Lincoln Electric SVM185-A User Manual

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Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on

your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before
you act and be careful.

SVM185-A

July, 2008

®

25M

For use with machine code numbers 11313

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

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader inWelding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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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

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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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

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SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

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

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

3.f.

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

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

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
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
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

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
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

vapors

to

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

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

Aug ‘06

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SSAAFFEETTYY

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

Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

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

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

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

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

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

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.

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Jan ‘07

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SSAAFFEETTYY

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.

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

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

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

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

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

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

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

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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a. Utiliser un bon masque avec un verre filtrant approprié ainsi

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

b. Porter des vêtements convenables afin de protéger la peau

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

c. Protéger l’autre personnel travaillant à proximité au

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

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

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.

POWER FEED® 25M

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

v v

SAFETY

Electromagnetic Compatibility (EMC)

Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com­plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national

codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip­ment.

Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

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h) the time of day that welding or other activities are to be carried out.

L10093 3-1-96H

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vi vi

SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions
Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con­nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.

Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-

1

tions.

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_________________________

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”

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L10093 3-1-96H

I I

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Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv

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

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

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

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

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-534

POWER FEED® 25M

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

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

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

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

Digital Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Control Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

TABLE OF CONTENTS - INSTALLATION SECTION

Coaxial Weld Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Electrode Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Changing The Drive Motor Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Wire Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Procedure to Install Drive Rolls and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Remote Sense Lead Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9

Loading Spools of Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9/A-10

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POWER FEED® 25M

A-2 A-2

TECHNICAL SPECIFICATIONS –

INSTALLATION

POWER FEED® 25M K2536-1

INPUT VOLTAGE and CURRENT

INPUT VOLTAGE ± 10%

INPUT AMPERES

GEARING - WIRE FEED SPEED RANGE-WIRE SIZE

GEARING

Normal Speed

(factory setting)

Extra torque

40 VDC

4A

RATED OUTPUT @ 104°F (40°C)

DUTY CYCLE

60% rating

100% rating

GMAW

WFS RANGE

50 – 800 ipm

(2.5 – 20.3m/min)

30 – 400 ipm

(1.3 – 10.4m/min)

INPUT AMPERES

WIRE SIZES

.023 – 1/16"

(0.6 – 1.6mm)

.023 – 1/16"

(0.6 – 1.6mm)

500
400

WFS RANGE

50 – 800 ipm

(2.5 – 20.3m/min)

30 – 400 ipm

(1.3 – 10.4m/min)

FCAW

WIRE SIZES

.030 – 5/64"

(0.8 – 2.0mm)

.030 – 3/32"

(0.8 – 2.4mm)

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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)

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POWER FEED® 25M

A-3 A-3

SAFETY PRECAUTIONS

INSTALLATION

HIGH FREQUENCY PROTECTION

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.

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POWER FEED® 25M

A-4 A-4

P

o

wer

S

ource

AA

BB

CC

DD

EE

W

i

re

Feeder

AA

BB

CC

DD

EE

AA

BB

CC

DD

EE

AA

BB

CC

DD

EE

AA

BB

CC

DD

FF

EE

AA

BB

GG

CC

DD

FF

EE

DIGITAL CONTROL CABLE, K1543-XX

INSTALLATION

CONTROL CABLE CONNECTION:

(See Figure A.3)
ArcLink/LincNet control cables are special high quality

Digital Control Cable: Figure A.3

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.

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.

Power Source

Pin Function

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

Wire Feeder

Pin Function

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

Control cables may be connected end to end to extend
their length. Use a maximum of 200 ft. (61.0m) of con­trol cable between components.

CABLE CONNECTIONS

There are three circular connectors on the front of the
POWER FEED® 25M.

FIGURE A.1

Function

5 pin trigger con­nector for push­only guns.

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

7 pin connector for
push-pull guns

PIN

A
B
C
D
E

A
B
C
D
E
F

A
B
C
D
E
F
G

Dual Procedure Selection

77 Remote potentiometer, 5K

75 Remote potentiometer, common

76 Remote potentiometer, wiper

77 Remote potentiometer, 5K

76 Remote potentiometer, wiper

75 Remote potentiometer, common

Wiring

Trigger

Not used

Trigger, Common

Dual, Common

Switch, On/Off

Switch, common

Not used

Motor -

Motor +

Switch, On/Off

Switch, common

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There is one circular connector on the rear of the POWER FEED® 25M.

FIGURE A.2

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Function

5 pin ArcLink con­nector.

PIN

A
B
C

67 Electrode Voltage Sense

D
E

Wiring

ArcLink
ArcLink

40VDC

40VDC, Common

POWER FEED® 25M

A-5 A-5

EElleecctrtrooddee

WWoorrkk

W

Woorrkk

ElectrodeElectrode

WWorkork

ElectrodeElectrode

WWorkork

Power SourcePower Source

Coaxial WCoaxial Weld Cableeld Cable

Wire FeederWire Feeder

WELD CABLE SIZE

INSTALLATION

COAXIAL WELD CABLE

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.

FIGURE A.5

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

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

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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).

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PERCENT

DUTY

CYCLE

60

100

20

40 & 30

30
40
60

100

60

100

60
60

100

60

0 to 50Ft.
(0 to15M)

2
2

4 or 5

3
3
2
1
1

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

50 to 100Ft.

(15 to 30M)

2
2
3
3
3
2
1
1

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

POWER FEED® 25M

100 to 150 Ft.

(30 to 46M)

2
2
2
2
2
1
1
1

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

150 to 200 Ft.

(46 to 61M)

1
1
1
1
1
1
1

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

200 to 250 Ft.

(61 to 76M)

1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0

A-6 A-6

ELECTRODE POLARITY

INSTALLATION

SHIELDING GAS CONNECTION

WARNING

The wire feeder is factory set for Electrode Positive
welding. Most GMAW welding procedures use
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.

• 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

• Shut off shielding gas supply when not in

• See American National Standard Z-49.1, "Safety

in Welding and Cutting” Published by the
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 tight-

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

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

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

6. Before opening the cylinder valve, turn the regulator

adjusting knob counterclockwise until the adjusting
spring pressure is released.

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

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

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

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

CYLINDER may explode if

damaged.

• Keep cylinder upright and
chained to support.

HARM HEALTH OR KILL.

use.

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POWER FEED® 25M

A-7 A-7

Extra Torque
Gearing

Normal Speed
Gearing

Extra
Torque
Gearing

Normal
Speed
Gearing

400

800

WFS

Feed Force

CHANGING THE DRIVE MOTOR GEAR RATIO

INSTALLATION

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

WARNING

8. With a 1/4" hex key wrench, loosen the socket head cap

• 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.

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

screw securing the gun bushing. Remove the gun bushing
from the wire drive.

9. 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.

10. Using a 5/16" nut drive, remove the four screws securing

the cover.

11. With a Phillips screwdriver, remove the three screws and

lock washers securing the motor. Remove the motor.

12. Place the motor in the new position.

13. Assemble the three screws and lock washer holding the

wire drive motor.

14. 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.

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
. Remove the spool of electrode from the wire feeder.

1

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

welding gun.

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

guide.

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

5. Use 9/16" socket and ratchet wrench to remove the lower

drive roll hub retainer. Remove the lower drive roll hub.

6. With a Phillips screwdriver, remove the screw, washer and

collar holding the pinion gear. Remove the pinion gear.

15. 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

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

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

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

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

20. Reassemble the gear cover.

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

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

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POWER FEED® 25M

A-8 A-8

GUN RECEIVER BUSHING

LOOSEN TIGHTEN

THUMB SCREW

OUTER WIRE GUIDE

SOCKET HEAD
CAP SCREW

CONNECTOR BLOCK

WIRE DRIVE CONFIGURATION

(See Figure A-6)

Changing the Gun Receiver Bushing

INSTALLATION

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.

WARNING

Slide the gun receiver bushing into the wire drive
and verify the thumb screw holes are aligned.

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the
welding power source before instal-

10. Tighten the socket head cap screw.

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

lation or changing drive rolls and/or
guides.

• Do not touch electrically live parts.

PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES

• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground

WARNING

and could remain energized several seconds
after the gun trigger is released.

• Only qualified personnel should perform mainte­nance work.

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

Tools required:

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

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

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

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

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

• 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.

• 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.

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

FIGURE A-6

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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-9 A-9

CCOONNNNEECCTT A ALLLL S SEENNSSEE
LLEEAADDSS A AT THT THEE E ENNDD
OOF THF THEE W WEELLDD

CCOONNNNEECCT AT A

LLLL

WWOORRKK LLEEAADD

SS A ATT

THTHEE B BEEGGINNINN

IINNG G

OFOF

THTHEE W WEELLDD

DDIREIRE

CCTIOTIONN

OF OF

TRTRAAVVEELL

REMOTE SENSE LEAD SPECIFICATIONS

INSTALLATION

LOADING SPOOLS OF WIRE

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.

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. Place the spool on the spindle and align the adapter
brake tab with one of the holes in the back side of
the spool. An indicator mark on the end of the spin­dle shows the orientation of the brake tab. Be cer­tain the wire feeds off of the spool in the proper
direction.

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

FIGURE A.7

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POWER FEED® 25M

A-10 A-10

INSTALLATION

TYPICAL SYSTEM CONFIGURATIONS

Standard Features

Arc Performance

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

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

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

User Interface

• 6 memories for easily selecting procedures.

• MSP4 panel located behind the memory panel door
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.

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POWER FEED® 25M

B-1 B-1

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

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Graphic Symbols that appear on this Machine or in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Definition of Welding Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

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

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

Recommended Processes, Equipment Limitations, Recommended Power Sources . . . . . . . . . . . . . . . . .B-4

Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

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

TABLE OF CONTENTS - OPERATION SECTION

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

Set-Up Feature Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-25/B-28

Procedure/Memory Panel Operaton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-29

Internal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-32

Cold Feed / Gas Purge Switch, Light Switch, Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-33

2 Step - 4 Step Trigger Operation and Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-33/B-38

Rear Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-39

Operation On LincNet™ Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-40

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

POWER FEED® 25M

B-2 B-2

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

WARNING

• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED fea­ture, when feeding with gun trig­ger, the electrode and drive
mechanism are always electri­cally energized and could
remain energized several sec­onds after the welding ceases..

• 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 protec-

tion.

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

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

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

U

U

U

I

INPUT POWER

ON

OFF

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

0

1

2

1

OPEN CIRCUIT
VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

I

POWER FEED® 25M

2

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

B-3 B-3

DEFINITION OF WELDING TERMS

OPERATION

GENERAL DESCRIPTION

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 sin-

gle 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

CAC

• Carbon Arc Cutting

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 six
button memory panel is included with the POWER
FEED® 25M and allows quick recall of favorite weld
procedures. All the components are packaged in an
engineered aluminum case protected by replaceable
skids.

The heart of the POWER FEED® 25M is the
MAXtrac™ drive. The patented features on the wire
drive offer tool-less changing of the drive rolls and the
wire guides for quick spool changes. Plus, the drive
can be configured for extra torque when feeding large
diameter flux cored electrodes.

The POWER FEED® 25M continues 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

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CAG

• Carbon Arc Gouging

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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

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

POWER FEED® 25M

B-4 B-4

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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

RECOMMENDED POWER SOURCES

• Power Wave® 355M

• Power Wave® 455M

• Power Wave® 455M/STT

• Power Wave® 655/R

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

POWER FEED® 25M

B-5 B-5

Fold Out
Memory Panel

CASE FRONT CONTROLS (See Figure B.1)

OPERATION

Connector for a remote control.

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.

14. 7- pin connector

Connector for a push-pull gun.

15. Cover

Covers location for optional water cooling line.

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

3

4

7

16

9

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

11

12
13

17

14
15

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

POWER FEED® 25M

B-6 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.

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

LED condition

Steady green
Blinking green.

Blinking green, fast
Blinking green fol-

lowed 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. Count the error code before the machine is turned off-see
below.

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. Record the red flash count (error code) for reference before turning unit off.

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

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

POWER FEED® 25M

B-7 B-7

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W
A
R
N

IN
G

R

E
M
O
T

E

P
O

W
E

R

O
F

F

O
N

P

O

W

E

R

W

A

V

E

3

5

5

1

6

4

3

2

5

MAKING A WELD WITH WAVEFORM

OPERATION

FIGURE B.2 - SMAW (STICK) WELDING

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
builder/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 FEED® lets the user
customize operation for the best performance.

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

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

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

SMAW (STICK) WELDING

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

During SMAW welding, the 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 POWER FEED® 25M
3 K1543-xx Digital Control Cable
4 K1842-xx Weld Power Cable, Lug to Lug

K910-xx Ground Clamp
5 K909-xx Electrode Holder
6 K2176-1 Twist-Mate™ to Lug Cable

Adapter

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)

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POWER FEED® 25M

B-8 B-8

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
Arc Force adjusts the short cir­cuit current for a soft arc, or for
a forceful, driving arc. It helps

to prevent sticking and shorting

of organic

coated

electrodes,

par

­ticularity globular transfer types
such as stainless and low
hydrogen. Arc Force is espe­cially effective for root pass on
pipe with stainless electrode
and helps to minimize spatter
for certain electrodes and pro­cedure as with low hydrogen,
etc.

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 the WFS/AMP knob 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

194

0

WFS AMPS

VOLTS TRIM

LESS
AMPS

MORE
AMPS

O

UTPUT

OFF

OUTPUT
ON

n

OPERATION

SMAW (Stick) Welding Display

FIGURE B.3

MSP4 OPERATION

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POWER FEED® 25M

B-9 B-9

6

4

3

2

5

1

OPERATION

NON-SYNERGIC GMAW AND FCAW
WELDING

(See Figure B.4)
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

Three non-synergic welding modes are available.

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

MIG welding.

GMAW, Power 40 Specialized mode

for short arc weld­ing and CV alu­minum welding.

FCAW 6 Best for cored

electrodes, such
as Innershield™
and Outershield™.

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K2368-1 Power Wave 355M

1 K2202-1 Power Wave 455M

K2203-1 Power Wave 455M/STT
K2230-1 Power Feed 10M, Bench Model
K2234-1
K2536-1 Power Feed 25M

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

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

KP1507-xx
3 K1543-xx Digital Control Cable
4 K1842-xx Weld Power Cable, Lug to Lug

5 See Magnum MIG gun

6 K586-1 Shielding Gases

K910-xx Ground Clamp

Literature

Power Feed 10M Dual, Bench Model

Deluxe Regulator for Mixed
Shielding Gas Hose

POWER FEED® 25M

B-10 B-10

300

25.3

WFS AMPS

VOLTS TRIM

Less
WFS

Less
Volts

More
Volts

More
WFS

250

54

W

FS AMPS

VOLTS TRIM

Less
WFS

S

horter

Arc

L

onger

Arc

More
WFS

START OPTIONS
E

ND OPTIONS

SET

SETUP

I

R PORT

STD CV MIG

WAVEFORM CONTROL TECHNOLOGY

WELD MODE
ARC CONTROL

5

EFFECT / RANGE
Postflow Time

0 to 10 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
time at the end of the weld
after the trigger is released.
During the Crater time, the
machine will ramp up or down
from the Weld Procedure to
the Crater Procedure.
The burnback time is the
amount of time that the weld
output continues after the wire
stops feeding. It prevents the
wire from sticking in the puddle
and prepares the end of the
wire for the next arc start.

PROCESS

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

WELD MODE

5

40

6

ARC CONTROL

W

ELD MODE

END OPTIONS

S

TART OPTIONS

DESCRIPTION

Pinch controls the arc characte-

-ristics when short-arc welding.

EFFECT / RANGE
(Soft)-10.0 to

(Crisp)+10.

PINCH

0

EFFECT / RANGE
P

reflow Time

0

- 10 seconds

Run-In WFS:
Off, 50 to150 in/min.

S

tart Procedure

0 - 10 seconds

DESCRIPTION

A

djusts

the

t

ime

t

hat

shielding

gas

f

lows

after the trigger is

p

ulled

a

nd

prior to feeding wire.

R

un-In sets the wire feed

s

peed from the time the trigger
is pulled until an arc is estab­lished.
The Start Procedure controls
t

he WFS and Volts for a speci­fied time at the beginning of
the weld. During the start time,
the machine will ramp up or
down from the Start Procedure
to the preset Welding
Procedure.

OPERATION

Non-Synergic GMAW and FCAW Welding Display

Modes 5 and 6:

MSP4 OPERATION

Mode 40:

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POWER FEED® 25M

B-11 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

K2368-1 Power Wave® 355M

1 K2202-1 Power Wave® 455M

K2203-1 Power Wave® 455M/STT
K2230-1

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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

K2234-1
K2536-1 Power Feed® 25M

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

B-12 B-12

220

26.4

WFS AMPS

VOLTS TRIM

L

ess

D

eposition

Shorter
Arc

Longer
Arc

M

ore

D

eposition

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

DESCRIPTION

-

EFFECT / RANGE
Preflow Time

0 - 10 seconds
Run-in WFS:

Off, 50 to150 in/min.

Start Procedure

DESCRIPTION

Adjusts

the

time

that

shielding

gas

flows

after the

trigger

is

pulled and

prior to feeding.
Run-In sets the wire feed
speed from the time the trigger
is pulled until an arc is estab­lished.
The Start Procedure controls
the WFS, Volts at a specified
time at the beginning of the
weld. During the start time, the
machine will ramp up or down
from the Start Procedure to the
preset Welding Procedure.

EFFECT / RANGE
Postflow Time

0 to 10 seconds
Burnback:

0 to .25 Seconds

Crater Procedure

DESCRIPTION

Adjusts the time that shielding
gas flows after the welding out­put turns off.
The burnback time is the
amount of time that the weld
output continues after the wire
stops feeding. It prevents the
wire from sticking in the puddle
and prepares the end of the
wire for the next arc start.
Crater Procedure controls the
WFS and volts for a specified
time at the end of the weld
after the trigger is released.
During the Crater time, the
machine will ramp up or down
from the Weld Procedure to
the Crater Procedure.

Steel
Steel

Stainless

Stainless

Aluminum 4043

Aluminum 5356

ELECTRODE AND GAS

CO

2

Ar(Mix)
Ar(Mix)

Ar/He/CO

2

Ar
Ar

WIRE SIZE

0.030 0.035 0.045 0.052

--- 10 20 24

94 11 21 25
61 31 41 --­63 33 43 ---

--- 148 71 ---

--- 151 75 ---

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

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.

OPERATION

SYNERGIC CV VOLTAGE DISPLAY

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

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

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

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

MSP4 OPERATION

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POWER FEED® 25M