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
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O
T

E

P
O

W
E

R

O
F

F

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4

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2

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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)

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-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

B-13 B-13

Trim .50

Arc Length Short

Trim 1.00

Arc Length Medium

Trim 1.50

Arc Le ngth Long

Arc Contr ol OFF

Medium Frequency and Width

Arc Contro l +10.0

High Frequency, Focused

Arc Control -10.0

Low Frequency, Wide

OPERATION

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
FEED® 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, with a nominal value of 1.00 for a 3/4" (19mm)
electrode stick-out. Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease 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

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POWER FEED® 25M

B-14 B-14

4

3

2

6

1

5

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A

R

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G

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C

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5

OPERATION

STAINLESS STEEL GMAW (MIG)WELDING

FIGURE B.8

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

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

POWER FEED® 10M Dual, Bench Model

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 K1796-xx, K2593-xx Coaxial

K910-xx Ground Clamp
5 See Magnum MIG gun

Literature

Deluxe Regulator for Mixed

6 K586-1 Shielding Gases

Shielding Gas Hose

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

POWER FEED® 25M

Weld Power Cable, Lug to Lug

B-15 B-15

220

1.06

W

FS AMPS

VOLTS TRIM

Less
Deposition

Shorter
A

rc

L

onger

Arc

More
Deposition

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 - 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 wire.

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, Trim 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

FUNCTION

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 Trim 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.

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

WAVEFORM CONTROL TECHNOLOGY

WELD MODE
ARC CONTROL

12

START OPTIONS
END OPTIONS

OPERATION

Steel and Stainless GMAW-P (Pulsed MIg)Display

MSP4 OPERATION

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-16 B-16

ALUMINUM SYNERGIC GMAW-P (PULSED

OPERATION

FIGURE B.11

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

FIGURE B.9

Narrow weld and ripple spacing, fast travel speed.

Frequency Modulation = 10

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.

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-17 B-17

Trim .50

Arc Length Short

Trim 1.00

Arc Length Medium

Trim 1.50

Arc Le ngth Long

OPERATION

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
FEED® 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, with a nominal value of 1.00 for a 3/4" (19mm)
electrode stick-out. Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease the
arc length.

FIGURE B.12

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

POWER FEED® 25M

B-18 B-18

7

4

3

2

6

1

5

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OPERATION

ALUMINUM GMAW-P AND GMAW-PP WELDING

FIGURE B.14

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

2

K2536-1 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
4 K1796-xx, K2593-xx Coaxial
5 K910-xx Ground Clamp
6 K2447-xx Python Plus Gun, Air cooled

7 K586-1 Shielding Gases

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

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

POWER FEED® 25M

B-19 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 auto­matically adjusts the back­ground current to maintain a
similar heat input into the weld.
Low frequencies give more con­trol over the puddle and high
frequencies minimize spatter.

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 wire.

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. Trim 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

FUNCTION

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 Trim 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.

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"

SET

SETUP

IR PORT

4043 Pulse Ar

WAVEFORM CONTROL TECHNOLOGY

WELD MODE
ARC CONTROL

72

START OPTIONS
END OPTIONS

220

1.06

WFS AMPS

VOLTS TRIM

Less
Deposition

S

horter

Arc

Longer
Arc

More
Deposition

OPERATION

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

MSP4 OPERATION

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POWER FEED® 25M

B-20 B-20

8

4

3

2

7

1

5

6

GMAW-STT™ WELDING

OPERATION

FIGURE B.15

Surface Tension Transfer, or STT™ welding, is a

break-through process offered exclusively by the
Lincoln Electric Company. STT™ is a low heat, low
spatter process created with Waveform Control
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

2 shielding gas, results in cost savings 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 FEED®
25M/STT.

For best results:

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

• Use only solid steel or silicon bronze electrodes.

1 K2203-1 Power Wave® 455M/STT

K2230-1
K2234-1

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

2 K2536-1 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

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 MIG Gun

Literature

Deluxe Regulator for Mixed
8 K586-1 Shielding Gases

Shielding Gas Hose

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POWER FEED® 25M

B-21 B-21

220

----

WFS AMPS

V

OLTS TRIM

Less
Deposition

More
Deposition

EFFECT / RANGE
PEAK CURRENT

BACKGROUND
CURRENT

TAIL OUT

(

STT ll MODES

ONLY)

DESCRIPTION

Peak Current acts similar to an

arc

pinch

control. Peak Current

sets the arc length

and

promotes

-

good fusion.

Higher

peak

current levels will cause

the arc to broaden

momentarily

while increasing arc length. If

set too high, globular transfer

may occur.

Setting it too low

may cause instability

and

wire

stubbing.

Best

practice is to

adjust for minimum spatter and

puddle

agitation.

Background Current controls

the

overall

heat input in the

weld.

Tail out provides additional

power

without the molten

droplet becoming

too

large.

Increase as necessary to add

heat input without increasing

arc length.

Often this results in

faster travel speeds.

Note that

as tail out increases, the peak

current

to be reduced.

and/or background

current

may need

PREFLOW TIME
0 - 10 seconds

RUN-IN WFS:
Off, 50 to150 in/min.

Start Procedure

FUNCTION

Adjusts the time that shielding

gas

flows

after

the trigger

is

pulled and

prior to feeding wire.

Run-in sets the wire feed
speed from the time the trigger
is pulled until an arc is estab­lished.

The Start Procedure is not
commonly used with STT
procedures.

PARAMETER
RANGE
Postflow Time:
0 to 10 seconds

FUNCTION

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

ELECTRODE AND GAS

STEEL CO

2

STAINLESS

Ar/CO

2

He/Ar/CO

2

STEEL CO

2

STAINLESS

Ar/CO

2

He/Ar/CO

2

WIRE SIZE

0.035 0.045 0.052

110 126 126
110 126 126

WELD MODES

START OPTIONS

END OPTIONS

ARC CONTROL

Steel
.035"

SET

SETUP

IR PORT

STT

WAVEFORM CONTROL TECHNOLOGY

WELD MODE
ARC CONTROL

109

START OPTIONS
END OPTIONS

STEEL CO

STEEL CO

STEEL AR/CO
STAINLESS He/Ar/CO

STAINLESS He/Ar/CO

STAINLESS Ar/CO

2

2

2

2

2

2

(with Hot Start)

(SYNERGIC STT)

SYNERGIC STT, OPEN ROOT

123 124 124
123 124 124

111 117 120
112 118 121

113 119 122
135 137 ---

127 129 ---

131 133 ---

Burnback: 0 to .25
Seconds

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 Procedur

e

Crater is not commonly used
in STT weld procedures.

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.

There is no Voltage control

when STT™ welding.

MSP4 OPERATION

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POWER FEED® 25M

B-22 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
current will be higher than when welding with blended
shielded gases. A longer arc length is required with

2 to reduce spatter.

CO

FIGURE B.16

2, the peak

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.

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

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POWER FEED® 25M

B-23 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.

Touch Start TIG
Weld Sequence

TIG torches without
built-in Gas Valves.

TIG torches with
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.

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-24 B-24

8

4

3

2

7

1

5

6

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W
A
R

N
I
N
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

220

OFF

W

FS AMPS

VOLTS TRIM

O

utput

O

N

O

utput

O

FF

Maximum
Amperage

No Arc Controls are active
for Touch Start TIG.

START PROCEDURE

The Start Procedure controls the Amperage at a
fixed level for the set amount of time.

No Arc End Options are
active for Touch Start TIG

MODE

TOUCH START 3

START OPTIONS

END OPTIONS

WELD MODE

ARC CONTROL

SET

SETUP

IR PORT

Touch Start TIG

W

AVEFORM CONTROL TECHNOLOGY

WELD MODE

ARC CONTROL

START OPTIONS

E

ND OPTIONS

3

OPERATION

GTAW (TIG) WELDING

1 K2202-1 Power Wave® 455M

2 K2234-1
3 K1543-xx Digital Control Cable

4 Electrode Cable
5 K910-xx Ground Clamp
6 K1782-xx, K1783-xx PTA-17, PTA-26 TIG torch

7 K870 Foot Amptrol
8 3100211 Harris Argon Flow Regulator

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

K2368-1 Power Wave® 355M
K2203-1 Power Wave® 455M/STT™

K2230-1
K2536-1 POWER FEED® 25M

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

(shown with valve)

POWER FEED® 25M

B-25 B-25

SET-UP FEATURES MENU

The Setup Menu gives access to the set-up configura­tion. Stored in the set-up configuration are user para­meters that generally need to be set only at installation.
The parameters are grouped as follows:

• P.1 through P.99 Unsecured Parameters (always
adjustable)

• P.101 through P.199 Diagnostic Parameters (always
read only)

• P.501 through P.599 Secured Parameters (accessi­ble only though a p.c. or palm application.)

To access the set-up menu, press the right and 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).

Unsecured Parameters

PARAMETER

P.0
P.1
P.2
P.4
P.5
P.6
P.7

P.8
P.11
P.12
P.13
P.80
P.99

Diagnostic Parameters

P.100
P.101
P.102
P.103
P.104
P.105
P.106
P.107

DESCRIPTION

Exit set-up menu

WFS Units

Arc Display Mode

Trigger Memory Recall

Trigger Procedure Change

Stall Factor Adjustment

Gun Offset Adjustment

TIG Gas Control

Set Timers

Travel Options

Adjust Arc Force

Sense From Studs

Show Test Modes

View Diagnostics

View Event Logs

View Fatal Logs

View Software Version

View Hardware Version

View Welding Software

View Ethernet IP Address

View Power Source Type

OPERATION

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

After changing a parameter it is necessary to press the
right hand button to save the new setting. Pressing the
left button will cancel the change.

To exit the set-up menu at any time, press the right and
left buttons of the MSP4 panel simultaneously.
Alternately, 1 minute of inactivity will also exit the set­up menu.

The following list includes all possible parameters
in ArcLink® equipment. Not all of the parameters
listed may appear for your system. Refer to Table
B.1 for active parameters.

TABLE B.1

POWER FEED®

10M (All Models)






















POWER

FEED® 25M






















POWER

FEED® 10A




















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

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

B-26 B-26

P.0 Press the left button to exit the set-up menu.
P.1 WFS units

Metric = m/min wire feed speed units
English = in/min wire feed speed units
(default)

P.2 Arc Display Mode

Amps = The left display shows Amperage
while welding. (default)
WFS = The left display shows Wire Feed
Speed while welding.

P.4 Trigger Memory Recall

Enable = Selecting memories 2 through 6 with
quick trigger pulls is enabled when the option­al dual procedure/memory panel is installed.
To recall a memory with the gun trigger, 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. Trigger memo­ry recall can only be performed when the sys­tem is not welding. Disable = Memory selec­tion is performed only by the buttons on the
optional dual procedure/memory panel.
(default)

P.5 Procedure Change Method (Three Settings)

In order for any of these procedure change methods
to function, the "A-Gun-B" switch must be on the
"Gun" position.

1. "External Switch" (the default value), the
machine will only change the selected procedure
when the procedure select digital input changes
state.

2. "Quick Trigger" (the optional value 1), the
machine will only change the selected procedure
when the trigger is released and quickly re-pulled
while welding in 2-step. Enable=Allows switching
between procedure A and procedure B while
welding. The exception is that the procedure
select digital input is no longer recognized.

3. "Integral Trigger Procedure" (the optional value

2), the machine will only change the selected pro­cedure when the procedure select digital input
changes state. Machine operation is similar to
the "External Switch" selection except that addi-
tional logic prevents procedure A from being re­selected when the trigger is quickly and com­pletely released at step 2 of the 4-step weld
sequence. This selection is intended to be used
when a MIG gun with an integral procedure select
switch built into the trigger (e.g.DS400) is used
with 4-step welding.

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OPERATION

P.6 Push Pull Gun, Stall Factor Adjustment. 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 while welding which results in the wire
burning back to the tip. If you are experiencing
bird nests, check for other feeding problems
before adjusting the stall factor.

Default value for the stall factor is 75, with a
range of 5 - 100.

To change the stall factor:

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

• Press the right hand button to save the new
setting.

P.7 Push Pull Gun, Gun Offset Adjustment The

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

To perform the calibration procedure:

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

• Set the wire feed speed to 200 ipm.

• Remove wire from the pull wire drive.

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

• Pull the trigger on the push-pull gun.

• Measure the rpm of the pull motor. The rpm
should be between 115 and 125 rpm. If nec­essary, decrease the calibration setting to
slow the pull motor, or increase the calibra­tion setting to speed up the motor.

The calibration range is -30 to +30, with 0 as

the default value.

• Press the right hand button to save the new
setting.

POWER FEED® 25M

B-27 B-27

P.8 TIG Gas Control (Two Settings)

1. "Valve (manual)", the internal solenoid will not
actuate while TIG welding, gas flow is manually
controlled by an external valve.

2. "Solenoid (auto)", the internal gas solenoid will
turn on and off automatically while TIG welding as
follows:

• Preflow time will not be accessible from the MSP4.

• Postflow time will be available in the MSP4 "End

Options" and have a range of OFF to 10.0 sec­onds.

• The postflow time value is maintained when

switching between MIG and TIG modes.

• When machine output on/off is controlled via the

right encoder, gas flow will not start until the tung­sten touches, the work piece, gas flow will stop
after the postflow time when the arc is broken.

• 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 stop flowing
after the postflow period after the output is turned
off.

P.11 Set Timers

This menu is used to adjust timer values for
Upslope, Downslope and Restrike. Press the
right button to enter the Set Timer menu.
Rotate the knob to select the timer to adjust
and then press the right button. Adjust the
value of the timer by rotating the knob. Press
the left MSP4 button to set the value and exit.
Continue to adjust other timers as necessary,
and then press the left button to exit the Set
Timer menu.

OPERATION

P.13 Adjust Arc Force

Use this menu to adjust Arc Force values for
Start, Weld and Crater. Press the right MSP4
button to enter the menu and rotate the knob
to choose either Start, Weld or Crater. Press
the right MSP4 button and then rotate the knob
to the desired value. Press the left MSP4 but­ton to set the value and exit. Continue to
adjust Arc Force for other states, and then
press the left MSP4 button to exit the menu.

P.80 Sense From Studs (two settings)

1. "False", the voltage sense lead is automat­ically selected based on the DIP switch con­figuration and the selected weld mode. This
is the default value that is used every time
the machine is powered up. Note that set­ting P.80 to "False" does not preclude volt­age sensing from the studs if studs sensing
is specified by the selected weld mode (for
example stick and TIG weld modes will still
sense voltage at the studs).

2. "True", voltage sensing is forced to "studs"
regardless of the DIP switch configuration
and selected weld mode. Setting P.80 to
"True" should only be done for trou­bleshooting purposes. P.80 will automatical­ly be set back to "False" the next time the
equipment is powered up or can be manual­ly changed back to "False" via the setup
menu.

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P.12 Travel Options

This menu is used to change the travel options
for a travel carriage, including starting and
ending functions. The right MSP4 button to
enter the Travel Options menu and rotate the
encoder to select either starting or ending
options. Press the right MSP4 button to select
the option. Press the left MSP4 button to set
the value and exit. Rotate the encoder to select
other options, or press the left MSP4 button to
exit the menu.

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In order to control the welding arc, the power
source continually monitors arc current and
arc voltage. Arc current is measured internal
to the power source. Arc voltage can be mea­sured as follows:

• Voltage internal to the power source ("studs")

• Voltage at the wire feeder ("67" lead)

• Voltage at a user-wired sense lead ("21"

lead)

Remote voltage sensing (anything other than
"studs") is used to obtain a more accurate volt­age measurement since the sense lead is
closer to the arc. Remote voltage sensing can
involve external wiring and DIP switch configu­ration, there is a potential for incorrect voltage
measurement which can lead to poor arc con­trol or wire burn back.

POWER FEED® 25M

B-28 B-28

P.99 Show Test Modes

Many weld tables include special modes for
testing and servicing the welding system. Set
this parameter to YES to show all test modes.

When the power source is turned off, the Show
Test Modes parameter automatically reverts
back to "NO".

P.100 View Diagnostics

Diagnostics are only used for servicing the
Power Wave system.
Yes = Shows P.101 through P.500 in the
SETUP menu.
No = Only P.0 through P.100 are shown in the
SETUP menu.

P.101 Event Logs

Press the right MSP4 button to view the Event
Logs. Rotate the encoder to select the object
to read and then press the right MSP4 button.
Various software information will appear about
key system events. Press the left MSP4 button
to exit.

OPERATION

P.106 Ethernet IP Address

Press the right MSP4 button to view the IP
address of the Ethernet board. If no Ethernet
Board is installed, the display shows "No Enet
Found." Press the left MSP4 button to exit.

P.107 Power Source

Press the right MSP4 button to view the type of
power source connected to the control box.
Press the left MSP4 button to exit.

P.102 Fatal Logs

Press the right MSP4 button to view the Fatal
Logs. Rotate the encoder to select the module
to read and then press the right MSP4 button.
Various software information will appear about
critical module actions. Press the left MSP4
button to exit.

P.103 Software Version

Press the right MSP4 button to view the soft­ware loaded into each module (p.c. board).
Rotate the encoder to select the module to
read and then press the right MSP4 button.
The panel will display the main software ver­sion loaded into the module. Press the left
MSP4 button to exit.

P.104 Hardware Version

Press the right MSP4 button to view the hard­ware version of each module (p.c. board).
Rotate the encoder to select the module to
read and then press the right MSP4 button.
The panel will display the main hardware ver­sion loaded into the module. Press the left
MSP4 button to exit.

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P.105 Welding Software

Press the right MSP4 button to view the weld­ing software version inside the power source.
Press the left MSP4 button to exit.

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POWER FEED® 25M

B-29 B-29

HOLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

GUN B

1

4

2

5

3

6

M

M

H

OLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

G

UN 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

PROCEDURE/MEMORY PANEL OPERA-

OPERATION

USER MEMORIES

TION

Recall a memory with memory buttons

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.

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.

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

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.

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.

Note that memories may 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

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PRESS TO

SELECT
PROCEDURE OR
QUICK TRIGGER-

WHILE

WELDING

POWER FEED® 25M

B-30 B-30

HOLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

GUN B

1

4

2

5

3

6

M

M

SET

SETUP

IR PORT

Set Limits

Memory 1

WAVEFORM CONTROL TECHNOLOGY

WELD MODE
ARC CONTROL

S

TART OPTIONS

E

ND OPTIONS

LIMITS

OPERATION

To set limits, press the desired memory button 1-6
and hold for 5 seconds. Release the memory button

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

when the LED begins to blink rapidly and the MSP4
displays "Memory X Set Limits" as shown below.

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 memo-

Set Limits:

Press 5

seconds

ry 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:

MSP4 DISPLAY

Parameter

Wire Feed

Speed

Range

Weld mode dependent

and gear box ratio

dependent

Units

in/min

Voltage

Trim

Arc Control

Preflow

Start Time

Run-In WFS

Crater Time

Burnback Time

Postflow Time

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

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

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

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POWER FEED® 25M

B-31 B-31

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

LoLo

IR PORT

Weld WFS

= 200
= 180

W

AVEFORM CONTROL TECHNOLOGY

WELD MODE

A

RC CONTROL

START OPTIONS
END OPTIONS

200

H

OLD 2 SECONDS TO SAVE

PROCEDURE

MEMORY

A

GUN B

1

4

2

5

3

6

M

M

S

ET

S

ETUP

IR PORT

Enable/Disable

Memory 1
Limits

WAVEFORM CONTROL TECHNOLOGY

WELD MODE
ARC CONTROL

START OPTIONS
E

ND OPTIONS

SET

SETUP

IR PORT

Yes No

Enable
Limits?

WAVEFORM CONTROL TECHNOLOGY

WELD MODE
ARC CONTROL

START OPTIONS
END OPTIONS

Four items show on the MSP4 panel.

• Memory Value

• High Limit

OPERATION

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

Memory Value

High Limit

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

Parameter Name

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.

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:

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.

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POWER FEED® 25M

B-32 B-32

2

-

S

TE

P

4

S

TE

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

to the Electrode Connection

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

INTERNAL CONTROLS

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POWER FEED® 25M

B-33 B-33

2-STEP

4 ST EP

C

OLD FEED

G

AS PURGE

ON

OFF

LIGHT

HEATER

OFF

ON

OPERATION

NOTE: All switches described on this page will func­tion only when power source is ON.

COLD FEED/GAS PURGE SWITCH

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

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

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

LIGHT SWITCH

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

2 STEP - 4 STEP - TRIGGER OPERATION

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

Place the toggle switch in the 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.

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.

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.

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POWER FEED® 25M

B-34 B-34

Shielding
Gas

Idle P refl ow Strike Weld Postflow Idl e

Power
Source
Output

WFS

On

Off

Run-in

Off

Wel d

Off

Wel d

Arc

Established

Trigger

Pulled

Trigger

Released

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

1.5 sec 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.

STRIKE:

After preflow time expires, the power source regulates
to the welding output and wire is advanced towards the
work piece at the strike 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.

FIGURE B.19

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POWER FEED® 25M

B-35 B-35

Shieldin

g

Gas

Idle Preflow Strike Upslope Weld Burnback Postflow Idle

WFS

On

Off

Run-in

Off

Weld

Off

Weld

Arc

Established

Trigger

Pulled

Trigger

Released

2 Step Trigger
Start = ON

Crater = OFF
Burnback = ON

1.5 s ec max.

Sta rt

Start

time

Burnback Time

Power
Source

Output

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)

OPERATION

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.

For this sequence,

PREFLOW:

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

STRIKE:

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

FIGURE B.20

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.

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POWER FEED® 25M

B-36 B-36

Shielding
Gas

Idle Preflow Strike Upslope Weld Burnba ck Postflow Idl e

WFS

On

Off

Run-in

Off

We ld

Off

We ld

Arc Established

Trigger Pulled

Trigger Released

2 Step Trigger
Start = ON

C rater = ON
Burnback = ON

1 .5 sec max .

Start

Start time

Burnback Time

Do wnslop e

Crat er

Cr ater ti me

Power
Source

Output

Crater

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

OPERATION

WELD:

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

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)

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

For this sequence,

DOWNSLOPE.

PREFLOW:

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

BURNBACK:

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

STRIKE:

burnback time.

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

POSTFLOW:

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

wire feed speed skips to the weld settings.

UPSLOPE:

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

FIGURE B.21

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POWER FEED® 25M

B-37 B-37

Shielding
Gas

I

dle Preflo w Strike Wel

d

Burnb ack Pos tf low I dle

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 = OFF

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.

STRIKE:

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

WELD:

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

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

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POWER FEED® 25M

B-38 B-38

Shielding
Gas

Idl e Preflow Strike Upslope Weld Burnba ck Postflo w 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

Crater = ON
Burnback = ON

1 . 5 sec m ax .

Start

Bur nb ack Time

Down slope

Crat er

Power
Source
Output

Crat er

Start

Trigger

Pulled

Crat er

T

ri

g

g

e

r

Re

l

e

a

s

e

d

St ar t

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

OPERATION

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.

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

WELD:

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

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)

DOWNSLOPE:

As soon as the trigger is released, the wire feed speed
and power source output ramp to the crater settings

In this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the gun

throughout the crater time. The time period of ramping
from the weld settings to the crater settings is called
DOWNSLOPE.

trigger is pulled.

CRATER:

STRIKE:

After preflow time expires, the power source regulates

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

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

BURNBACK:

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

START:

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

POSTFLOW:

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

FIGURE B.23

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POWER FEED® 25M

B-39 B-39

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

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POWER FEED® 25M

B-40 B-40

OPERATION

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 CO
is for reference purposes only. The middle of the ball
indicates the flow rate of shielding gas.

Adjust the flow rate while depressing 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.

2, Ar, and CO2/Ar blends. It is not calibrated and

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

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. (Counts of red flashes)

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

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POWER FEED® 25M

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Factory Installed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Drive Roll Kits used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Common Packages with Accesories Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3/C-6

Installation of Water Cooling Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

Python water cooled Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7

TABLE OF CONTENTS - ACCESSORIES SECTION

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POWER FEED® 25M

C-2 C-2

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).

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.

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POWER FEED® 25M

C-3 C-3

K2429-1

K857

K857-1

K2596-1

ArcLink "T" Cable Adapter

Remote Output Control

Remote Output Control

Aluminum Case

ACCESSORIES

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

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.

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K1842-xx

Weld Power Cable, Lug to Lug

POWER FEED® 25M

Includes: Twist-Mate to Lug,

1/0 cable of length "xx".

C-4 C-4

K1543-xx

Digital Control Cable

ACCESSORIES

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.

K910-1

K910-2

K1500-1

K1500-2

(Included

with PF25M)

Ground Clamp

Ground Clamp

Gun Receiver Bushing (for guns

with K466-1 Lincoln gun connec-

tors; Innershield and Subarc guns)

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.

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K1500-3

K1500-4

Gun Receiver Bushing (for guns

with K613-7 Lincoln gun connec-

tors; Magnum 550 guns and com-

patible with Tweco® #5)

Gun Receiver Bushing (for gun

with K466-3 Lincoln gun connec-

tors; compatible with Miller®

guns.)

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-5 C-5

K1500-5

Gun Receiver Bushing (compatible

with Oxo® guns.)

ACCESSORIES

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.)

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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-6 C-6

j

j

oo

ee

w

waa

ss

hh

ee

rr

e

e

22

0000

11

jj

oo

ee

w

w

aa

ss

hh

ee

rr

e

e

22

0000

11

INSTALLATION OF THE K590-6 WATER
COOLING KIT

ACCESSORIES

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.

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.

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

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

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

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.

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POWER FEED® 25M

C-7 C-7

THUMB THUMB
SCREWSCREW

CONDUITCONDUIT

ELECTRODEELECTRODE
CABLECABLE

GUNGUN
BUSHINGBUSHING

WATERWATER
HOSESHOSES

WATERWATER
HOSEHOSE

ACCESSORIES

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.

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

Water cooled guns require the installation of the K590­6 Water Connection Kit. The kit components are rated
up to 70 psi (5bar) and 158°F (70°C). See this Section
for kit installation instructions.

PYTHON WATER COOLED GUNS

(See Figure C.1)
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.

FIGURE C.1

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POWER FEED® 25M

C-8 C-8

NOTES

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POWER FEED® 25M

D-1 D-1

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

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Calibration Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

TABLE OF CONTENTS - MAINTENANCE SECTION

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POWER FEED® 25M

D-2 D-2

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not operate with covers
removed.

• Turn off power source before
installing or servicing.

• Do not touch electrically hot
parts.

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

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

ROUTINE MAINTENANCE

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

• Clean and tighten all weld terminals.

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.

• Adjust the wire feed speed to 300 in/min (7.62m/min).

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

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

• If no feed speed meter is available, cut the wire at gun tip. Cold inch
for 5 seconds at 300 inches/minute. Measure the wire - should be 24
inches +1, -2 inches.

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.

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POWER FEED® 25M

E-1 E-1

VOLTAGE

SENSE

LEAD #67A

LEAD #67

PUSH PULL
DAUGHTER

DRIVE

MOTOR

GEAR BOX

AND

CONDUCTOR

BLOCK

FEEDBACK

TACH

STATUS LED

GUN TIGGER AND

DUAL PROCEDURE

RECEPTACLE

2-STEP/
4-STEP

CONTROL BOARD

FEEDHEAD

DIP SWITCHES

TO POWER
SOURCE

INPUT

NETWORK

RECEPTACLE

HEATER LIGHT

CONNECTOR
FOOT AMPTROL

COLD
INCH/

GAS

PURGE

GAS

SOLENOID

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

General Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

General Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

POWER FEED® 25M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Component Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

FIGURE E.1 BLOCK LOGIC DIAGRAM

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POWER FEED® 25M

VOLTAGE

SENSE

LEAD #67A

LEAD #67

PUSH PULL
DAUGHTER

DRIVE

MOTOR

GEAR BOX

AND

CONDUCTOR

BLOCK

FEEDBACK

TACH

STATUS LED

GUN TIGGER AND

DUAL PROCEDURE

RECEPTACLE

2-STEP/
4-STEP

CONTROL BOARD

FEEDHEAD

DIP SWITCHES

TO POWER
SOURCE

INPUT

NETWORK

RECEPTACLE

HEATER LIGHT

CONNECTOR
FOOT AMPTROL

COLD
INCH/

GAS

PURGE

GAS

SOLENOID

E-2 E-2

THEORY OF OPERATION

FIGURE E.2 - GENERAL PHYSICAL DESCRIPTION

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GENERAL DESCRIPTION

The POWER FEED® 25 Single Wire Feeder is a wire
feeder, consisting of two components - a wire drive
and a control box - are available assembled as a
bench unit or as a boom system. High speed, highly
reliable digital cables connect the components togeth­er and to the Power Wave power source.

The POWER FEED® 25M Wire Feeder system has the
ability to connect to one power source, use the same
power source.

The powerful two roll wire drive system sets the indus­try standard for ease of use. Its patented design allows
for tool-less change out of wire guides and drive rolls
greatly reducing set up time.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

POWER FEED® 25M

GENERAL FUNCTIONAL
DESCRIPTION

• The POWER FEED® 25M Wire Feeder is a highly
versatile wire feeder with easy to use features that
make it easy for the operator to adjust the arc for
specific preferences.

• The new MSP4 panel clearly displays key welding
information. Use the MSP4 panel to quickly adjust
weld settings, arc starting parameters, arc end para­meters and set-up variables.

• The POWER FEED® 25M Wire Feeder is provided
with an infrared red (IR) port. Transferring welding
settings is accomplished with a common palm com­puter.

• When the POWER FEED® 25M Wire Feeder is cou­pled to a Power Wave welding power source, the
result is a welding system with absolutely superior
arc performance.

E-3 E-3

VOLTAGE

SENSE

LEAD #67A

LEAD #67

PUSH PULL
DAUGHTER

DRIVE

MOTOR

GEAR BOX

AND

CONDUCTOR

BLOCK

FEEDBACK

TACH

STATUS LED

GUN TIGGER AND

DUAL PROCEDURE

RECEPTACLE

2-STEP/
4-STEP

CONTROL BOARD

FEEDHEAD

DIP SWITCHES

TO POWER
SOURCE

INPUT

NETWORK

RECEPTACLE

HEATER LIGHT

CONNECTOR
FOOT AMPTROL

COLD
INCH/

GAS

PURGE

GAS

SOLENOID

THEORY OF OPERATION

FIGURE E.3 - GAS SOLENOID CONTROLS

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POWER FEED® 25M

The POWER FEED® 25M is a two roll, high perfor­mance, digitally controlled, modular wire feeder that
operates on 40 VDC input power. It is designed to be
a part of a modular, multi-process welding system.
Refer to Figure E.2.

Network communications, intelligence, PC board input
power, and arc voltage feedback is received and
transmitted through the input network receptacle.

The feed head drive control board processes the
information it receives from the various user operated
switches such as the gun trigger, 2-step/4-step, and
cold inch switches and sends this information to other
system components. This information is evaluated
and the correct commands are transmitted to the feed
head drive. The feed head drive control board then
sends the signals to energize the active components
such as the solenoid and wire drive motor. The tach
feedback signal is processed on the feedhead board
which regulates the motor armature voltage so as to
maintain the required wire feed speed.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

POWER FEED® 25M

When the gun trigger is pulled, the voltage sense
board relays the electrode sense signal to the input
network receptacle for processing by the power
source.

The STATUS LED is designed to blink a red and
green code if a fault should occur.

There is one DIP switch bank located on the wire
feedhead drive board. It is labeled S1 and is used to
set gear ratios and arc polarity.

GAS SOLENOID

The gas solenoid permits the POWER FEED® 25M to
be used for gas metal arc welding (GMAW) processes.
When the gun trigger circuit is activated, the control
board signals the solenoid to activate, which allows
sheilding gas to flow through the gun to the arc.

E-4 E-4

DISPLAY AND

ENCODER PANEL

(

STANDARD)

STATUS

LED

SMALL
PANEL

MEMORY

LARGE

PANEL

MSP4

THEORY OF OPERATION

FIGURE E.4 - CONTROL BOX

CONTROL BOX
(USER INTERFACE)

The POWER FEED® 25M wire feeders do not have
User Interface Boards in the control box. On these
models the User Interface Bd circuitry is on the feed
head Bd located in the wire drive box.

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POWER FEED® 25M

E-5 E-5

COMPONENT STATUS LIGHTS

Each network component has a single status light. The
light is a bicolor, Green/Red, LED. The purpose of the
status light is to allow the operator to quickly identify
that the system is working properly or, if not, which

NOTE: The green light ON and steady indicates a normal functioning system.

TROUBLESHOOTING

component is causing the problem. By using the status
lights the operator can quickly pinpoint the system
problem to a particular component. See the following
table for a complete listing and description of all status
light conditions.

STATUS LIGHT STATES

LED State

Off

Green LED blink­ing at a “normal”
rate

Red LED blinking
at a “normal” rate

Power Source LED

Power Source is not turned ON or is not
ing correctly.

It should only blink for a few seconds while
the system is mapping (identifying compo­nents). If blinking continues every group may
have a mapping error. (DIP switches may be
set incorrectly).

Indicates a recoverable communication fault.
The power source should automatically
recover: If it cannot recover the LED will be
solid red.

function-

LED on any other nodes (components);
Wire Feeder, Control Box Etc.

The system component is not receiving input
power or

It should only blink for a few seconds until the
system component (node) has been recog­nized. If the blinking continues at least one
node in the group has a mapping error (DIP
switches may be set incorrectly). The node or
nodes with mapping errors will be blinking
red.

• There may be too many components in the
group. All components in the group will be
blinking green.

• The power source bus may not be available.
The bus may be being used to program
another component.

• The LED’s of the power source and the
component being programmed will be solid
green.

Indicates a recoverable communication fault
most likely caused by one of the following.

• More than one control box (UI) in the group.
All control boxes in the group will be blinking
red.

• No control box (UI) in the group. All nodes in
the group will be blinking red.

• More than one node, of the same equip­ment type, has the same group and feed
head (FH) numbers. All these nodes will be
blinking red.

• The feed head DIP switches may be set to
zero. The nodes with DIP switches set to zero
will be blinking red.

•The node bus may be off.

is faulty.

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Red/Green LED
blinking at a “nor­mal” rate

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Indicates a recoverable hardware fault such
as over temperature, overload shutdown etc.

POWER FEED® 25M

Indicates a recoverable hardware fault such
as over temperature, overload shutdown etc.
Could also be an open shutdown circuit at the
feed head (leads 570, 572 with tab terminals)
typically used for water flow shutdown switch­es.

E-6 E-6

TROUBLESHOOTING

STATUS LIGHT STATES (CON’T)

LED State

Red LED blinking
at a fast rate

Red LED ON and
steady

Green LED ON
and steady

Power Source LED

Power source needs to be reprogrammed.
Contact your Local Authorized Lincoln Field
Service Facility.

Power source has a non-recoverable hard­ware fault. Contact your Local Authorized
Lincoln Field Service Facility.

System normal and functional.

Normal Blinking LED - Each illumination should exist for 0.5 seconds.

Fast Blinking LED - Each illumination should exist for 0.1 seconds.

LED on any other nodes (components);
Wire Feeder, Control Box Etc.

System component (node) needs to be
reprogrammed. Contact your Local
Authorized Lincoln Field Service Facility.

System component (node) has a non-recov­erable hardware fault. Contact your Local
Authorized Lincoln Field Service Facility.

System normal and functional.

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POWER FEED® 25M

F-1 F-1

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4 / F-12

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13 / F-21

Voltage Sense PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Tach Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15

Drive Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17

Gear Box and Drive Motor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19

Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-22

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POWER FEED® 25M

F-2 F-2

TROUBLESHOOTING AND REPAIR

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.

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

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.
Symptoms are grouped into the following
categories: output problems, function prob­lems, wire feeding problems, and welding
problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con­tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with­out removing the case wrap-around cover.

Step 3. RECOMMENDED
COURSE OF ACTION

The last column labeled “Recommended
Course of Action” lists the most likely com­ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com­ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed
one possibility at a time until you locate the
cause of your problem.

All of the referenced test procedures referred
to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

to eliminate

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.

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

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POWER FEED® 25M

F-3 F-3

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK
can kill.

•

Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.

CAUTION

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.

2. Check for loose connections at the PC board to
assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:

PC board can be damaged by static electricity.

- Remove your body’s static
charge before opening the static­shielding bag. Wear an anti-static
wrist strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

frame.

- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.

- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield­ing bag.

- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.

- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop­er failure analysis.

4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.

NOTE: It is desirable to have a spare (known good)

PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all

electrical components can reach their operating
temperature.

5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.

6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.

NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.

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- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

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POWER FEED® 25M

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The ammeter on the POWER FEED® 25M does not function properly even though the STATUS LEDs are steady green.

The display and/or indicator LEDs
do not change when their corre­sponding switches and or knobs
are activated or turned.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make sure the DIP switches are
configured correctly for the weld­ing process and polarity used.
See Setting DIP Switches in

the Wire Drive in the
Installation section of this manu-

al.

2. Check the following connections
on the POWER WAVE®
machine. Check for loose or
faulty connections between plug
J90 at the current transducer and
plug J21 on the Power Source
control board.

1. Check for loose or faulty connec­tions between the encoder panel
and the Control Box control
board.

2. Check for loose or faulty connec­tions between the appropriate
switches and the Control Box
control board.

RECOMMENDED

COURSE OF ACTION

1. Perform the Current Transducer
Test in the Power Source
Service Manual.

2. The control board, located in the
power source, may be faulty.

1. Check suspected potentiometer
and/or switches for correct resis­tances and operation.

2. Refer to machine schematics for
lead numbers and voltages.

3. The Control Box control board
may be faulty.

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The mode and/or settings change
while welding under normal condi­tions.

Contact “powerwave software.com”

1.
for the latest updated software.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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POWER FEED® 25M

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The wire feed speed is consistent and adjustable, but runs at the wrong speed.

The unit shuts off while welding or attempting to weld. The STATUS LED is alternating between red and green every second. The unit tries to recover after 30 seconds and may repeat sequence.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. The DIP switch on the wire drive

unit may not be set for the correct
gear ratio. See the Installation
section of this manual.

1. The drive motor may be over-

loaded due to a mechanical
restriction in the wire feeding
path. See Operation section of
this manual.

RECOMMENDED

COURSE OF ACTION

1. The feed head control board
may be faulty.

2. The wrong gear may be installed.

1. If there are no restrictions in the
wire feeding path, the drive
motor or gear box may be faulty.

2. The feed head control board
may be faulty.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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

POWER FEED® 25M

F-6 F-6

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

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

No shielding gas.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. The POWER FEED® 25M power
switch is OFF.

2. The Power Wave power source is
OFF.

3. The circuit breaker for the wire
feeder on power source have
tripped.

4. The control cable may be loose or
damaged.

5. The power switch is damaged.

1. The gas supply is OFF or empty.

2. The gas hose is cut or crushed.

3. Dirt or debris is in the solenoid.

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

RECOMMENDED

COURSE OF ACTION

1. Turn the POWER FEED® 25M
power switch ON.

2. Turn ON the Power Wave power
source.

3. Reset the circuit breakers.

4. Tighten, repair or replace the
control cable.

5. Replace the power switch.

1. Verify the gas supply is ON and
flowing.

2. Route the gas hose so it avoids
sharp corners and make sure
nothing is on top of it. Repair or
replace damaged hoses.

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

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

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

1. The gun cable is kinked and/or
twisted

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

3. The gun liner is dirty or worn.

4. The electrode is rusty or dirty.

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

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

7. Incorrect tension arm pressure on
the drive rolls.

8. Worn drive roll.

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

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

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

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

5. Replace the contact tip.

6. Verify the proper parts are
installed.

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

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

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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

POWER FEED® 25M

F-7 F-7

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Variable or "hunting" arc.

Poor arc starts with sticking or "blast-offs", weld porosity, narrow and ropy looking bead.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

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

2. Worn work cable or poor work
connection.

3. Wrong polarity.

4. The gas nozzle is extended
beyond the contact tip or the wire
stickout is too long.

5. Poor gas shielding on processes
requiring gas.

1. Improper procedures or tech­niques.

RECOMMENDED

COURSE OF ACTION

1. Replace the contact tip.

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

3. Adjust polarity to the recom­mended procedure.

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

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

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

The wire feed speed/amperage
and voltage/trim display work dur­ing preset but show nothing during
welding.
Can only select mode 12 or other
(Factory Reset) setting - or unit
returns to the factory setting

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

1. Contact the local authorized
Lincoln Field Service Shop.

2. Download update from power­wavesoftware.com

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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

POWER FEED® 25M

F-8 F-8

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Major physical or electrical damage is evident when the sheet metal cover(s) are removed.

No wire feed, solenoid or arc volt­age. The STATUS LED’s are
steady green.

No control of wire feed speed. All STATUS LEDs are steady green. The preset wire feed speed is adjustable on the front panel.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Contact your local authorized
Lincoln Electric Field Service
Facility for assistance.

1. The gun trigger may be faulty.

Check or replace.

2. Check panel connections and

switch(s) for proper operation.

1. Check P9 plug and set at feed-

head control.

RECOMMENDED

COURSE OF ACTION

1. Contact the Lincoln Electric
Service Department, 1-888­935-3877.

1. Check the continuity of leads
from the gun trigger receptacle
to plug J85. See wire drive
wiring diagram.

2. The wire drive feedhead board
may be faulty.

1. Perform the Tach Feedback

Test.

2. The wire drive feedhead board
may be faulty.

No welding arc voltage when the
gun trigger is activated. The wire
feeds normally and the gas sole­noid functions properly. The STA­TUS LEDs are steady green on the
wire drive unit.

The wire feed speed does not change when welding current is established. The WFS stays at the run-in speed. The STATUS LEDs are steady green.

1. The Power source may unable to
produce welding output due to a
thermal fault or other malfunction.
Check STATUS LED on Power
Source. See PowerWave®
Troubleshooting.

1. The run in and weld wire feed

speeds may be set to the same
value. Set run in speed to a
value that gives best starting
results.

CAUTION

1. Make certain the Power Wave

power source is functioning
correctly. (Green Status LED)

2. Check weld + work cable rout­ing.

1. Perform the Current Transducer
Test in POWERWAVE® service
manual.

2. If the run in wire feed speed can­not be adjusted, perform the
Tach Feedback Test and also
the Drive Motor Test.

3. The wire drive feedhead board
may be faulty.

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

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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

POWER FEED® 25M

F-9 F-9

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The purge switch does not activate the gas solenoid, but gun trigger closure in the MIG or pulse modes does activate the solenoid. The LEDs are steady green on the power source, and wire drive unit.

The COLD INCH/GAS PURGE switch does not turn on the wire drive motor but gun trigger closure in the MIG or Pulse modes does activate the wire drive motor. The LEDs are steady green on the power source, and wire drive unit.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make certain the COLD
INCH/GAS PURGE switch is
operating properly.

2. Check for loose or faulty leeds
between COLD INCH/GAS
PURGE switch and the feedhead
board. See wiring diagram.

1. Make certain the COLD
INCH/GAS PURGE switch is
operating properly.

2. Check for loose or faulty leeds
between the COLD INCH/GAS
PURGE switch and the feedhead
board. See wiring diagram.

RECOMMENDED

COURSE OF ACTION

1. If the COLD INCH/GAS PURGE
switch is operating correctly and
the associated leeds are OK.
The feedhead board may be
faulty.

1. If the COLD INCH/GAS PURGE
switch is operating correctly and
the associated leads are OK.
The feedhead board may be
faulty.

The voltmeter on the wire feeder does not function properly even though the STATUS LEDS are steady green.

1. Make sure the DIP switches are
configured correctly for the weld­ing polarity being used. See

Setting Dip Switches in the Wire
Drive in the Installation section

of this manual.

2. Check the #67 lead on the wire
drive unit. Make sure it is connect­ed to the motor gear box and also
the voltage sense PC board.

3.Check the work sensing leads on

the POWER FEED® 25M power
source. Check leads #202 (Neg.
output terminal) and #206 (pos.
output terminal). See POWER
FEED® 25M wiring diagram. If
external voltage sensing is utilized,
Check the #21 lead between the 4­pin receptacle on the front of the
POWERWAVE® and the work­place.

1. Check leads #513 and #514 from
J85 on the feedhead board to the
voltage sense PC board. Verify
placement in proper cavities.

2. Perform the Voltage Sense
Board Test.

3. The display board may be faulty.

4. The feedhead control board may
be faulty.

5. The Control Box control board
may be faulty.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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POWER FEED® 25M

F-10 F-10

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The displays are blank (not lit). The wire feeds when the gun trigger is activated.

The dual procedure is not function­al when using the remote Dual
Procedure switch. The STATUS
LEDs are steady green on the
power source, and wire drive units.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Check for loose or faulty connec­tions at plug on the display board,
to plug on the memory board to
the plug on the msp-4 board to
the plug on the push-pull daugh­ter board to the feed head board.

1. Make certain the LED indicator on
the Dual Procedure Panel is in the
middle position. This enables the
gun remote dual procedure
switch.

RECOMMENDED

COURSE OF ACTION

1. Check for 5VDC at J37 pins 2
and 10 on the display board. If 5
VDC is present, then the display
board may be faulty.

2. If the 5VDC is low or not present,
check for loose or faulty connec­tions in SPI circuit. See machine
schematic.

3. The feedhead control board may
be faulty.

1. Check shielded cable lead and
connections from J86 on PC BD
to MSP panel. Check SPI cable
from MSP panel to Dual/memory
panel. Per machine schematic.

2. Check for 5VDC at J86 pins 2
and 10. Check for 15VDC at J86
pins 1 and 10. If voltage is not
present replace feed head. If
leads and voltages are good
replace dual/memory panel.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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POWER FEED® 25M

F-11 F-11

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Fault Code

Err 81 Motor overload, long term.

Err 82 Motor overload, short term.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

ArcLink System Error Codes

Description

1. The wire drive motor has over­heated.

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

RECOMMENDED

COURSE OF ACTION

Possible Adjustments

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

2. Remove tight bends from the
gun and cable.

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

4. Verify a high quality electrode is
being used.

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

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

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

Err 263 No usable weld modes.

Err 53 Voltage sense loss.

Err 95 Spool gun or pull gun
motor overload.

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

1. The system detected that one

of the voltage sense lead
cables was disconnected from
the welding circuit during a
weld.

1. The drive motor in the spool

gun or push-pull gun is
drawing too much current.

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

Verify that leads 67 and 21 is

enabled and connected. See
enhanced schematic.

Check spool gun brake or feeding

for binding. Replace spool gun
circuit board.

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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POWER FEED® 25M

F-12 F-12

NOTES

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POWER FEED 25M

F-13 F-13

TROUBLESHOOTING AND REPAIR

VOLTAGE SENSE PC BOARD TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the voltage sensing board is receiving the correct activation
signal from the control board and also if the voltage sensing board is processing arc volt­age sensing information.

MATERIALS NEEDED

3/8" in. nut driver
Volt-Ohm Meter

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POWER FEED® 25M

23

4

5

2

J1

J2

F-14 F-14

TROUBLESHOOTING AND REPAIR

VOLTAGE SENSE PC BOARD TEST (continued)

FIGURE F.1 – PLUG J1 AND J2 LOCATIONS

NOTE: Inspect the molex plug con­nector pins on the Voltage Sense
Board. If any of them are gold plat­ed the P.C. board should be
replaced.

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PROCEDURE

1. Remove input power from the wire feed unit.

2. Using the 3/8 in. nut driver, remove the cover
from behind the wire reel.

3. Locate the voltage sense PC board and plugs
J1 and J2. Do not remove the plugs from the
voltage sense pc board. Refer to Figure F.1.

4. Apply the correct input power (from the
POWER FEED® 25M control cable) to the wire
feeder. With the gun trigger activated, check
for approximately 12 VDC at plug J1 pin 1 (+)
to pin 4 (-). If the 12 VDC is NOT present, the
feedhead board may be faulty. Also check for
trigger closure at J85 pins 1 & 2 on feedhead
board and loose or faulty wires and connec­tions between the feedhead board (plug J85
and plug J1 on the voltage sense PC board.
This voltage is polarity sensitive.

5. With the gun trigger activated and arc voltage
present at the conductor block, check for arc
voltage from plug J1 pin 3 (lead 67) to the
workpiece. If actual arc voltage is NOT pre­sent, check the continuity of lead 67 from the
conductor block to plug J1 pin 3 on the voltage
sense PC board.

6. If the actual arc voltage IS present at plug J1
pin 3 (lead 67), then check for arc voltage from
plug J2 pin 2 (lead 67B) to the workpiece. See
wiring diagram.

7. If the 12 VDC IS present in step #4 and the arc
voltage IS present in step #5 but the arc volt­age is NOT present in step #6 (lead 67A), the
voltage sense PC board may be faulty.

8. Remove all input power from the wire feeder
unit.

9. Install the wire feeder cover with the 3/8 in. nut
driver.

POWER FEED® 25M

F-15 F-15

TROUBLESHOOTING AND REPAIR

TACH FEEDBACK TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the tach unit is receiving the correct supply voltage from the control
board, and also if the tach unit is sending feedback information to the control board.

MATERIALS NEEDED

3/8" in. nut driver
Volt-Ohm Meter

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POWER FEED® 25M

BLUE

Black

RED

J84

F-16 F-16

TROUBLESHOOTING AND REPAIR

TACH FEEDBACK TEST (continued)

FIGURE F.2 – PLUG J84 LOCATION

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PROCEDURE

1. Remove input power from the wire feeder unit.

2. Using the 3/8 in. nut driver, remove the cover
from behind wire reel.

3. Locate plug J84 on the feed head board. Refer
to Figure F.2. Do Not remove the plug from the
feed head board.

4. Apply the correct input power (from the POWER
FEED® 25M control cable) to the wire feeder
unit and check for approximately 5VDC from
(red wire) positive to (black wire) negative. This
is the supply voltage from feedhead board to the
tach feedback unit. If the 5VDC is missing or
not correct, the feedhead board may be faulty.
Also check for loose or faulty wires and connec­tions.

POWER FEED® 25M

5. With the gun trigger activated and the motor
running, check the feedback voltage at plug J84
(blue wire) positive to (black wire) negative.
Normal feedback voltage is approximately 2
VDC. If the correct supply voltage is present
and the feedback voltage is missing, the tach
unit may be faulty. With the motor NOT running,
the feedback voltage may be either 0 or 5 VDC
depending upon where the motor stopped.

6. Remove input power from the wire feeder unit.

7. Install the wire feeder cover with the 3/8 in. nut
driver.

F-17 F-17

TROUBLESHOOTING AND REPAIR

DRIVE MOTOR TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the wire drive motor is receiving the correct voltage, and if it is capa­ble of running properly.

MATERIALS NEEDED

3/8" in. nut driver
Volt-Ohmmeter

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POWER FEED® 25M

14

2

5

6

3

#550

#551

F-18 F-18

TROUBLESHOOTING AND REPAIR

DRIVE MOTOR TEST (continued)

FIGURE F.3 – QUICK CONNECTOR #550 AND #551 LOCATIONS

PROCEDURE

1. Remove input power to wire feed unit.

2. Using the 3/8 in. nut driver, remove the

3. Locate the two quick connectors in the two

4. Apply the correct input power (from the

cover from the wire feeder.

motor armature leads. Refer to Figure F.3.
Do NOT disconnect the leads.

POWER FEED® 25M control cable) to the
wire feeder. Activate the gun trigger and
with the motor running check at the quick
connectors [#550 White (+) to #551 / Black
(-)] for approximately 1 VDC to 32 VDC
dependent upon motor speed. The motor
speed should vary with changes in motor
armature voltage.

5. If the correct voltages are NOT present at
the motor leads, check the associated
leads between the motor and plug J83 on
the feedhead board. If the leads are OK,
the feedhead board may be faulty.

6. If the correct voltages are present at motor
armature leads and the motor does not run
and vary speed with changes in armature
voltage, the motor or gear box may be
faulty. See Gear Box and Drive Motor
Removal and Replacement.

7. Install the wire feeder cover using the 3/8
in. nut driver.

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POWER FEED® 25M

F-19 F-19

TROUBLESHOOTING AND REPAIR

GEAR BOX AND DRIVE MOTOR

REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will aid the technician in the removal and replacement of the wire feed drive motor.

MATERIALS NEEDED

3/8 in. nut driver
Slot head screwdriver
Phillips head screwdriver
7/16 in. socket wrench with extension
Needlenose pliers
5/16 in. wrench
3/16 in. Allen wrench

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POWER FEED® 25M

THUMB THUMB
S

CREWSCREW

CONDUITCONDUIT

E

LECTRODEELECTRODE

CABLECABLE

G

UNGUN

BUSHINGBUSHING

WATERWATER
HOSESHOSES

WATERWATER
HOSEHOSE

F-20 F-20

TROUBLESHOOTING AND REPAIR

GEAR BOX REMOVAL AND DRIVE MOTOR

REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.4 – GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT

PROCEDURE

1. Remove input power to wire feed unit.

2. Using the 3/8 in. nutdriver, remove the
case cover.

3. Locate and remove plug J84 from the
feedhead - control board, located under
control box cover Refer to figure F.4.

4. Thread plug J84 and associated leads
through the vertical baffle. Cut any
necessary cable ties.

5. Locate and disconnect the motor leads
(#551 and #550) at the quick connects.
Cut any necessary cable ties.

Control Box Cover

7. Using the needlenose pliers, disconnect the
gas hose from the brass gun connector
block.

8. Using the 7/16 in. socket wrench, remove
the four mounting bolts, lock washers, and
flat washers from the plastic base insulator.

9. Carefully slide and remove the entire gear
box, drive motor, and wire drive assembly
from the wire feeder case. Note insulation
placement for reassembly.

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POWER FEED® 25M

6. Using the Phillips head screwdriver, remove
the #67 lead from the conductor block.

F-21 F-21

TROUBLESHOOTING AND REPAIR

GEAR BOX REMOVAL AND DRIVE MOTOR

REMOVAL AND REPLACEMENT PROCEDURE (continued)

TO REMOVE THE DRIVE MOTOR
FROM THE GEAR BOX:

10. Using the slot head screwdriver, remove the
gear box inspection cover nearest to the drive
motor.

11. Using the 5/16 in. wrench, remove the

motor mounting screw located inside the
gear box.

12. Using the slot head screwdriver, remove

the two screws mounting the “top” of the
motor to the gear box.

13. Carefully remove the motor from the gear

box assembly. Note motor lead
placement for reassembly.

TTOO RREEMMOOVVEE TTHHEE WWIIRREE DDRRIIVVEE

AASSSSEEMMBBLLYY FFRROOMM TTHHEE GGEEAARR
BBOOXX::

14. Using the 3/16 in. Allen wrench, loosen the

two Allen type screws at the bottom of the
wire drive unit.

15. Remove lead #67 from the conductor block.

16. Carefully slide and remove the wire drive

assembly from the gear box assembly.

RREEPPLLAACCEEMMEENNTT PPRROOCCEEDDUURREESS

“top” of the drive motor to the gear box.

6. Install the mounting screw located inside
the gearbox using the 5/16 in. wrench.

7. Install the gear box inspection cover and
secure it with slot head screws.

8. Properly place insulation in the bottom of
the wire feeder case.

9. Place the entire gear box, drive motor and
wire drive assembly into the wire feeder
case, aligning the holes in the plastic base
insulator with the mounting holes in the
case.

10. Mount the gear box and drive motor

assembly to the wire feeder case using
the four mounting bolts, lock washers ad
flat washers.

11. Connect the gas hose to the brass gun

connector block.

12. Connect drive motor leads #550 and #551

to their quick disconnects.

13. Thread plug J4 and associated leads

through the vertical baffle and attach it to
the control board. Install cable ties as
necessary.

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1. Carefully slide the wire drive assembly and
gear box together.

2. Tighten the two Allen type screws at the
bottom of the wire drive unit using the 3/16
in. Allen wrench.

3. Attach lead #67 to the conductor block.

4. Carefully slide the drive motor into the gear
box assembly. Be sure to position the
motor leads so that they can be properly
connected.

5. Install the slot head screws that mount the

POWER FEED® 25M

14. Install the wire feeder cover using the 3/8
in. nut driver.

F-22 F-22

NOTES

RETEST AFTER REPAIR

Retest a machine:

• If it is rejected under test for any reason that requires you to remove any part which
could affect the machine’s electrical characteristics.

OR

• If you repair or replace any electrical components.

SET UP

1. Once the repairs have been completed, the feeder must be connected to a Powerwave®
455M power source, or simular ArcLink® power source.

2. Go to the Service Navigator under Diagnostic Utility and perform the status check proce­dure.

3. With the use of a load bank and the utility, all functions of the feeder can be tested.

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POWER FEED® 25M

G-1 G-1

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram Entire Machine Code 11313 (G5585) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2

Schematic – Entire Machine - Code 11313 - (G5638) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3

Schematic - 42VAC & ArcLink Feeder PC Board #1 (Feeder PC Board) - Code 11313 - (G3883-1) . . . .G-4*

Schematic - 42VAC & ArcLink Feeder PC Board #2 (Feeder PC Board) - Code 11313 - (G3883-1) . . . .G-5*

Schematic – MSP4 Optional Display PC Board (G4456) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6*

Schematic - SPI Display PC Board - (L11756) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7

PC Board Assembly - SPI Display - (L11757-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8

Schematic – Voltage Sense Select PC Board - (S24779) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9

TABLE OF CONTENTS - DIAGRAM SECTION

PC Board Assembly - Voltage Sense Select - (M19540) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10

Schematic - Spool Gun PC Board (L12008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11

PC Board Assembly - Spool Gun (M20159) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12

* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered

and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.

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POWER FEED® 25M

-

+

POW ER

ARCLINC

RECEPTACLE

A
B
C
D
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54

1

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54

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54

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64

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5C

54

3A

57

0F

58

7A

58

1A

58

0A

58

2A

J8

3

J8

2

J8

1

J8

4

CONTROL P.C.BOARD

1

1 2345

1 234 1 2341 2345 66 7 8

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16

1
2
3
4
5
6
7
8
9

10

1
2
3
4
5
6
7
8
9

10

50

0D

54

2A

54

0C

55

0

55255

4

55155

3

64

0A

53

1

53553

7

53452

6

51

8

53

2E

1
2
3
4
5
6
7
8

P

89

1
2

59

5

64

0

52

6

54

8

77

76

75

3218
3214

23456

51

8C

57

8

59

5

J1

VOLTAGE SENSE

SELECT P.C

.

BOAR D

J2

51

3

51

4

67

B

50

0C

40

0

5
6

3
4

2

1

2

1

67

A

COLD INCH

/

GAS PURGE

S3

57

9B

58

6A

N.D.

53

5A

58

6A

53

5A

57

8A

57

9A

57

9A

1
2
3
4

P11

5
6
7
8

54

1

54

2
67
54

0
50

0

50

0B

54

1A

54

2A

67

A

54

0A

50

0A

50

0C

57

0F

57

0C

57

0E

LIGHT

LED

S4

59

0

B

B

N.C.

HEATER

S5

53

0A

N.D.

52

0

R2

R3

HEATER

53

0

50

0A

50

0D

54

0E

51

8B

5
6

51

8B

51

8D

57

9C

57

9C

LIGHT LED S

51

8C

51

8

51

8D

7
8
9

10

53

0

54

0D

53

0A

54

0E

R1

59

0

B

54

0B

54

0C

40

40

475

W

W

N.C.

TRIGGER INPUT

DUAL

PROCEDURE

I

NPUT

1
2
3
4
5
6
7
8
9

10

SHIELDEDCABLE

(CONTROL BO

X, B

OT T O

M)

40

0

(CONTROL
BOX,TOP)

40

0B

40

0G

(FRONT
PANE

L)

L7

FL

EX

40

0F

.15

uF

40

0H

40

0F

40

0C

40

0B

40

0C

40

0D

40

0E

40

0D

40

0E

ON

O

FF

ON

O

FF

G-2
WIRING DIAGRAM - COMPLETE MACHINE - CODE 11313 (G5585)

ELECTRICAL DIAGRAMS

G-2

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

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

POWER FEED® 25M

EN-170

S

O

L

ID

E

D

G

E

G5638

E

NGINEERINGCONTROLLE

D

MANUFACTURE

R:

No

RELEASEDA.02 FROM "

X".

A

T

HE INFOR MATIONON THIS

PRINTIS FOR

REFER

ENC

E

ON

LY.

COMP ONENTSAND

CIRCUITRY MAY

BE

DIFFER

ENT

FROM

AN ACT

UAL MACHIN

E.

G5638

POW ER FEED 25M

MACHINE SCHEM ATIC

NO

NE

G4440

JIMJ/KJ

ENYEDY

D

RAWN

BY:

DESIGNI

NFO

RMATI

ON

ENGINEER:

AP

PRO

VED

:

REFERENCE:

EQ

UIPMENT

TYPE:

SUBJECT:

SCALE:

MATERIAL
DISPOS

IT

ION:

APPROVAL
DATE:

PROJECT
NUMBER:

NA

C

RM38268

1

PAGE ___ OF

___

1

DOCUMENT
NUMBE

R:

DOCUMENT
REVISION:

THIS DOCUMENT CONTAINS PROPRIETARYINFORMATION OWNED BYLINCOLN GLOBA

L, INC.

AND MAYNOT BE DUPLICATED, COMMUNICATED

TO O

THER PARTIES OR US

ED FOR

ANYPURPOS

E WITHOUTTHE EXPRES

S WRIT

TEN PERMISSION

OF LINCOLN GLOBAL, INC.

PRO

PRIETARY & C

ONFIDENTIAL:

9/13/200

6

J8

6

C

AVI

TY NUMBE

RIN

G SEQ

UENCE

(

COMPONENT SIDE OF P.C.BOARD

)

J8

1,J

82

6

5

10

1

3

4

1

2

J8

5,J

87

9

8

16

1

4

6

1

3

J8

4,J

810

5

4

8

1

J1,J83,J

88

J2,J

811

1

2

LEADCOLOR

COD

E:
B-BLACK
R-

RED
U-BLUE
W-WHIT

E

C

OM

PONE

NT VALUEUNIT

S:

CAPA

CITOR: MFD/V

OLT

S

RE

SISTO

R: OHMS/W

ATT

S

CONNE

CTORPINNUM

BER

S:

VIEW OF CONNECTOR ON PC BOAR D

1

6

7

12

LA

TCH

EX. 12PINCONNECTOR

LABELS:

C

OMM

ON

FRAME

GROUND

FEEDHEA

D

P.C. BOARD

4J88

3

21

CURRENT

W

FS

VOLTS

TRIM

PANEL ENCODERS

2 S

TEP

/4 S

TEP

SWIT

CH

-

+

DIODE BRID

GE

5-32 V

DC

3.1 OHMS
13 S

EC. AVERAGE

CURRENT

LIMIT=3.5

A

(LIMIT IS SOFTWA

RE SET)

PUSH-P

ULL

GUN

DAUGHTE

R

P.C. BOARD

5K

7 PIN

PUSH-P

ULL

GUN

CONNE

CTI

ON

PROVIDESBRAKING
O

FTHE

PUSH-PULL

GUN

MO

TOR AND

COND

ITIONS

THE

SIGNAL

FRO

M T

HE

POTEN

TI

OMETER.

2J811

TO PUSH-PULL
GUNMOTORDRIVE

+40VDC S

UPPLY FOR

PUSH-P

ULLGUN

MOT

OR

(NON-

ISOLATED

)

DISPLAY P. C. BOARD

(SCHE

MATIC: L11

897)

FLE

X

E

3J81 4J81

{

TRIGGE

R

0VTOC

OMMONWHEN

SWITCHCLOSE

D

5J84

6J85

9J85

COLD INCH/

GAS PURGE S

WIT

CH

GAS PURGE

COLD I

NCH

579

586

535

GAS

PERFORMSALLUSER
INTERFAC

E, WIREDRIVE,

AND

GASSOLENOID

CONTRO

L

FUNCTION

S.

(SCHE

MATIC: G4456)

LEDS

LED

DISPLAY

LED

DISPLAY

A-

GUN

-B

PUSHBUTTO

N

LEDS

O
N

SIN

GLE

HEA

D

D

UAL

HEA

D

FEEDER

F

UTURE

SEE I

M MANU

AL FO

R E

RRORCOD

ES

ORWWW

.PO

WERW

AVESOFTWAR

E.C

OM

O

R SERVICE NAVIGATORDIAGNOSTICUTILITIES

SET

SWITCH 1 "ON"

(SINGLE

HEA

D)

AN

D S

WITCH 2 "ON"(FEEDER)

AS SHOWNON

DIP S

WITCH S9.

MOTORS

WILLNOT

RU

N IFDIODE IS

OPE

N,

REVE

RSE

D,

ORDIS

CONNECTE

D

MOTOR +

CAPA

CITOR

CONNECTS

FR

OM PI

N 10 OF S

HIELDED

CABLE TO FRA

ME G

ROUN

D.

2J81

1J81

4J82

3J82

2J82

1J82

14J85

13J85

+15V

OV WHEN "ON"

INP

UT ELECTRODE

CABLE

CONNECTI

ON

67B

FEED PLATE

GENERAL

GMA

W STD.

CV

5

CV

GMA

W POWERMO

DE 40

FCAW STD.

CV

6

STICK SOFT(7018)1
S

TICK C

RISP

(6010)2

CC

TIGTOUC

H STA

RT 3

GOU

GE --- 9

AL

UMINUM

0.035 3/64 1/16

GMAW

Ar 148

71 7

3

4043

PULSE

Ar 149

72 74

PULSE O

N P

ULSE Ar98 99 10

0

+15V

DC

+5V

DC

SIG

NAL

STEEL

0.030 0.035 0.045 0.052

GMA

W

C

O2

--- 10 20 2

4

GMA

W

Ar(MIX) 94 11 21 25
PULSE(CRISP)Ar(MIX) 95 12 22 26
PULSE(SOFT)

Ar(MIX)

--- 14 19 28

ST

T (NO TAIL OUT)CO2 Ar/C

O2

109 109 125 125

ST

Tll

C

O2 Ar/C

O2

110 110 126 12

6

0.035 3/64 1/16

GMA

W

Ar 151

75 7

7

5356

PULSE

Ar 152

76 7

8

PULSE O

N P

ULSE Ar 101

102 10

3

STAINLESS

0.030 0.035 0.04

5

GMA

W A

r (MIX)

61 31 41

GMA

W Ar/He/CO2 63

33 43

PULSE Ar/CO2 6

6 36 4

6

PULSE Ar/

O2

62 32 42

PULSE Ar/

He/CO2

---

34 44

STTAr/

He/CO2 109

109 125

ST

Tll

Ar/

He/CO2 110

110 126

METAL CORE

0.045 0.052 1/1

6

GMA

W Ar/C

O2 8

1 83 85

PULSE Ar/CO2 8

2 84 86

WFSAMPS

VOLTS

TRIM

3

21

580

585B

585A

587

585

582

581

FLE

X

SET UP
LED

WELDMO

DE, WIRE SI

ZE,
ERRORCODES, SEVEN
SEGME

NTAND ALP

HA

NUMERIC

DISPLAY

INFRARE

D T

RANS

CEIVE

R

(

WI

RELESS COMMUNICATI

ON)

WELDMO

DE LE

D

ARCCONTR

OL LE

D

SELECT
PUSHBUTTO

N

SELECT PUSHBUTTO

N

ENDOPTIO

NS LE

D

START OPTIO

NS LE

D

16 DETENT
ENCODE

R

541A

542A

500D

540C

CAN

CAN

COM

+40VDC

8

7

6

5

4

3

2

1

SHIELDED

CABLE

6J810
4J810
3J810
2J810

8J810
1J810

5J810

526

548

6J84

6J85

8J84

1J88

518

PUSH-P

ULL

GUN

BRAKE SIG

NAL

(0 V

OLT=MOTOR B

RAKE

0-5V PUSH-PULL

GUN

POTENTI

OMETE

R SIGNAL

REQUIRED

FOR

4 S

TEPMODE

SEE ERRO

R TABLE

IN IM MANUAL

NOR

MAL

SPE

ED

ON D

E

F

.

LO

W SPEE

D

EX

TRA TORQUE

OF

F

D

E

F

.

FEEDSPEED GEAR

8

F

U

N

C

T

I

ON

7

6

5

4

3

2

DI

P SWITCHS1SETT

ING CHART

T

OG

GL

E

N

O

.

1

POL

AR

ITY

NE

G

SP

AR

E

POS

10J86

9J86

8J86

7J86

6J86

5J86

4J86

3J86

2J86

1J86

10P86

9P86

8P86

7P86

6P86

5P86

4P86

3P86

2P86

1P86

(SCHE

MATIC L120

08)

ON

O

FF

S1

SEE DIPSWITCH S1
SET

TINGCHART

(SCHE

MATIC

G3883)

1J811

5J83
5J83

554
640

A

5J88

595

640

SETUP MENU

To

access, pres

s the right and lef

t push but

tons

on t

he MSP

4 pa

nel simult

ane

ousl

y

Setu

p feature

numbe

rs m

ay vary betwee

n s

oft

ware

ve

rsions.

Must

read s

mal

l displ

ay to

fin

d y

our

spec

ific

feature youwant.ThesePnumbe

rs liste

d

ar

e fo

r reference.

SETUP MENU FEATURES

P.0 =

On/

Off enter exit set upmode

P1 =

W

FS Engli

sh/metri

c
P2 = Left display amps/wfs
P4 = Trigger memoryre

call
P5 = Trigger procedu

re

change
P6 = Stall facto

r

P7 = Push pull gun

offset

P8 = New

TIG solenoid fe

ature

P80-89 = Sense

s f

rom stud

s on S256

29-09

P99 = Showtest m

ode 200.201

P10

0 = Viewdiag

nosti

cs

P10

2 =

Fatal log

P10

3 = Viewsoftware

P10

4 =Hardware version

P10

5 =

Welding software

P20

0 =CC te

st 25

-600

P20

1 =

CV te

st 10

-35

P20

2 =CC te

st 10A

P20

3 =CC te

st 355A

P20

4 =CC te

st 455A

P205 =C

C test 550A

P206 =C

V test 10V

to

30 V

P207

= 1/0 test 25-600

P208 =STTtest

170A

P209

= 1curv

e 0-600A
P210 =Step resp background
P211 =V curve 0-70V 10-70V
P212 =OC

V test

P215

= Touc

h sen

se

P255 =Sho

w w

eld file

10J85

7J85

5J85
12J85
11J85

580

A

587

A

585C

582

A
581

A

S3

S2

1J83
2J83
3J83
4J83

D

UAL

PROCEDURE

A
C

PROCEDURE
A =

OPE

N

B =CLOSE

D

1J84
7J84
4J84

2J85
1J85
3J85

532

E

570F

543

A

MOTOR

GEARBOX

TAC

H

3
4
5
6

R
U

B

R
U
B

5VD

C TACH S

UPPLY

TAC

H SIGNAL

TACH COM

W

B

(ACCESSTH

IS

CONNECTOR

BY

REMOVING

TH

E WIREDRIVE

ASSEMBLY)

550
551
553

554

PWMCONTROLLE

D

6.5VDCWHENGAS IS
FLOWING.COIL
MEASU

RES 21 OHMS.

12 VDCC

OIL

L

5

TOROI

D

MOTOR

+

MOTOR

-

GAS SOLENOID+

GAS SOLENOID-

531
537

534

TRIGGE

R

SUPPLY FOR TRIGGER ANDDUAL

D

UAL PROCEDURE

0VDC@

50 IN/MI

N

24VDC@

700

IN/MI

N

6 PINREMOTEFOOT
AMPTROLCONNECTI

ON

(LOWER CASEFRONT)

570

B

532

B

77B

76B

75B

DA

C

B

F

B
A

M

E

F

C

DG

75A

76A

77A

MOTOR -

532

A

570

A

P5

P3

321

8A

321

4A

321

8

321

4

76

75

77

(LOCATED AT

REAR

O

F

FEEDER)

(CAS

E

FRONT)

PUSH-P

ULLGUNWIRE

FEE

D SPEEDCONTR

OL

PUSH-P

ULL

GU

N TRIGGER

AMPHENOL

(LOWER CASEFRONT)

+40

AC

(WIREDRIVE

AREAFRONTTOP)

(WIREDRIVE

FRONTTOP)

PCT AND

RESISTO

RS

PR

OTE

CTED

ON

DAUGHTE

R BOARD

J87NOT

USE

D

CLEANRO

OM

USE

P1

P2

(D

IVI

DER PANELREAR

ACCES

S

DOOR

SI

DE)

532
570D

543

D
E
B

{

SPARE
SP

AR

E

SP

AR

E

SP

AR

E

SP

AR

E

(BEHIND COVER AND
MOTOR

A

REA)

PUSH-P

ULL MOTOR

FLOW ME

TER

(OUTSIDEBAC

K OFCASE)

GOODFO

R Ar, C

O2,CO2/ArBLEN

DS

ADJUST VALVE

BALL

FL

OAT
USE MIDDLE OF
BALL

TO SET

25

TO 35

NOR

MAL

FLOW

RATE

L

6

TOROI

D

AR

C V

OLTAGE

FEE

DBA

CK

6J1

VOLTAGE SENSE

SELECT P.C. BOA

RD

2J2

513

400

2J1

1J1

3J1

4J1

J2

67B

514

N

OTE: WILL WORK

WIT

H LINKNET

POWE

R S

OUR

CE BUTWILL

ONLY SHOW AND

HAVE

L

INK

NET

FEATURES

A
B
C

D
E

541

542

67

67A

540

500

500

B

500C

(SCHE

MATIC S247

79)

67A

(LOCATED AT

REAR OF

FEEDER)

(LOCATED BEHIND WIRE
REE

L

COVER)

1
2
3

4
5
6

7

8

P11

541

A

542

A

540

A

500

A

500C

520

530

7P7

P8

8

7

P10

500D

1
2

R3 R2

530

A

8P7

540

E

S5 HEATER

540

B

540D

DIP S

WITCH S9

4
3
5
7
6

W

B

RED/G

REE

N

STA

TUS LED

1
2

15J85
16J85

1B

1W

8

1

4

3

579

A

586

A

535

A

2

578

578

A

579C

579

B

R1

590

B

W

B

W

1J88

518C

518D

6

518

B

8J84

518

MOTORFRA

ME

IS H

OT TO

ELECTRODE

TYP: I

PM

50 - 800/IPM NORMAL SP

EED

30-400/IPM EXTRA TORQUE

570G

P4

P6

1
2
3

532

570D

543

532C

L2TOROID

5
4

10

6

7

321

4A

321

8A

L1TOROID

9
8

532

A

570

A

532D

570C

570

E

543

A

321

4

321

8

77A

75A

76A

76
75

77

P6

L1TOROID

J1

(SCHE

MATIC: L11

756)

MEMORY P.C. BOARD

MSP4 P

.C. BOARD

LIG

HT LE

D S

WIT

CH

(

USE

D INDA

RK A

REAS

)

S4

P89

L4TOROID

540

B

S1 POWE

R

(LEFTLOWER CASEFRONT)

40 VD

C

C

OMMUNI

CATI

ON

{

{

5 PIN ARCLI

NK

CONNECTOR T

O

POWER S

OUR

CE

HELPS KEEP MOISTU

RE

OFFOFWI

RE

(ABOV

E WIRE

FEED

MO

TOR)

(BEHIND

WIRE

REELCOVER)

P9

40 OHMS

10 WAT

TS

AR

CLINKOPTIONUSE

J86 SPI USE

WI

RE

MOT

OR

USE

SERIAL NUMBER A

ND

CO

DENUMBER LOCATE

D

BELO

W WIREFEE

D

D

RIVE ROLL A

REA

SEE IM MAN

UAL

FORMO

RE

DETAILS

1

2

475 OH

MS

(BAC

K OFWIREDRIV

E

PANE

L - S

OLDER

ON

B

RACKET)

P7

OPEN=

4 S

TEP

: CL

OSED=

2 S

TEP

(ABOV

E WIRE

FEED

MO

TOR TOP)

(LOCATED

ONB

ACK

SIDE OFBOARD)

(ON PULLDOWN DOOR FRONT)

(BEHIND

PULL

DOWN DOOR FRONT)

(BEHIND

F

RONTPULLDOWN DOOR)

(TO

P

FRONT)

(BEHIND DISPLAYBOARD)

(TOPFRONT)

(BAS

E

CONTROL

BD.

A

REA)

(BEHIND

WIRE

FEED

MO

TOR)

400H

ADAPTER

L

7

TOROI

D

L3TOROID

400

E

CON

NE

CTS TO S4

(LEFTLOWER CASEFRONT)

(BEHIND CASE
FRONT)

CAPA

CIT

OR

400F

400G

400D

400C

400

B

(CONTROLBOXTOP)

(CONTROL
BO

X

TOP)

(BEHIND CASEFRONT)

(CONTROL
BO

X

BOTTO

M)

G-3
SCHEMATIC - COMPLETE MACHINE - CODE 11313 (G5638)

ELECTRICAL DIAGRAMS

G-3

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

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

POWER FEED® 25M

G-4
SCHEMATIC - 42 VAC & ARCLINK FEEDER PC BOARD #1 (G3883-2)

ELECTRICAL DIAGRAMS

G-4

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

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

POWER FEED® 25M