the front of the
POWER FEED™ 25M.
(See 5-pin, 6-pin and 7-pin- Figure A.1)

FIGURE A.1

Function

PIN

Wiring

A-3

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

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

Control cables may be conn ected end to end to
ext e n d their length. Use a m a x i mum of 200 ft.
(61.0m) of control cable between components.

Figure A.3

Power Source

Pin Function

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

Wire Feeder

Pin Function

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

5 pin trigger con­nector for push­only guns.

6 pin connector for
remote control or
foot/hand amptrol.

7 pin connector for
push-pull guns

A
B
C
D

Dual Procedure Selection

E

A

77 Remote potentiometer, 5K

B

75 Remote potentiometer, common

C

76 Remote potentiometer, wiper

D
E
F

A
B
C

77 Remote potentiometer, 5K

D

76 Remote potentiometer, wiper

E
F
G

75 Remote potentiometer, common

Trigger

Not used

Common

Common

Switch, On/Off

Switch, common

Not used

Motor -

Motor +

Switch, On/Off

Switch, common

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

FIGURE A.2

Function

5 pin ArcLink con­nector.

PIN

A
B

C

67 Electrode Voltage Sense

D

E

Wiring

ArcLink
ArcLink

40VDC

Common

POWER FEED™ 25M

A-4

E

Elleecctrtrooddee

WWoorrkk

WWoorrkk

E

lectrode

E

lectrode

WWorko

rk

ElectrodeElectrode

WWorkork

P

ower SourcePower Source

Coaxial WCoaxial Weld Cableeld Cable

Wire FeederWire Feeder

INSTALLATION

WELD CABLE SIZE

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.

COAXIAL WELD CABLE

(See Table A.2)
Coaxial welding cables are specially designed welding cables for
pulse welding or STT™ welding. Coaxial weld cables feature low
inductance, allowing fast changes in the weld current. Regular
cables have a higher inductance which may distort the pulse or
STT™ wave shape. Inductance becomes more severe as the weld
cables become longer.

Coaxial cables work best for high performance waveforms and
when:

• long cables are present.

• the cables are housed in a metal tray.

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

TABLE A.2

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

AMPERES

250
300
350

DUTY

CYCLE

100%

60%
60%

0 to 25Ft.

(0 to7.6M)

1
1

1/0

To install:

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

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

3. Connect the outer lead bundle to the power source work
con n e c t i o n, and the other end to the work piece.
Minimize the length of any work lead extension for best
results.

4. Insulate all connections.

FIGURE A.5

COAXIAL CABLE LENGTH

25 to 50Ft.

(7.6 to 15.2M)

1
1

1/0

50 to 75 Ft.

(15.2 to 22.9M)

1
1

--

75 to 100 Ft.

(22.9 to 30.5M)

1

1/0

--

A-4

TABLE A.1

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

AMPERES

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

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

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

PERCENT

DUTY

CYCLE

60

100

20

40 & 30

30
40
60

100

60

100

60
60

100

60

0 to 50Ft.
(0 to15M)

2
2

4 or 5

3
3
2
1
1

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

50 to 100Ft.

(15 to 30M)

2
2
3
3
3
2
1
1

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

100 to 150 Ft.

POWER FEED™ 25M

(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-5

INSTALLATION

ELECTRODE POLARITY

The wire feeder is factory set for Electrode Positive
weld i n g. Most GMAW wel d i ng p roce d ures us e
Electrode Positive welding. Most GTAW and some
Innershield procedures use Electrode Negative weld­ing.

CAUTION

When changing the electrode polarity, the weld
cables must be changed at the power source studs
and the DIP switch inside the wire feeder must be
properly set. Operation with the DIP switch in the
wrong position will cause erratic arc performance.

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the weld­ing power source before changing
electrode polarity.

• Do not touch electrically live parts.

• Only qualified personnel should per­form maintenance work.

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

Electrode Polarity DIP switch #7 setting
Positive OFF (Factory setting)
Negative ON

Tools required:

• 5/16" nut driver

To change the DIP switch from Electrode Polarity:

1. Turn power off at the welding power source

2. Remove the spool of wire from the feeder.

3. Remove the 4 screws holding the cover. Lift the
cover out of the feeder.

4. Move DIP switch #7 on the feed head board to the
appropriate position.

5. Install the cover and secure with the screws.

A-5

SHIELDING GAS CONNECTION

WARNING

CYLINDER may explode if

damaged.

• Keep cylinder upright and
chained to support.

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

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

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

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

• Shut off shielding gas supply when not
in use.

• See American National Standard Z-49.1, "Safety
in W eldin g and Cutt ing” Published by th e
American Welding Society.

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

MAXIMUM INLET PRESSURE IS 100 PSI. (6.9 BAR.)

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

3. Stand to one side away from the outlet and open the

cylinder valve for an instant. This blows away any dust
or dirt which may have accumulated in the valve out­let.

4. Attach the flow regulator to the cylinder valve and

tighten the union nut(s) securely with a wrench. Note:
if connecting to 100% CO2cylinder, insert regulator
adapter betwee n regulator and cylind er valve. If
adapter is equipped with a plastic washer, be sure it is
seated for connection to the CO2cylinder.

5. Attach one end of the inlet hose to the outlet fitting of

the flow regulator. Attach the other end to the welding
system shielding gas inlet. Tighten the union nuts with
a wrench.

6. Before opening the cylinder valve, turn the regulator

adjusting knob counterclockwise until the adjusting
spring pressure is released.

7. Standing to one side, open the cylinder valve slowly a

fraction of a turn. When the cylinder pressure gage
stops moving, open the valve fully.

8. The flow regulator is adjustable. Adjust it to the flow

rate recommended for the procedure and process
being used before making a weld.

POWER FEED™ 25M

A-6

Extra Torque
Gearing

Normal Speed
Gearing

Extra
Torque
G

earing

N

ormal

S

peed

Gearing

400

800

WFS

Feed Force

INSTALLATION

CHANGING THE DRIVE MOTOR GEAR RATIO

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.

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

A-6

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

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

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

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

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

ing the cover.

12. With a Phillips screwdriver, remove the three screws

and lock washers securing the motor. Remove the
motor.

13. Place the motor in the new position.

14. Assemble the three screws and lock washer holding the

wire drive motor.

Tools required:

• 1/4" hex key wrench

• 3/4" open end wrench

• 9/16" socket and ratchet wrench

• 7/16" nut driver

• 5/16" nut driver

• Phillips screw driver

1. Turn power off at the welding power source.

. Remove the spool of electrode from the wire feeder.

2

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

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

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

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

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

15. Assemble the molex connections and place the wire
drive assembly inside the wire feeder. Route the gas
hose through the opening in the wire drive panel.

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

Gear Select DIP Switch #8 Setting Range
Normal Speed ON 50 – 800 ipm
Extra Torque OFF 30 – 400 ipm

17. 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.

18. Reassemble the busbar and tighten the mounting hard­ware with a 3/4" open end wrench.

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

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

21. Reassemble the gear cover.

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

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

POWER FEED™ 25M

A-7

GUN RECEIVER BUSHING

LOOSEN TIGHTEN

THUMB SCREW

OUTER WIRE GUIDE

SOCKET HEAD
CAP SCREW

CONNECTOR BLOCK

INSTALLATION

WIRE DRIVE CONFIGURATION

(See Figure A-6)

Changing the Gun Receiver Bushing

WARNING

ELECTRIC SHOCK can kill.

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

• Do not touch electrically live parts.

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

• Only qualified personnel should perform mainte­nance work.

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

Tools required:

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

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

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

Import ant: Do not attempt to com pletely
remove the socket head cap screw.

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

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

FIGURE A-6

A-7

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

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

10. Tighten the socket head cap screw.

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

PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES

WARNING

ELECTRIC SHOCK can kill.

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

• Do not touch electrically live parts.

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

• Only qualified personnel should perform mainte­nance work.

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

1. Turn power off at the welding power source.

2. Release the idle roll pressure arm.

3. Remove the outer wire guide by turning the knurled

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

4. Rotate the triangular lock and remove the drive

rolls.

5. Remove the inner wire guide.

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

over the two locating pins in the feed plate.

7. Install a drive roll on each hub assembly secure

with the triangular lock.

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

pins and tightening the knurled thumbscrews.

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

arm. Adjust the pressure appropriately

POWER FEED™ 25M

A-8

CCOONNNNEECCTT AA LLLL SSEENNSSEE
LLEEAADDSS AATT THTHEE EENNDD
OOF F THTHEE WWEELLDD

CCOONNNNEECCTT AA

LLLL

WWOORRKK LLEEAADD

SS AATT

THTHEE BBEEGGINNINN

IINNG G

OFOF

THTHEE WWEELLDD

DDIREIRE

CCTIOTIONN

OF OF

TRTRAAVVEELL

INSTALLATION

A-8

REMOTE SENSE LEAD SPECIFICATIONS

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

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

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

LOADING SPOOLS OF WIRE

WARNING

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

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

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

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

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

A K468 spindle adapter is required for loading 2"
(51mm) wide spools on 2" (51mm) spindles. Use a
K468 spindle adapter for loading 2-1/2" (64mm) wide
spools.

1. Squeeze the release bar on the retaining collar and
remove it from the spindle.

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

3. Pl a c e the spool on the spin d l e a n d align the
adapter brake tab with one of the holes in the back
side of the spool. An indicator mark on the end of
the spindle shows the orientation of the brake tab.
Be certain the wire feeds off of the spool in the
proper direction.

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

FIGURE A.7

POWER FEED™ 25M

A-9

INSTALLATION

TYPICAL SYSTEM CONFIGURATIONS

A-9

Standard Features

Arc Performance

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

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

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

User Controls

• (code 11313) 6 memories for easily selecting proce­dures.

• (code 11456 and higher) 8 memories for easily
selecting procedures.

• MSP4 panel located behind the memory panel for
protection.

• Full sequence control for tailoring the weld from
start to end.

• All welding controls located at the wire feeder,
including process selection

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

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

Extras:

• Flowmeter with gas control valve

• Push-Pull ready.

• Remote control / Foot amptrol ready.

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

• Internal lights for illuminating the wire drive compart­ment.

Options

• Water cooling kit for use with water cooled guns.

Wire Drive

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

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

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

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

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

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

• All gear driven rolls for more feeding force.

• Changeable gun bushings easily accept guns from
other manufacturers.

POWER FEED™ 25M

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 a nd 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.

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

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

• 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.

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

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.

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

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

INPUT POWER

ON

OFF

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

U

U

U

I

0

1

2

1

OPEN CIRCUIT
VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

I

POWER FEED™ 25M

2

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

B-2

OPERATION

B-2

DEFINITION OF WELDING TERMS

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding

process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of

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

WFS

• Wire Feed Speed

CC

• Constant Current

CV

• Constant Voltage

GMAW

• Gas Metal Arc welding

GMAW-P

• Gas Metal Arc welding-(Pulse Arc)

GMAW-STT

• Gas Metal Arc welding-(Surface Tension Transfer)

SMAW

• Shielded Metal Arc welding

FCAW

• Flux Core Arc Welding

CAG

• Carbon Arc Gouging

GENERAL DESCRIPTION

General Physical Description

The POWER FEED™ 25M is a premium portable wire
feeder for use with the Power Wave products. The
wire feeder features a 2 roll MAXtrac™ drive coupled
to a powerful motor for driving wire through difficult sit­uations. The easy-to-use, MSP4 interface provides
ready access to all welding modes in the Power
Wave. A memory panel is included with the POWER
FEED™ 25M and allows quick recall of favorite weld
procedures. Two cases are available: An engineered
aluminum case with replaceable skids, or an impact
resistant polycarbonate plastic case.

The he a rt of the POW E R FEE D ™ 25M is the
MAXtrac™ drive. The patented features on the wire
drive offer tool-less changing of the drive rolls and the
wire guides for quick spool changes. Plus, the drive
can be configured for extra torque when feeding large
diameter flux cored electrodes.

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

General Functional Description

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

DUTY CYCLE

The POWER FEED™ 25M is rated for 500 amps,
60% duty cycle and 400 amps, 100% duty. The duty
cycle is based on a 10 minute cycle.

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

POWER FEED™ 25M

B-3

OPERATION

RECOMMENDED PROCESSES

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

• FCAW

• SMAW

• GTAW (Lift Start only)

• Solid wires .025" to 1/16"

• Cored wires .035" to 5/64"

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

EQUIPMENT LIMITATIONS

• Works only on ArcLink®or LincNet Power Wave
power sources.

• When operating on LincNet power sources, not all
features are available.

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

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

• Spool guns do not work with the POWER FEED™
25M.

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

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

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

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

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

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

B-3

RECOMMENDED POWER SOURCES

• Power Wave®355M

• Power Wave

• Power Wave

• Power Wave

®

455M

®

455M/STT

®

655/R

POWER FEED™ 25M

B-4

Fold Out
Memory Panel

OPERATION

CASE FRONT CONTROLS (CODE 11313)

(SEE FIGURE B.1)

B-4

15. Cover

Covers location for optional water cooling line.

1. Left DISPLAY window

Shows WIRE FEED SPEED or AMPERAGE.

2. Left KNOB

Adjusts values in left display.

3. Right Display window

Shows VOLTAGE or TRIM.

4. Right Knob

Adjusts values in the right display.

5. Status LED

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

6. IR port

Used to transfer information to palm computers,
etc.

7. MSP4 display window

Shows detailed welding and diagnostic information.

8. Left Button

Changes the MSP4 display to show the Weld Mode
or Arc Control.

16. Set-Up

Lights when feeder is set-up.

17. Memory Panel Door

(See Memory Panel Operations in this Section)

FIGURE B.1

1

2

5

6

8

10

11

12

3

4

7

16

9

14

9. Right Button

Changes the MSP4 display to show Start Options
or End Options.

10. Set Knob

Changes the value on the MSP4 display.

11. ON/OFF switch

Controls power to the POWER FEED™ 25M.

12. 5-pin connector

Trigger connector for a push-only gun.

13. 6-pin connector

Connector for a remote control.

14. 7- pin connector

Connector for a push-pull gun.

13

17

15

POWER FEED™ 25M

B-5

OPERATION

B-5

CASE FRONT CONTROLS (CODE 11456 and

higher) (See Figure B.1a)

1. Left DISPLAY window

Shows WIRE FEED SPEED or AMPERAGE.

2. Left KNOB

Adjusts values in left display.

3. Status LED

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

4. MSP4 display window

Shows detailed welding and diagnostic information.

5. Left Button

Changes the MSP4 display to show the Weld Mode
or Arc Control.

6. Procedure Button

Selects A or B procedure, or gun control.

7. 2-Step/4-Step Button

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

8. 5-pin connector

Trigger connector for a push-only gun.

18. Right Button

Changes the MSP4 display to show Start Options
or End Options.

19. Set Knob

Changes the value on the MSP4 display.

20. Memory Buttons

(For selection of common procedures.)

FIGURE B.1a

1

2

3

4

5

6

7

13

14

15

16

17

18

19

9. ON/OFF switch

Controls power to the POWER FEED™ 25M.

10. 6-pin connector

Connector for a remote control.

11. Cover

Covers location for optional water cooling line.

12. 7- pin connector

Connector for a push-pull gun.

13. Right Display window

Shows VOLTAGE or TRIM.

14. Right Knob

Adjusts values in the right display.

15. Thermal

Lights when the drive overheats.

16. Set-Up

Lights when feeder is set-up

17. IR port

Used to transfer information to palm computers,
etc.

8

9

10

11

20

12

POWER FEED™ 25M

B-6

S

TAT

US

OPERATION

11. ON-OFF SWITCH

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

WARNING

ELECTRIC SHOCK can kill.

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

• Do not touch electrically live
parts.

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

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

• Only qualified personnel should perform mainte­nance work.

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

B-6

LED condition

Steady green
Blinking green.

Blinking green, fast

Blinking green fol­lowed by blinking
red.

STATUS LED

(See Table B.1)

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

TABLE B.1

Definition

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

Error codes are detailed in the Troubleshooting Section E. Individual code digits are flashed in red with a
long pause between digits. After each error code the LED will flash green and codes will repeat. There may
be more than one error code indicated.

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

POWER FEED™ 25M

B-7

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5

OPERATION

MAKING A WELD WITH WAVEFORM
TECHNOLOGY POWER SOURCES

WARNING

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

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

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

B-7

FIGURE B.2

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 i nterf ace.
Because of the different configuration options your
system may not have all of the following adjustments.
Regardless of availability, all controls are described
below.

SMAW (STICK) WELDING

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

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

K2368-1 Power Wave®355M

1 K2202-1 Power Wave®455M

®

K2203-1 Power Wave

455M/STT

K2230-1 POWER FEED™ 10M, Bench

Model

2 K2234-1

POWER FEED™ 10M Dual,

Bench Model

K2536-1,-2,-3 POWER FEED™ 25M

3 K1543-xx Digital Control Cable

K2683-xx

4 K1842-xx Weld Power Cable, Lug to Lug

K910-xx Ground Clamp

5 K909-xx Electrode Holder

6 K2176-1 Twist-Mate to Lug Cable

Adapter

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

SMAW Welding (See Figure B.2)

POWER FEED™ 25M

START OPTIONS

END OPTIONS

SET

SETUP

IR PORT

CC Stick Soft

WAVEFORM CONTROL TECHNOLOGY

Stick

WELD MODE

ARC CONTROL

I
I

ARC FORCE
(Soft)-10.0 to
(Crisp)+10.0

DESCRIPTION

START TIME:

0 to 10 seconds

FUNCTION

If no remote control is installed,
this control sets the time for
the weld output to ramp up or
down from a preset Start cur­rent to the preset Weld current.
Use t h e W F S /AMP kno b to
adjust Start current while the
Start Options LED is displayed.

No arc ending options are active for

SMAW

(Stick) welding modes.

PROCESS

Stick Soft(7018)
Stick Crisp(6010)

MODE

1
2

CC STICK MODES

START OPTIONS

END OPTIONS

ARC CONTROL

Lower values will provide less short
circuit current and a softer arc.
Higher settings will provide a higher
short circuit current, a more forceful
arc and possibly more spatter.

194

0

WFS AMPS

VOLTS TRIM

LESS
AMPS

MORE
AMPS

OUTPUT
OFF

OUTPUT
ON

n

SMAW (Stick) Welding Display

MSP4 OPERATION

OPERATION

FIGURE B.3

B-8B-8

POWER FEED™ 25M

B-9

6

4

3

2

5

1

OPERATION

NON-SYNERGIC GMAW AND FCAW
WELDING

(See Figure B.4)

B-9

Three non-synergic welding modes are available.

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

MIG welding.

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

FIGURE B.4

GMAW, Power 40 Specialized GMAW

mode.

FCAW 6 Best for self shield-

ed electrodes like
Innershield™.

K2368-1 Power Wave®355M

®

1 K2202-1 Power Wave

K2203-1 Power Wave®455M/STT
K2230-1
K2234-1
K2536-1,-2,-3 POWER FEED™ 25M

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

3 K1543-xx Digital Control Cable

4 K1842-xx Weld Power Cable, Lug to Lug

5 See Magnum MIG gun

6 K586-1 Shielding Gases

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

K2683-xx

K910-xx Ground Clamp

Literature

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

Deluxe Regulator for Mixed

Shielding Gas Hose

POWER FEED™ 25M

455M

B-10

300

25.3

W

FS AMPS

V

OLTS TRIM

L

ess

W

FS

L

ess

Volts

M

ore

V

olts

M

ore

W

FS

250

54

WFS AMPS

VOLTS TRIM

Less
WFS

Shorter
Arc

Longer
Arc

More
WFS

START OPTIONS

END OPTIONS

SET

SETUP

IR PORT

STD CV MIG

WAVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

5

EFFECT / RANGE

Postflow Time
0 to 25.0 seconds

Crater Procedure
0 TO 10.0 SECONDS

Burnback:
0 to .25 Seconds

DESCRIPTION

Adjusts the time that shielding
gas flows after the welding out­put turns off.
Crater Procedure controls the
WFS and Volts for a specified
ti me at the e nd of the w e ld
after t he t ri gg er is released.
Du ring t h e C rat e r t ime , t he
machine will ramp up or down
from the W el d Proce du re to
the Crater Procedure.

Th e bu r n b ack t i m e i s t h e
amount of time that the weld
output continues after the wire
stops feeding. It prevents the
wire from sticking in the puddle
and p repares t he end of the
wire for the next arc start.

PROCESS

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

W

ELD MODE

5

40

6

ARC CONTROL

W

ELD MODE

END OPTIONS

START OPTIONS

DESCRIPTION

Pinch controls the arc characte-

-ristics when short-arc welding.

EFFECT / RANGE

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

PINCH

0

E

FFECT / RANGE

Preflow Time
0

- 25.0 seconds

Run-In WFS:
O

ff, 30 to150 in/min.

Start Procedure
0

- 10 seconds

DESCRIPTION

A

djusts the

time

t

hat

s

hielding

g

as

flows

after the trigger is

pulled

a

nd

prior to feeding wire.
Ru n - I n sets t h e wire f e e d
s

peed from the time the trigger
is pulled until an arc is estab­l

ished.
The Start Procedure controls
the WFS and Volts for a speci­fied time at the beginni ng of
the weld. During the start time,
the m ac hi ne w ill ramp up or
down from the Start Procedure
to th e p rese t W e l d i ng
Procedure.

Spot Timer
0 to 120.0 Seconds

Ad j u s t the t i m e we l d i n g wil l
co n t i n ue e v e n if th e t rigge r
is s t i ll p u l l e d. Th i s optio n
ha s n o eff e c t in 4 - S t e p
Tr i g g e r Mo d e .

OPERATION

Non-Synergic GMAW and FCAW Welding Display

Modes 5 and 6:

MSP4 OPERATION

B-10

Mode 40:

POWER FEED™ 25M

B-11

6

4

3

2

5

1

OPERATION

GMAW (MIG) SYNERGIC WELDING

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

FIGURE B.5

B-11

K2368-1 Power Wave®355M

®

1 K2202-1 Power Wave

K2203-1 Power Wave®455M/STT
K2230-1
K2234-1

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

3 K1543-xx Digital Control Cable

4 K1842-xx Weld Power Cable, Lug to Lug

5 See Magnum

6 K586-1 Shielding Gases

K2536-1,-2,-3 POWER FEED™ 25M

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

K2683-xx

K910-xx Ground Clamp

Literature

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

®

MIG gun

Deluxe Regulator for Mixed

Shielding Gas Hose

455M

POWER FEED™ 25M

B-12

220

26.4

W

FS AMPS

VOLTS TRIM

Less
Deposition

S

horter

Arc

Longer
Arc

More
Deposition

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

DESCRIPTION

-

EFFECT / RANGE

Preflow Time
0 - 25.0 seconds

Run-in WFS:
Off, 30 to150 in/min.

Start Procedure

DESCRIPTION

A

djusts

the

t

ime

that

shielding

gas

flows

after the

trigger

is

pulled

and

prior to feeding.
Ru n - I n s ets the w i r e f eed
speed from the time the trigger
is pulled until an arc is estab­lished.
The Start Procedure controls
the WFS, Volts at a specified
time a t the begin ni ng of the
weld. During the start time, the
machine will ramp up or down
from the Start Procedure to the
preset Welding Procedure.

EFFECT / RANGE

Postflow Time
0 to 25.0 seconds

Burnback:

0 to .25 Seconds

Crater Procedure

DESCRIPTION

Adjusts the time that shielding
gas flows after the welding out­put turns off.
Th e b u r n b a ck t i m e i s t h e
amount of time that the weld
output continues after the wire
stops feeding. It prevents the
wire from sticking in the puddle
and p re pares the end of the
wire for the next arc start.
Crater Procedure controls the
WFS and volts for a specified
ti me at the en d o f t he wel d
after the trigger is released.
Du ring the C r ater ti m e, the
machine will ramp up or down
from t he Weld P roced ur e to
the Crater Procedure.

Steel
Steel

Stainless

Stainless

Aluminum 4043

Aluminum 5356

E

LECTRODE AND GAS

C

O

2

Ar(Mix)
Ar(Mix)

Ar/He/CO

2

Ar
Ar

WIRE SIZE

0.030 0.035 0.045 0.052

--- 10 20 24

9

4 11 21 25
61 31 41 --­63 33 43 ---

--- 148 71 ---

--- 151 75 ---

WELD MODE

ARC CONTROL

END OPTIONS

STEEL
.035"

SET

SETUP

IR PORT

CV CO2

WAVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

10

START OPTIONS

Pinch controls the arc characte-

-ristics when short-arc welding.

START OPTIONS

E

ND OPTIONS

Spot Timer

0 to 120.0 Seconds

Ad j u s t the ti m e w e l ding w i l l
co n t i n u e even i f t h e trig g e r
is s t i l l pull e d . T h is opt i o n
ha s n o effect i n 4 - Step
Tr i g g e r Mode.

OPERATION

GMAW (MIG) Synergic Welding Display

Synergic CV programs feature an ideal voltage best

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

MSP4 OPERATION

B-12

SYNERGIC CV VOLTAGE DISPLAY

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

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

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

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

POWER FEED™ 25M

B-13

Trim .50

Arc Length Short

Trim 1.00

Arc Length Medium

Trim 1.50

Arc Length Long

Arc Control OFF

Med ium Fr equency and Wi dth

Arc Control +10.0

High Frequency , Fo cused

A rc Con trol -10.0

Low F requency, Wi de

OPERATION

B-13

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

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

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

FIGURE B.6

ARC CONTROL

For steel and stainless pulse modes, Arc Control regulates 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 0.0 decrease the pulse frequency while
increasing the background current, for a soft arc good for out-of-position welding.

FIGURE B.7

POWER FEED™ 25M

B-14

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5

OPERATION

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

FIGURE B.8

B-14

K2368-1 Power Wave®355M

1 K2202-1 Power Wave

K2203-1 Power Wave

®

455M

®

455M/STT
K2230-1 POWER FEED™ 10M, Bench Model
K2234-1

POWER FEED™ 10M Dual, Bench Model

K2536-1,-2,-3 POWER FEED™ 25M

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

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

3 K1543-xx, K2683-xx Digital Control Cable
4 K1796-xx, K2593-xx Coaxial

KP1507-xx

Weld Power Cable, Lug to Lug

K910-xx Ground Clamp

5 See Magnum

®

MIG gun

Literature

Deluxe Regulator for Mixed

6 K586-1 Shielding Gases

Shielding Gas Hose

POWER FEED™ 25M

B-15

220

1.06

WFS AMPS

VOLTS TRIM

Less
D

eposition

Shorter
Arc

L

onger

Arc

More
D

eposition

ARC
FOCUS

-10.0 (SOFT to

10.0 (STIFF)

DESCRIPTION

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

PREFLOW TIME

0 - 25.0 seconds

RUN-IN WFS:
Off, 30 to150 in/min.

Start Procedure

DESCRIPTION

Adjusts the time that shielding

gas

flows

after

the trigger

is

pulled

and

prior to feeding wire.

Ru n - i n s e t s t h e w i r e f e e d

speed from the time the trigger

is pulled until an arc is estab-

lished.

The Start Procedure controls

the WFS, Trim at a specified

time a t the beginn ing o f the

weld. During the start time, the

machine will ramp up or down

from the Start Procedure to the

preset Welding Procedure.

EFFECT / RANGE

Postflow Time:
0 to 25.0 seconds

Burnback: 0 to .25
Seconds

Crater Procedure

FUNCTION

Adjusts the time that shielding
gas flows after the welding out­put turns off.
Th e burnback time i s the
amount of time that the weld
output continues after the wire
stops feeding. It prevents the
wire from sticking in the puddle
and prepares the end of the
wire for the next arc start.
Crater Procedure controls the
WFS and Trim for a specified
ti me at t he end of the we ld
after the trigge r is released.
Du r ing the Cra t er t ime, the
machine will ramp up or down
from the Weld Pr ocedu re to
the Crater Procedure.

ELECTRODE AND

Steel(Crisp)
Steel(Soft)
Stainless
Stainless

Stainless

GAS

2

CO

2

CO

2

Ar(Mix)

Ar(Mix)

Ar/He/CO

Ar/

Ar/

WIRE SIZE

0.030 0.035 0.045 0.052

---

14 19 28

95 12 22 201

66 36 46 --­62 32 42 ---

--- 34 44 ---

START OPTIONS

END OPTIONS

WELD MODE

ARC CONTROL

STEEL
.035"

SET

SETUP

IR PORT

Pulse Crisp ArMix

W

AVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

12

S

TART OPTIONS

END OPTIONS

Spot Timer
0 to 120.0 Seconds

Ad j u s t t h e time weldi n g w i l l
co n t i n u e e v en if the t r i g g e r
is s t i l l p u lled. This o p t i o n
ha s n o e f f e ct in 4-St e p
Tr i g g e r M o d e.

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

MSP4 OPERATION

OPERATION

B-15

POWER FEED™ 25M

B-16

OPERATION

B-16

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

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

Pulse-on-Pulse Welding

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

FIGURE B.9

FIGURE B.11

Frequency Modulation = 10

Narrow weld and ripple spacing, fast travel speed.

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

FIGURE B.10

Frequency Modulation = -10

Wide weld and ripple spacing, slow travel speed.

POWER FEED™ 25M

B-17

Trim .50

Arc Length Short

Trim 1.00

Arc Length Medium

Trim 1.50

Arc Length Long

OPERATION

B-17

ALUMINUM GMAW-P AND GMAW-PP

ALUMINUM PULSE WELDING

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

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

FIGURE B.12

POWER FEED™ 25M

B-18

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OPERATION

ALUMINUM GMAW-P AND GMAW-PP WELDING

FIGURE B.14

B-18

K2368-1 Power Wave®355M

1 K2202-1 Power Wave

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

K2234-1

2

K2536-1,-2,-3 POWER FEED™ 25M
KP1695-xx Drive Roll Kit, 2 Roll Feeder

KP1507-xx Drive Roll Kit, 4 Roll Feeder
3 K1543-xx, K2683-xx Digital Control Cable
4 K1796-xx, K2593-xx Coaxial
5 K910-xx Ground Clamp
6 K2447-xx Python Plus Gun, Air cooled

7 K586-1 Shielding Gases

®

455M

®

455M/STT

Requires K1634-1 Spool cover
POWER FEED™ 10M Dual, Bench Model
Requires K1634-1 Spool cover

Weld Power Cable, Lug to Lug

Deluxe Regulator for Mixed

Shielding Gas Hose

POWER FEED™ 25M

B-19

PULSE

PULSE-ON-PULSE

FREQUENCY:

FREQ.MODULATION

(Low)-10.0 to
(High)+10.0

(Low)-10.0 to
(High)+10.0

DESCRIPTION

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

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

For Pulse

modes, Arc Control
changes the pulsing frequency.
When the frequency changes,
the Power Wave system auto­ma t i c a l l y ad justs the back­ground curren t to main tain a
similar heat input into the weld.
Low frequencies give more con­trol over the puddle and high
frequencies minimize spatter.

PREFLOW TIME

0 - 25.0 seconds

RUN-IN WFS:
Off, 30 to150 in/min.

Start Procedure

DESCRIPTION

Adjusts the time that shielding

gas

flows

after

the trigger is

pulled

and

prior to feeding wire.

Ru n - i n s e t s t h e w i r e f e e d
speed from the time the trigger
is pulled until an arc is estab­lished.
The Start Procedure controls
the WFS. Trim at a specified
time a t the beginn ing o f the
weld. During the start time, the
machine will ramp up or down
from the Start Procedure to the
preset Welding Procedure.

EFFECT / RANGE

Postflow Time:
0 to 25.0 seconds

Burnback: 0 to .25
Seconds

Crater Procedure

FUNCTION

Adjusts the time that shielding
gas flows after the welding out­put turns off.
Th e burnback time i s the
amount of time that the weld
output continues after the wire
stops feeding. It prevents the
wire from sticking in the puddle
and prepares the end of the
wire for the next arc start.
Crater Procedure controls the
WFS and Trim for a specified
ti me at t he end of the we ld
after the trigge r is released.
Du r ing the Cra t er t ime, the
machine will ramp up or down
from the Weld Pr ocedu re to
the Crater Procedure.

ELECTRODE AND GAS

ALUMINUM 4043
ALUMINUM 4043
ALUMINUM 5356
ALUMINUM 5356

Ar
Ar
Ar
Ar

WIRE SIZE

0.035 3/64 1/16

149 72 74

98 99 100
152 76 78
101 102 103

WELD MODES

START OPTIONS

END OPTIONS

ARC CONTROL

Aluminum
3/64"

S

ET

SETUP

IR PORT

4043 Pulse Ar

W

AVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

72

START OPTIONS

END OPTIONS

Spot Timer
0 to 120.0 Seconds

Ad j u s t t h e time weldi n g w i l l
co n t i n u e e v en if the t r i g g e r
is s t i l l p u lled. This o p t i o n
ha s n o e f f e ct in 4-St e p
Tr i g g e r M o d e.

220

1.06

WFS AMPS

V

OLTS TRIM

Less
Deposition

S

horter

Arc

Longer
A

rc

More
Deposition

Aluminum Pulse and Pulse-On-Pulse (Synergic) Weld Display

MSP4 OPERATION

OPERATION

B-19

POWER FEED™ 25M

B-20

8

4

3

2

7

1

5

6

OPERATION

B-20

GMAW-STT™ WELDING

Surface Tension Transfer, or STT™ welding, is a

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

Several sets of STT™ weld modes are available.

• Modes 110 and 126 provide individual control of
peak current, background current and tail-out, and
are most often used in robotic applications.

• Modes 123 and 124 include Hot Start and give total
control of the arc.

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

Note: STT™ is available only with specially equipped
Power Wave power sources, like the Power Wave
455M/STT.

2 shielding gas, results in cost sav-

FIGURE B.15

For best results:

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

• Use only solid steel , stainless steel o r silicon
bronze electrodes.

1 K2203-1 Power Wave 455M/STT

K2234-1

K2230-1

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

l

2 K2536-1,-2,-3 POWER FEED™ 25M

KP1695-xx, Drive Roll Kit, 2 Roll Feeder
KP1507-xx Drive Roll Kit, 4 Roll Feeder

3 K1543-xx Digital Control Cable

K2683-xx

K1796-xx, K2593-xx

4

Coaxial Weld Power Cable, Lug to Lug
5 K910-xx Ground Clamp
6 K940-xx Sense Lead Kit

7 See Magnum

Literature

®

MIG Gun

Deluxe Regulator for Mixed
8 K586-1 Shielding Gases

Shielding Gas Hose

POWER FEED™ 25M

B-21

220

----

WFS AMPS

V

OLTS TRIM

Less
Deposition

More
Deposition

EFFECT / RANGE

PEAK CURRENT

B A C K G R O U N D
CURRENT

TAIL OUT

(

ST T ll M O D ES

ONLY)

DESCRIPTION

Peak Current acts similar to an

arc

pinch

control. Peak Current

sets th e arc leng th

and

promotes

-

go o d fusi o n .

H i g her

peak

current levels will cause

the arc to broaden

momentarily

while increasing arc length. If

set too high, globular transfer

may occur.

Setting it too low

may cause instability

and

wire

stubbing.

Best

practice is to

adjust for minimum spatter and

puddle

agitation.

Background Current controls

the

overall

heat inp ut i n the

wel d.

Ta il out p r ovi des ad dit iona l

po w e r

witho u t t he m o l t en

drop let b eco min g

too lar ge.

Increase as necessary to add

heat input without incr easing

arc length.

Often this results in

faster travel speeds.

Note that

as tail out increases, the peak

current

to be reduced.

and/or background current

may need

P

REFLOW TIME

0 - 25.0 seconds

RUN-IN WFS:
Off, 30 to150 in/min.

Start Procedure

FUNCTION

Adjusts the time that shielding
gas

flows

after

the trigger

is

pulled and

prior to feeding wire.

Ru n - i n s e t s t h e w i r e f e e d
speed from the time the trigger
is pulled until an arc is estab­lished.

The Start Proce dure is not
commonly used w ith STT
procedures.

PARAMETER
RANGE

Postflow Time:
0 to 25.0 seconds

FUNCTION

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

ELECTRODE AND GAS

STEEL CO

2

S

TAINLESS

A

r/CO

2

He/Ar/CO

2

S

TEEL CO

2

STAINLESS

A

r/CO

2

He/Ar/CO

2

W

IRE SIZE

0

.035 0.045 0.052

110 126 126
1

10 126 126

WELD MODES

START OPTIONS

END OPTIONS

ARC CONTROL

Steel
.035"

S

ET

SETUP

I

R PORT

STT

W

AVEFORM CONTROL TECHNOLOGY

WELD MODE

A

RC CONTROL

109

S

TART OPTIONS

E

ND OPTIONS

STEEL CO

STEEL CO

STEEL AR/CO
STAINLESS He/Ar/CO

STAINLESS He/Ar/CO

S

TAINLESS Ar/CO

2

2

2

2

2

2

(with Hot Start)

(SYNERGIC STT)

SYNERGIC STT, OPEN ROOT

1

23 124 124

123 124 124

111 117 120
112 118 121

113 119 122
135 137 ---

127 129 ---

131 133 ---

Burnback: 0 to .25
Seconds

Th e b u r nback t i m e is t h e
amount of time that the weld
output continues after the wire
stops feeding. It prevents the
wire from sticking in the puddle
and p repares the e nd of the
wire for the next arc start.

Crater Procedure

Crater is not commonly used
in STT weld procedures.

Spot Timer

0 to 120.0 Seconds

Ad j u s t the t i m e weld i n g will
co n t i n ue ev e n i f the t r i gger
is s t i ll pu l l e d . Thi s o p tion
ha s n o effe c t i n 4-S t e p
Tr i g g e r Mod e .

OPERATION

GMAW-STT™

Waveform Control Technology™ maximizes the

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

• Wire Feed Speed - sets the deposition rate.

• Peak Current - controls the arc length.

• Background Current - regulates the bead contour.

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

B-21

There is no Voltage control

when STT™ welding.

MSP4 OPERATION

POWER FEED™ 25M

B-22

Peak
Current
Too Low

Peak
Current
Optimum

Peak
Current
Too High

Background
Current
Too Low

Background
Current
Optimum

Background
Current
Too High

OPERATION

PEAK CURRENT (Figure B.16)

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

2 to reduce spatter.

FIGURE B.16

B-22

2,

BACKGROUND CURRENT (Figure B.17)

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

FIGURE B.17

2 requires less

TAILOUT

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

POWER FEED™ 25M

B-23

OPERATION

GTAW (TIG) WELDING

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

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

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

B-23

Touch Start TIG
Weld Sequence

TIG torches without
built-in Gas Valves.

TIG to rche s wi t h
built-in Gas Valves.

No Foot / Hand Amptrol

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

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

3. Touch the tungsten to the work piece.

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

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

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

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

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

3. Open the gas valve on the TIG torch.

4. Touch the tungsten to the work piece.

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

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

7. Close the gas valve on the TIG torch.

With Foot / Hand Amptrol

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

2. Touch the tungsten to the work piece.

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

4. Lift the tungsten to create an arc.

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

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

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

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

2. Touch the tungsten to the work piece.

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

4. Open the gas valve on the TIG torch.

5. Lift the tungsten to create an arc.

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

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

8. Close the gas valve on the TIG torch.

POWER FEED™ 25M

B-24

8

4

3

2

7

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OFF

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V

OLTS TRIM

Output
ON

Output
OFF

Maximum
Amperage

No Arc Controls are active
for Touch Start TIG.

START PROCEDURE

During the Crater Time, the
Amperagr will ramp up or
down from the weld Amperage
to the Crater Amperage.

No Arc Contro are
a

ctive for Touch Start TIG

M

ODE

T

OUCH START 3

S

TART OPTIONS

END OPTIONS

W

ELD MODE

ARC CONTROL

SET

S

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I

R PORT

Touch Start TIG

WAVEFORM CONTROL TECHNOLOGY

WELD MODE

A

RC CONTROL

START OPTIONS

END OPTIONS

3

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

FIGURE B.17a

OPERATION

B-24

1 K2202-1 Power Wave

2 K2234-1

4 Electrode Cable
5 K910-xx Ground Clamp

3 K1543-xx, K2683-xx Digital Control Cable

6 K1782-xx, K1783-xx PTA-17, PTA-26 TIG torch

7 K870 Foot Amptrol
8 3100211 Harris Argon Flow Regulator

K2368-1 Power Wave®355M

®

455M

K2203-1 Power Wave
K2230-1

POWER FEED™ 10M, Bench Model

®

455M/STT

POWER FEED™ 10M Dual, Bench Model

K2536-1,-2,-3 POWER FEED™ 25M

(shown with valve)

POWER FEED™ 25M

B-25

LED

Indicator

Mode Select

Panel (MSP4)

Right

button

SET Knob

Left

buttom

LED

Indicator

Mode Select

Panel (MSP4)

Right

button

SET Knob

Left

buttom

OPERATION

B-25

SETUP MENU FEATURES

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

PARAMETER

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

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

2. After changing a parameter it is necessary to press

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

DEFINITION

Unsecured Parameters (always adjustable)

Diagnostic Parameters (always read only)

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

SET-UP FEATURES MENU

(See Figure B.17b and B.17c for specific Codes)

Left buttons of the MSP4 panel simultaneously.
Note that the set-up menu cannot be accessed if

the system is welding, or if there is a fault (The sta­tus LED is not solid green).

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

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

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

FIGURE B.17b - SETUP MENU

(Only parameters below can be accessed in Code 11313)

P.0 P.7 P.100 thru P.107
P.1 P.8
P.2 P.11
P.3 P.12
P.4 P.13
P.5 P.80
P.6 P.99

FIGURE B.17c - SETUP MENU

(All parameters can be accessed in Code 11456 and higher)

POWER FEED™ 25M

B-26

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

Exit Setup Menu

P.0

This setup menu parameter can be used to exit the setup menu. When P.0 is displayed, press
the left Mode Select button to exit the setup menu.

P.1 Wire Feed Speed Units

P.1 selects which units wire feed speed will be displayed in. English = in/minute wire feed speed

units (default). Metric = m/minute wire feed speed units.

P.2 Arc Display Mode

P.2 selects what value will be shown on the upper left display while welding. Amps = The left
display shows Amperage while welding (default). WFS = The left display shows Wire Feed
Speed while welding.

P.3 Display Energy

P.3 selects whether or not energy is displayed on the MSP4 while welding. The total energy

from the previous weld will persist on the MSP4 display until another weld is started, or a user
interface control is changed. P.3 will only show up in the list if the power source is capable of
calculating energy (a power source software update may be necessary). When P.3 = No, ener­gy will not be displayed (default). When P.3 = Yes, energy is displayed.

B-26

P.4 Recall Memory with Trigger

Allows the operator to recall a memory by quickly pulling and releasing the gun trigger. To recall
a memory, quickly pull and release the trigger the number of times that correspond to the mem­ory number. For example, to recall memory 3, quickly pull and release the trigger 3 times. To
recall memory 1, quickly pull and release the trigger the number of user memories plus 1.
Memories cannot be recalled while the system is welding. A memory panel must be installed in
order to use this feature.

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

POWER FEED™ 25M

B-27

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.5 Procedure Change Method

Selects how remote procedure selection (A/B) will be made. The selected procedure can be
changed locally at the user interface by pressing the 'A-Gun-B' button. The following methods
can be used to remotely change the selected procedure:

• Use an external switch wired to the procedure select input.

• Quickly releasing and re-pulling the gun trigger.

• Using a dual-schedule gun which incorporates a procedure select switch in the trigger mecha­nism (pulling the trigger more than half way changes the procedure from A to B).

The possible values for this parameter are:

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

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

1. Select "GUN" on the memory panel.

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

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

B-27

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

P.6 Stall Factor Adjustment

Allows the adjustment of the stall factor in Push/Pull operation. The stall factor controls the stall
torque of the push motor when using a push-pull gun. The wire feeder is factory-set to not stall
unless there is a large resistance to feeding wire. The stall factor can be reduced to stall more
easily and possibly prevent bird nesting. However, low stall factors can cause motor stalling
during normal welding conditions, which results in the wire burning back to the tip or rapid tack
welds. If you are experiencing bird nests, check for other feeding problems before adjusting the
stall factor. The default value for the stall factor is 75, with a range of 5 to 100.

POWER FEED™ 25M

B-28

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.7 Gun Offset Adjustment

Range: -30 to 30 (default = 0)

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

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

• Set the wire feed speed to 200 ipm.

• Remove wire from the pull wire drive.

• Hold an 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.

P.8 TIG Gas Control

Allows control over which gas solenoid actuates while TIG welding.

B-28

• Valve (manual) = No MIG solenoid will actuate while TIG welding, gas flow is manually con­trolled by an external valve.

• Feeder Solenoid = The internal (feeder) MIG solenoid will turn on and off automatically while
TIG welding.

• Power source Solenoid = Any gas solenoid connected to the power source will turn on and off
automatically while TIG welding.

Notes:

• Preflow is not available while TIG welding.

• Postflow is available - the same postflow time will be used in MIG and TIG.

• When machine output on/off is controlled via the upper right knob, gas flow will not start until
the tungsten touches the work. Gas flow will continue when the arc is broken until the
Postflow time expires.

• When machine output on/off is controlled via an arc start switch or foot Amptrol, gas will begin
flowing when the output is turned on and will continue flowing until the output is turned off and
the Postflow time expires.

P.9 Crater Delay

Range: Off to 10.0 seconds (default = Off)

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

P.14 Reset Consumable Weight

Only appears in the list with systems using Production Monitoring. Use this option to reset the
initial weight of the consumable package. Press the right Mode Select Button to reset the con­sumable weight.

POWER FEED™ 25M

B-29

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.16 Push-Pull Gun Knob Behavior

Determines how the potentiometer on the Push/Pull torch will behave.

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

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

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

P.80 Sense From Studs

Use this option for diagnostic purposes only. When power is cycled, this option is automatically
reset to False.

B-29

• False = Voltage sensing is determined by the DIP switch configuration and the selected weld
mode (default).

• True = Voltage sensing is forced to "studs" regardless of the DIP switch configuration and
selected weld mode.

P.99 Show Test Modes

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

P.100 View Diagnostics

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

P.101 View Event Logs

Used for viewing all the system event logs. Press the right MSP Button to enter the option.
Rotate Set knob to select the desired system log to read. Press the right button again to enter
the selected log. Rotating the Set knob will scroll through the event log, displaying the log index
number, event code and some other data. Press the left button to back out to select another
log. Press the left button again to exit this option.

P.102 View Fatal Logs

Used for viewing all the system fatal logs. Press the right MSP Button to enter the option.
Rotate Set knob to select the desired log to read. Press the right button again to enter that log.
Rotating the Set knob will scroll through the log, displaying the log index number and fatal
code. Press the left button to back out to select another log. Press the left button again to exit
this option.

POWER FEED™ 25M

B-30

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.103 View Software Version Information

Used for viewing the firmware versions for each board in the system. Press the right MSP
Button to enter the option. Rotate Set knob to select the desired board to read. Press the right
button again to read the firmware version. Press the left button to back out to select another
board. Rotate the SET knob to select another board, or press the left button to exit this option.

P.104 View Hardware Version Information

Used for viewing the hardware version for each board in the system. Press the right MSP
Button to enter the option. Rotate Set knob to select the desired board to read. Press the right
button again to read the hardware version. Press the left button to back out to select another
board. Press the left button again to exit this option.

P.105 View Welding Software Information

Used for viewing the Weld Set in the Power Source. Press the right MSP Button to read the
Weld Set version. Press the left button to back out and exit this option.

B-30

P.106 View Ethernet IP Address

Used for viewing the Ethernet Network IP address if there is an Ethernet board present in the
system. Press the right MSP Button to read the IP Address. Press the left button to back out
and exit this option. The IP address cannot be changed using this option.

P.107 View Power Source Protocol

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

P.500 View Lockout Parameters

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

P.501 Encoder Lockout

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

P.502 Memory Change Lockout

Determines if the memories can be overwritten with new contents.

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

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

This parameter can only be accessed using Power Wave Manager.

POWER FEED™ 25M

B-31

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.503 Memory Button Disable

Disables the specified memory button(s). When a memory is disabled, welding procedures can­not be restored from or saved to that memory. If an attempt is made to save or restore a dis­abled memory, a message will be displayed on the Mode Select Panel indicating the memory
number is disabled. In multi-head systems, this parameter disables the same memory buttons
on both feed heads. This parameter can only be accessed using Weld Manager or Power
Wave Manager software.

P.504 Mode Select Panel Lock

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

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

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

• Start & End Options Locked = The Start and End parameters on the Mode Select Panel are
locked, all others are unlocked.

• Weld Mode Option Locked = The weld mode cannot be changed from the Mode Select Panel,
all others Mode Select Panel settings are unlocked.

• Wave Control Options Locked = The Wave Control parameters on the Mode Select Panel are
locked, all others are unlocked.

• Start, End, Wave Options Locked = The Start, End and Wave Control parameters on the
Mode Select Panel are locked, all others are unlocked.

• Start, End, Mode Options Locked = The Start, End and Weld Mode Select parameters on the
Mode Select Panel are locked, all others are unlocked.

B-31

This parameter can only be accessed using Power Wave Manager.

P.505 Setup Menu Lock

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

• No = The operator can change any set menu parameter without first entering the passcode
even if the passcode is non-zero (default).

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

This parameter can only be accessed using Power Wave Manager.

P.506 Set User Interface Passcode

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

• changes to memory limits

• saving to memory (if P.502 = Yes)

• changes to setup parameters (if P.505 = Yes)

This parameter can only be accessed using Power Wave Manager.

POWER FEED™ 25M

B-32

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

P.507 UI Clear All Memories

Allows the operator to quickly set all memories to the default weld mode and welding parame­ters. Presently, this option does not exist in any setup menu.

P.509 UI Master Lockout

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

B-32

POWER FEED™ 25M

B-33

HOLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

GUN B

1

4

2

5

3

6

M

M

HOLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

GUN B

1

4

2

5

3

6

M

M

HOLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

GUN B

1

4

2

5

3

6

M

M

OPERATION

B-33

PROCEDURE/MEMORY PANEL OPERA­TION

(For Code 11313):

The Dual Procedure/Memory Panel performs three
functions:

• Weld procedure selection

• Memory save and recall

• Limits setting

There are two procedure memories (A and B) and six
user memories (1-6).

Procedure Memory vs. User Memory

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

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

USER

PROCEDURE

MEMORY

MEMORIES

USER MEMORIES

Recall a memory with memory buttons

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

Recall a memory with the gun trigger

If desired, memories 2 through 6 can be recalled with
the gun trigger. For example, to recall memory 3,
quickly pull and release the gun trigger 3 times without
welding.

Note: the POWER FEED™ Wire Feeders are factory
set with this feature disabled. Use the SETUP menu
and change P.4 to enable memory recall with the gun
trigger.

Save a memory with memory buttons

To save a memory, press and hold the desired memo­ry button for two seconds. When the button is initially
pressed, the corresponding LED will illuminate. After
two seconds, the LED will turn off. Do not hold the
button for more than 5 seconds when saving a user
memory.

Using Procedure Memories

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

PRESS TO

SELECT

PROCEDURE OR

QUICK TRIGGER-

WHILE

WELDING

Note: that memor ies ma y be locked using Weld
Manager from a P.C. or Palm application to prevent
accidental overwrite of the memories. If an attempt is
made to save a memory when memory saving is
locked, the message "Memory save is Disabled!" will
appear briefly in the MSP4 display.

RECALL
PRESS 1
SECOND

SAVE

PRESS 2

SECONDS

POWER FEED™ 25M

B-34

H

OLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

GUN B

1

4

2

5

3

6

M

M

SET

SETUP

I

R PORT

Set Limits

Memory 1

W

AVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

S

TART OPTIONS

END OPTIONS

OPERATION

B-34

LIMITS

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

Each user memory may have a different set of limits.
For example, memory 1 can be set to limit the WFS to
200 through 300 in/min, and memory 2 can be set to
limit the WFS to 275 through 310 in/min, while memo­ry 3 may not have any WFS limits.

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

Machine limits are:

Parameter

Wire Feed Speed

Voltage

Range

Weld mode dependent

and gear box ratio

dependent

Weld mode dependent

Units

in/min

Volts

Set Limits:

Press 5

seconds

To set limits, press the desired memory button 1-6
and hold for 5 seconds. Release the memory button
when the LED begins to blink rapidly and the MSP4
displays "Memory X Set Limits" as shown below.

MSP4 DISPLAY

Trim

0.50 to 1.50

--

Limits may be set for:

• Wire Feed Speed/Amperage

• Voltage/Trim

• Arc Control

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

POWER FEED™ 25M

B-35

SET

SETUP

HiHi

LoLo

IR PORT

Weld WFS

= 200

= 180

WAVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

START OPTIONS

END OPTIONS

200

SET

S

ETUP

HiHi

L

oLo

IR PORT

Weld WFS

= 200
= 180

WAVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

START OPTIONS

END OPTIONS

200

HOLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

G

UN B

1

4

2

5

3

6

M

M

SET

S

ETUP

IR PORT

Enable/Disable

Memory 1
Limits

WAVEFORM CONTROL TECHNOLOGY

WELD MODE

A

RC CONTROL

START OPTIONS

END OPTIONS

SET

SETUP

IR PORT

Yes No

Enable
Limits?

WAVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

START OPTIONS

END OPTIONS

OPERATION

B-35

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

Memory Value

High Limit

Low Limit

Parameter Name

If the passcode has been set to zero (0000), SETUP will
illuminate on the MSP4 panel and the display will show
the following:

Four items show on the MSP4 panel.

• Memory Value

• High Limit

• Low Limit

• Parameter Name
One of these items will flash to indicate which item will
change when the MSP4 encoder is rotated. Press the
right button on the MSP4 panel to select the item to
change.

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

After setting limits, press the memory button with the
flashing LED. The MSP4 will ask to save or discard
the limit changes just made. Press the left MSP4 for
button (YES) to save and enable the limits and exit.
Press the right MSP4 button (NO) to exit and leave
limits unchanged.

Enabling/Disabling Limits

Enable/Disable

Limits: Press

10 seconds

Limits for each memory may be enabled or disabled
by pressing and hold the appropriate memory button
for 10 seconds. Release the memory button when the
MSP4 display shows the following:

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

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

Rotate to

Change

Value.

Press to

select item

to change.

If the passcode does not equal zero, enter the passcode
now. If the passcode is zero (0000), SETUP will light
and the MSP4 displays the following:

Press the left MSP4 button (YES) to enable limits or
the right MSP4 button (NO) to disable limits. Disabling
limits does not change any limits values that may
have been previously set.

POWER FEED™ 25M

B-36

A

GUN B

1

5

2

6

3

7

4

8

A

GUN B

1

5

2

6

3

7

4

8

A

GUN B

1

5

2

6

3

7

4

8

OPERATION

B-36

DUAL PROCEDURE/MEMORY OPERATION

(For Code 11456 and Higher)

The Dual Procedure/Memory buttons performs three
functions:

• Weld procedure selection

• Memory save and recall

• Limits setting

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

Procedure Memory vs. User Memory

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

PROCEDURE

MEMORY

USER MEMO-

RIES ARE COPIED

TO PROCEDURE

MEMORIES

USER

MEMORIES

USER MEMORIES

Recall a memory with memory buttons

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

Recall a memory with the gun trigger

If desired, memories 2 through 8 can be recalled with
the gun trigger. For example, to recall memory 3, quick­ly pull and release the gun trigger 3 times without weld­ing.

Note: the wire feeder is factory set with this feature dis­abled. Use the SETUP menu and change P.4 to enable
memory recall with the gun trigger.

Save a memory with memory buttons

To save a memory, press and hold the desired memo­ry button for two seconds. When the button is initially
pressed, the corresponding LED will illuminate. After
two seconds, the LED will turn off. Do not hold the
button for more than 5 seconds when saving a user
memory.

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

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

PRESS TO

SELECT

PROCEDURE

Note: that memories may be locked in the set-up menu
to prevent accidental overwrite of the memories. If an
attempt is made to save a memory when memory sav­ing is locked, the message "Memory save is Disabled!"
will appear briefly in the MSP4 display.

RECALL
PRESS 1
SECOND

SAVE

PRESS 2

SECONDS

POWER FEED™ 25M

B-37

A

GUN B

1

5

2

6

3

7

4

8

S

ET

Set Limits

Memory 2

WELD MODE

A

RC CONTROL

START OPTIONS

E

ND OPTIONS

OPERATION

LIMITS

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

Each user memory may have a different set of limits.
For example, memory 1 can be set to limit the WFS to
200 through 300 in/min, and memory 2 can be set to
limit the WFS to 275 through 310 in/min, while memo­ry 3 may not have any WFS limits.

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

The system machine limits are:

B-37

Set Limits:

Press 5

seconds

To set limits, press the desired memory button 1-8
and hold for 5 seconds. Release the memory button
when the LED begins to blink rapidly and the MSP4
displays "Memory X Set Limits" as shown below.

Parameter

Wire Feed Speed

Voltage

Trim

Arc Control

Preflow

Start Time

Run-In WFS

Crater Time

Burnback Time

Postflow Time

Range

Weld mode and wire

feeder dependent.

Weld mode dependent

0.50 to 1.50

-10.0 to 10.0

0.0 to 2.5

0.0 to 10.0

Off, 50 to 150

0.0 to 10.0

0.00 to 0.25

0.0 to 10.0

Units

in/min

Volts

--

Weld mode dependent

Seconds

Seconds

in/min

Seconds

Seconds

Seconds

Limits may be set for:

• Wire Feed Speed/Amperage • Start Time

• Voltage/Trim • Burnback Time

• Arc Control • Crater Wire Feed Speed

• Preflow Time • Crater Voltage/Trim

• Run-In Speed • Crater Time

• Start Wire Feed Speed • Postflow Time

• Start Voltage/Trim

MSP4 DISPLAY

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

POWER FEED™ 25M

B-38

WELD WFS

HI = 200

LO = 180

WELD MODE

ARC CONTROL

START OPTIONS

END OPTIONS

200

WELD WFS

HI = 200

LO = 180

WELD MODE

ARC CONTROL

START OPTIONS

END OPTIONS

200

A

GUN B

1

5

2

6

3

7

4

8

MEMORY 2 LIMITS
ENABLE/DISABLE

WELD MODE

A

RC CONTROL

START OPTIONS

END OPTIONS

ENABLE LIMITS?

WELD MODE

ARC CONTROL

START OPTIONS

END OPTIONS

Yes No

OPERATION

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

Memory Value

Low Limit

High Limit

Parameter Name

If the passcode has been set to zero (0000), SETUP will
illuminate on the MSP4 panel and the display will show
the following:

B-38

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

After setting limits, press the memory button with the
flashing LED. The MSP4 will ask to save or discard
the limit changes just made. Press the left MSP4 for
button (YES) to save and enable the limits and exit.
Press the right MSP4 button (NO) to exit and leave
limits unchanged.

Enabling/Disabling Limits

Enable/Disable

Limits: Press

10 seconds

Four items show on the MSP4 panel.

• Memory Value

• High Limit

• Low Limit

• Parameter Name
One of these items will flash to indicate which item will
change when the MSP4 encoder is rotated. Press the
right button on the MSP4 panel to select the item to
change.

Rotate to

Change

Value.

Press to

select item

to change.

Limits for each memory may be enabled or disabled
by pressing and hold the appropriate memory button
for 10 seconds. Release the memory button when the
MSP4 display shows the following:

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

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

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

and the MSP4 displays the following:
Press the left MSP4 button (YES) to enable limits or
the right MSP4 button (NO) to disable limits. Disabling
limits does not change any limits values that may
have been previously set.

POWER FEED™ 25M

B-39

2

-

S

T

E

P

4

S

T

E

P

1 2 Step / 4 Step Trigger Switch

2 Cold Feed / Purge Switch
3 Wire Drive Pressure Arm

4 Internal Light Switch

5 Internal Heater Switch
6 Spindle Brake
7 Gun Bushing

ITEM DESCRIPTION

1

9

8

7

6

3

2

8 Thumb Screw for securing the welding Gun

9 Socket Head Cap Screw for securing the Gun Bushing

H

E

A

T

E

R

O

N

O

F

F

O

N

C

O

L

D

F

E

E

D

G

A

S

P

R

U

G

E

O

F

F

4

5

OPERATION

B-39

INTERNAL CONTROLS (FOR CODE 11312)

POWER FEED™ 25M

B-40

1 Cold Feed / Purge Switch
2 Wire Drive Pressure Arm
3 Internal Light Switch
4 Internal Heater Switch

5 Spindle Brake
6 Gun Bushing

ITEM DESCRIPTION

1

8

7

6

3

2

7 Thumb Screw for securing the welding Gun

8 Socket Head Cap Screw for securing the Gun Bushing

4

5

OPERATION

INTERNAL CONTROLS (FOR CODE 11456 and higher)

B-40

POWER FEED™ 25M

B-41

COLD FEED

GAS PURGE

ON

OFF

LIGHT

HEATER

OFF

ON

ALUMINUM

F

LUX CORE

ARC WELDING

GAS METAL
ARC WELDING

6

1
3

2

5

4

Aluminum wires

Cored wires

Steel, Stainless wires

OPERATION

B-41

COLD FEED/GAS PURGE SWITCH

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

To a c t i vate Cold Feeding, hold t h e
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.

LIGHT SWITCH

PRESSURE ARM ADJUSTMENT

ELECTRIC SHOCK can kill.

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

• Do not touch electrically live parts.

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

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

• Only qualified personnel should perform mainte­nance work.

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

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

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

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

Turn the internal light switch ON to
illuminate the inside of the POWER
FEED™ 25M.

HEATER SWITCH

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

FIGURE B.18

POWER FEED™ 25M

B-42

2-STEP

4 STEP

OPERATION

B-42

2 STEP - 4 STEP - TRIGGER OPERATION

(For Code 11313)

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 g i v e s t h e ability to control the
amount of time spent in the arc start
and arc crater steps.

Place the toggle switch in the UP posi­tion for 4 Step operation and in the
DOWN position for 2 Step operation.

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

2 Step Trigger

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

4 Step Trigger

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

2- STEP 4- STEP- TRIGGER OPERATION

Code 11456 and higher:

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

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

The 2-Step, 4-Step trigger has no effect when 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
th e gun trigger is activate d . Once the tr igger is
released, the welding system cycles through the arc
ending steps

4-Step Trigger

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

POWER FEED™ 25M

B-43

Shielding
Gas

Idle Pre flow

Run-In

WeldPos tfl ow Idle

Power
Source
Output

WFS

On

Off

Run- in

Off

Weld

Off

Weld

Arc

Established

Trigger

Pulled

Trigger

Released

2 Step Tri gger
Start = OFF
Crater = OFF
Burnback = OFF

1.5 s ec max.

OPERATION

EXAMPLE 1 - 2 STEP TRIGGER: Simple operation

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

For this sequence,

PREFLOW:

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

RUN-IN:

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

WELD:

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

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

B-43

FIGURE B.19

POWER FEED™ 25M

B-44

Shieldi n

g

Gas

Idle Preflow Strike Upslope Weld B urnback 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-44

EXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start

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

For this sequence,

PREFLOW:

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

RUN-IN:

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

FIGURE B.20

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™ 25M

B-45

Shielding
Gas

Idle Preflow Strike U pslope W eld Burnback Postf low Idle

WFS

On

Off

Run -in

Off

We ld

Off

We ld

Arc Established

Trigger Pulled

Trigger Released

2 Step Trig ger
Start = ON

C rat er = ON
Burnback = ON

1 .5 se c m a x .

Start

Start time

Burnback Time

Do wnslop e

Crat er

Cr ater ti me

Power
Source

Output

Crater

OPERATION

B-45

EXAMPLE 3 - 2 STEP TRIGGER: Customized Arc

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

For this sequence,

PREFLOW:

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

RUN-IN:

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

START & UPSLOPE:

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

WELD:

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

CRATER:

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

CRATER & DOWNSLOPE:

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

BURNBACK:

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

POSTFLOW:

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

FIGURE B.21

POWER FEED™ 25M

B-46

Shielding
Gas

I

dle Preflow Strike Wel

d

Burnb ack P ostf low Idl e

WFS

On

Off

Ru n-in

Off

We l d

Off

We l d

Arc

Established

Trigger

Pulled

Trigger

Released

4 Step Trigger
Start = OFF
Crater = OFF
Burnback = OF F

1. 5 s e c ma x .

Start

Crater

Power
Source

Output

Crat er

Trigger

Pulled

T

r

ig

g

e

r

R

e

l

e

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.22)

For this sequence,

PREFLOW:

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

RUN-IN:

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

WELD:

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

B-46

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.22

POWER FEED™ 25M

B-47

Shielding
Gas

Idle Pref low 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 m ax .

Start

Bur nba ck Time

Down slope

Crat er

Po we r
So ur ce
Output

Crat er

Start

Trigger

Pulled

Crat er

T

ri

g

g

e

r

Re

l

e

a

s

e

d

St a r t

OPERATION

B-47

EXAMPLE 5 - 4 STEP TRIGGER: Manual control of

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

In this sequence,

PREFLOW:

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

RUN-IN:

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

START:

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

UPSLOPE:

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

WELD:

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

DOWNSLOPE:

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

CRATER:

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

BURNBACK:

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

POSTFLOW:

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

FIGURE B.23

POWER FEED™ 25M

B-48

1 Flow Meter

2 Shielding Gas Inlet

3 5-Pin Arclink Cable Connector

4 Electrode Cable

5 Cover for Optional Water Line Connector

ITEM DESCRIPTION

1

2

3

4

5

REAR CONTROLS:

OPERATION

B-48

POWER FEED™ 25M

B-49

OPERATION

B-49

FLOW METER

The flowmeter shows the flow rate of shielding gas
and has a valve to adjust the flow. The flow meter is
scaled for CO2, Ar, and CO2/Ar blends. It is not cali­brated and is for reference purposes only. The middle
of the ball indicates the flow rate of shielding gas.

Adjust th e f low rate w h i le depres s i ng the GAS
PURGE switch by turning the valve at the bottom of
the meter. Most weld procedures require 25-40 scfh
(11.8 - 18.9 lpm) for sufficient shielding gas coverage.
Gun angle, nozzle diameter, joint configuration and
wind conditions may effect the amount of shielding
gas required.

When using a wire feeder with a flow meter, adjust the
regulator at the shield gas bottle or supply to a flow
rate that is higher than the flow rate indicated on the
feeder flow meter. Note that most regulators are cali­brated based upon having low restrictions on the out­let. The valve on the feeder flow meter creates a high
restriction and may cause errors in the readings at the
supply regulator. Set the gas flow rate using the
feeder flow meter reading and not the supply regulator
reading.

OPERATION ON LINCNET POWER
SOURCES

The POWER FEED™ 25M is an ArcLink wire feeder
and is designed for operating on ArcLink Power Wave
power sources. It is also capable of operating on older
LincNet Power Wave power sources though not all of
the features will be active.

When operating with a LincNet power source,

• Limits and Lock-outs are not available.

• The weld mode description is not displayed when
choosing weld modes.

• When the weld mode is changed, any Arc Control
values will remain as set for the previous weld
mode.

• Push-Pull guns will not function.

• The IR port will not operate.

• Error codes will by displayed as "ERR100". Error
codes are deciphered by the flashing of the Status
LED.

• In the Set-Up menu, only parameters P.0 to P.99
are available.

Only use a pressure regulator (like K586-1) at the gas
bottle or supply. Do not use a flow regulator.

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

POWER FEED™ 25M

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)
3/32” (2.4mm)

.035" (0.9 mm)

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

KP KIT

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

KP1696-1/16S

KP1696-1

KP1696-2
KP1697-035C
KP1697-045C
KP1697-052C

KP1697-1/16C

KP1697-068
KP1697-5/64
KP1697-3/32

KP1695-035A

KP1695-040A
KP1695-3/64A
KP1695-1/16A

Includes: 2 V groove
drive rolls and inner

wire guide.

Includes: 2 Knurled
drive rolls and inner
wire guide.

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

POWER FEED™ 25M

C-2

K2429-1

K857

K857-1

K2596-1

ACCESSORIES

ArcLink "T" Cable Adapter

Remote Output Control

Remote Output Control

Aluminum Case

C-2

Includes: 1 "T" adapter for

connecting two wire feeders to

one power source.

Includes: 1 remote output con-

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

welding.

Includes: 1 remote output con-

trol pendant with a 100’ cable.

Used most often with SMAW

welding.

Includes: a complete alu-

minum case. Decals, skids,

insulation and latches are all

preassembled.

K2596-2

K2593-xx

K1796-xx

K1803-1

K1840-xx

Plastic Case

#1 Co-Axial Power Cable

1/0 Co-Axial Power Cable

Work and Feeder Cables Package

Weld Power Cable, Twist-Mate to

Lug

Includes: a complete engineered
plastic case. Decals and latches

are all preassembled.

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

Use for Pulse or STT™ welding.

Includes: 1/0 Coaxial weld

cable of length "xx". Ends of

the weld cable have lug con-

nections. Use for Pulse or

STT™ welding.

Includes: 1/0 Coaxial weld

cable of length "xx". Ends of

the weld cable have lug con-

nections. Use for Pulse or

STT™ welding.

Includes: Twist-Mate to Lug

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

Ground Clamp, and Twist-

Mate to Lug 2/0 Cable 9'

(2.7m) long.

K1842-xx

Weld Power Cable, Lug to Lug

POWER FEED™ 25M

Includes: Twist-Mate to Lug,

1/0 cable of length "xx".

C-3

K1543-xx

K2683-xx

ACCESSORIES

Digital Control Cable

Heavy Duty ArcLink Control Cable

C-3

Includes: 5 pin to 5 pin wire

feeder to power source control

cable. Cables may be con-

nected end-to-end to make a

longer cable.

Includes: 5 pin to 5 pin wire feeder
power source to control cable. Cables
may b e co n n ecte d end - to-e n d to
make a longer cable. The male con­nect o r i s s t ainl e ss ste e l a nd th e
fema l e connec t or is bra s s .
Recommended for outdoor applica­tions.

K910-1

K910-2

K1500-1

K1500-2

Ground Clamp

Ground Clamp

Gun Receiver Bushing (for guns

with K466-1 Lincoln gun connec-

guns)

®

and Subarc

®

tors; Innershield

Gun Receiver Bushing (for guns

with K466-2, K466-10 Lincoln gun

connectors; Magnum

200/300/400 guns and compatible

with Tweco® #2-#4)

Includes: One 300 Amp

Ground Clamp.

Includes: One 500 Amp

Ground Clamp.

Includes: Gun receiver bush-

ing, set screw and hex key

wrench.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

K1500-3

K1500-4

Gun Receiver Bushing (for guns

with K613-7 Lincoln gun connec-

tors; Magnum

patible with Tweco® #5)

Gun Receiver Bushing (for gun

with K466-3 Lincoln gun connec-

tors; compatible with Miller® guns.)

®

550 guns and com-

POWER FEED™ 25M

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

C-4

K1500-5

ACCESSORIES

Gun Receiver Bushing (compatible

with Oxo® guns.)

C-4

Includes: Gun receiver bushing

with hose nipple, 4 guide tubes,

set screw and hex key wrench.

K489-7

K2339-1

K590-6

K435

Gun Receiver Bushing (for Lincoln

Fast-Mate guns.)

Push-Pull Gun Connection Kit

Water Connection Kit

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

in (51 mm) spindles.

Includes: Gun receiver bushing

with trigger connector.

Used with K2211-xx and K2212-

xx Python Guns. Includes: Push-

Pull gun bushing, fittings, valve

removal tool, modified gas

bypass valve and control cable

extension.

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

Includes: Spindle Adapter made

from 2 coil retainers. (Electrode

not included.)

K468

K659-1

3000290

K586-1

Spindle Adapter, for mounting 8in

(203mm) diameter spools on 2 in

(51 mm) spindles.

Gas Guard Regulator

Adjustable Gas Regulator

Deluxe Adjustable Gas Regulator

POWER FEED™ 25M

Includes: 2 Spindle Adapters,

one for 2" wide spools and the

other for 3" wide spools.

Includes: Gas Guard Regulator

and adjustment key.

Includes: Gas Regulator for

Mixed Gases and 10' (3.0m)

Hose.

Includes: Deluxe Gas Regulator

for Mixed Gases, Adapter for

CO2 and 1

0' (3.0m) Hose.

C-5

jj

oo

ee

ww

aa

ss

hh

ee

rr

ee

22

0000

11

jj

oo

ee

ww

aa

ss

hh

ee

rr

ee

22

0000

11

ACCESSORIES

INSTALLATION OF THE K590-6 WATER
COOLING KIT

WARNING

ELECTRIC SHOCK can kill.

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

• Do not touch electrically hot parts.

• Only qua lified person nel sho uld
install, use or service this equipment.

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

The K590-6 components are rated up to 70 psi (5 bar)
and 158°F (70°C). Use a coolant fluid that is compati­ble with the water cooler and the gun.

Tools required:

• 3/8" wrench

• 5/16" nut driver

• medium flat bladed screw driver

• cutting tool

C-5

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

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

1. Turn power off at the welding power source.

2. Remove the screws securing the case to the inner
module using a 3/8" wrench.

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

6. Secure the module to the case with the screws.
(Shown in Step 2)

7. Install the fitting assembly to the rear of the case.

Aluminum Case

Plastic Case

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

POWER FEED™ 25M

C-6

Power

Conduit

Gas

ACCESSORIES

C-6

WATER COOLED GUNS

WARNING

ELECTRIC SHOCK can kill.

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

• Do not touch electrically hot parts.

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

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

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

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

1. Turn power off at the welding power source.

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

3. Remove the wire spool from the feeder, if present.

b. Remove the rea r panel of the POWER

FEED™ 25M. Route the water hoses from
the rear of the case in between the inner
module and the case. Assemble the rear
panel, with the water hoses routed in the
bottom cut-out of the panel.

c. Install Adapter, 5/8” L.H. Fitting to the

Push-Pull Bushing.

8. Slide the Push-Pull Bushing into the wire drive.
Align the thumb screw with one of the threaded
holes on the bushing.

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

4. 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.

5. 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.

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

7. For water cooled guns:

a. Install the hose assembly from K590-6 to

the rear of the POWER FEED™ 25M case.

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

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

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

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

14. Connect the control cable from the push-pull gun
to the 7 pin circular connector on the front of the
POWER FEED™ 25M.

POWER FEED™ 25M

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not oper ate wit h 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™
25M.

To verify the wire feed speed:

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

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

• Adjus t the wire feed spee d to 3 0 0 i n / min
(7.62m/min).

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

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

To verify the voltage display:

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

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

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

POWER FEED™ 25M

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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

__________________________________________________________________________

E-1

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

Step 1. LOCATE PROBLEM (SYMPTOM).

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

Step 2. POSSIBLE CAUSE.

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

Step 3. RECOMMENDED COURSE OF ACTION

This colu mn provi des a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

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

CAUTION

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

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

POWER FEED™ 25M

E-2

PROBLEMS

(SYMPTOMS)

Fault Code

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Linc-Net System Error Codes

Description

RECOMMENDED

COURSE OF ACTION

Possible Adjustments

E-2

Err 006

Err 100

Err 53 Voltage sense loss.

Err 81 Motor overload, long term.

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

1. The power source has issued a
shutdown command.

ArcLink System Error Codes

1. The wire drive motor has over­heated.

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

2. Check control cable for loose or
broken leads.

3. See pow e r sourc e Instr u ction
Manual.

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

2. Check control cable for loose or
broken leads.

3. See pow e r sourc e Instr u ction
Manual.

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

2. Remove tight bends from the gun
and cable.

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

4. Verify a high quality electrode is
being used.

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

Err 82 Motor overload, short term.

Err 95 Spool gun or pull gun motor

overload.

Err 263 No usable weld modes.

1. The wire drive motor current draw
has e x cee d e d li m its, us uall y
because the motor is in a locked
rotor state.

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

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

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

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

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

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

1. See the power source Instruction
Manu a l f or loa d w eldi n g pro­grams.

CAUTION

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

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

POWER FEED™ 25M

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

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

No shielding gas.

TROUBLESHOOTING

POSSIBLE

CAUSE

Output Problems

1. The POWER FEED™ 15M power
switch is OFF.

2. The Power Wave power source is
OFF.

3. The circuit breaker for the wire
feede r on pow e r sou r c e hav e
tripped.

4. The control cable may be loose or
damaged.

5. The power switch is damaged.

1. The gas supply is OFF or empty.

2. The gas hose is cut or crushed.

3. Dirt or debris is in the solenoid.

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

5. The solenoid has failed.

E-3

RECOMMENDED

COURSE OF ACTION

1. Turn the POWER FEED™ 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 c o r ners an d make su r e
nothing is on top of it. Repair or
replace damaged hoses.

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

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

5. Replace the solenoid.

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

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

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

3. The gun liner is dirty or worn.

4. The electrode is rusty or dirty.

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

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

7. Incorrect tension arm pressure on
the drive rolls.

8. Worn drive roll.

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

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

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

4. Use only c lean elec trode. Us e
quality electrode, like L-50 or L-56
from Lincoln Electric.

5. Replace the contact tip.

6. Verif y the pr o per p arts ar e
installed.

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

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

CAUTION

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

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

POWER FEED™ 25M

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Wire feed speed consistently oper­ates at the wrong value.

TROUBLESHOOTING

POSSIBLE

CAUSE

Output Problems

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

E-4

RECOMMENDED

COURSE OF ACTION

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

Variable or "hunting" arc.

Poor arc st a rts wit h s t icki n g o r
"blast-offs", weld porosity, narrow
and ropy looking bead.

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

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

2. Worn work c able or poo r work
connection.

3. Wrong polarity.

4. The gas noz z le is exte n ded
beyond the contact tip or the wire
stickout is too long.

5. Poor gas shielding on processes
requiring gas.

1. Improp e r pro c e dure s or te c h ­niques.

1. The so f t ware i n the P OWER
FEED™ 25M must be upgraded.

1. Replace the contact tip.

2. Verify all work and electrode con­nections are tight and that the
cabl e s are i n goo d con d i tio n .
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 mi xtur e .
Remo v e or b lock so urce s of
drafts.

1. See "G as Me tal Arc Weldi n g
Guide". (GS-100).

1. Conta c t th e lo c al a u thor i zed
Lincoln Field Service Shop.

CAUTION

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

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

POWER FEED™ 25M

F-1

-

+

POWER

ARCLINC

RECEPTACLE

A

B

C

D

E

541

L6

540B

540A

640A

BRIDGE

RECTIFIER

554

AC

AC

RED / GREEN

STATUS LED

A

P4

532

TRIGGER

CONNECTOR

L3

P10

S1

570G

W

B

2

3

1

581

585B

582

VOLTAGE

/ TRIM

ENCODER

2

3

1

587

585A

580

CURRENT

/ WFS

ENCODER

P1

P2

56734

2

8

9

10

1

MEMORY

P.C. BOARD

56734

2

8

9

10

1

DISPLAY

P.C. BOARD

MSP4

P.C. BOARD

56734

2

8

9

10

1

FLEX

FLEX

ADAPTER

WIRING DIAGRAM - POWER FEED 25M

G5585

A.04

R - RED

B - BLACK

U - BLUE

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537.

W - WHITE

O

N

D

E

F

.

O

F

F

D

E

F

.

FEED SPEED GEAR8

SPARE

F

U

N

C

T

I

O

N

7

SPARE

65432

DIP SWITCH S1 SETTING CHART

T

O

G

GL

E

N

O

.

SPARE

1

POLARITY

NEG

SPARE

SPARE

SPARE

POS

J86

CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)

J6, J81, J82

6

5

10

1

3

4

1

2

J85

9

8

16

1

4

6

1

3

J84, J810

5

4

8

1

J1, J83,J88

J2, J811

2

1

GENERAL INFORMATION

8
7

6

5

4

3

2

1

A

FOOT AMPTROL

P3

3218A

77B

A

P5

3214A

B

C

76BD570BE532BF75B

G

PUSH-PULL

FEED

PLATE

P9

8

MOTOR /

GEARBOX

W

R

TACH

U

B

531

B

B

W

INPUT ELECTRODE

CABLE CONNECTION

552

553

GAS

SOLENOID

2 STEP/

4 STEP

R

U

B

77A

570A

76A

532A

75A

570D

543

B

C

D

E

537

534

551

550

54267540

500

532

543

532E

585

570D

7

6

5

432

1

500B

N.C.

N.C. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)

ALIGNS WITH WHITE LEAD OF LED SOCKET.

N.D. TOGGLE SWITCHES SHOWN FROM REAR CONNECTION

SIDE OF SWITCH.

1

S2

579B

234

586

535

578

579

578A

640

D E C B F

P7

EXTRA

TORQUE

NORMAL

SPEED

123

4P85

6

1W1B587A

580A

585C

581A

WB587

580

585

581

7

8

582A

582

L2

123

4P65

6

532

789

10

570D

543

3218A

3214A

77A

76A

570A

532A

75A

532C

570E

543A

3218

32147776

570C

532D

75

L1

532B

77B 570B 76B

75B

N.D.

67B

L5

L4

FLEX

J811

SPOOL GUN

DAUGHTER

PC BOARD

J88

P86

FLEX

J87

J85

J86

J810

1W

1B

514

513

548

586

541A

579

585C

543A

570F

587A

581A

580A

582A

J83

J82

J81J84

CONTROL P.C. BOARD

1

1 2 3 4 5

1 2 3 4 1 2 3 41 2 3 4 5 66 7 8

1

2345678

9

10111213141516

123456789

10111213141516

123456789

10

123456789

10

500D

542A

540C

550

552 554

551 553

640A

531 535 537

534 526

518

570

532E

1234567

8

P89

1

2

595

640

526

5487776

75

3218

3214

2 3 4 5 6

518C

578

595

J1

VOLTAGE SENSE

SELECT P.C. BOARD

J2

513

514

67B

500C

400

563

4

2

1

2

1

67A

COLD INCH /

GAS PURGE

S3

579B

586A

N.D.

535A

586A

535A

578A

579A

579A

123

4

P11

567

8

541

54267540

500

500B

541A

542A

67A

540A

500A

500C

570F

570

570C

570E

LIGHT

LED

S4

590

B

B

N.C.

HEATER

S5

530A

N.D.

520

R2

R3

HEATER

530

500A

500D

540E

518B

5

6

518B

518D

579C

579C

LIGHT LEDS

518C

518

518D

789

10

530

540D

530A

540E

R1

590

B

540B

540C

40Y

40Y

475Y

W

W

N.C.

TRIGGER INPUT

DUAL

PROCEDURE INPUT

Enhanced Diagram

Wiring Diagram for Code 11313

DIAGRAMS

F-1

POWER FEED™ 25M

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

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

F-2

DIAGRAMS

F-2

POWER FEED™ 25M

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

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

F-3

14.0

16.9

23.3

8.5

5.4

16.9

14.5

16" Circle

12" x 18" Ellipse

Dimensions for Code 11313

DIMENSION PRINT

F-3

POWER FEED™ 25M

F-4

14.0

16.9

23.3

8.5

5.4

16.9

14.5

16" Circle

12" x 18" Ellipse

Dimensions for Codes 11456, 11557

DIMENSION PRINT

F-4

POWER FEED™ 25M

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 •

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