Lincoln Electric Welder SVM185 A User Manual
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SVM185-A  
July, 2008  
POWER FEED® 25M  
For use with machine code numbers 11313  
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 READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before  
you act and be careful.  
SERVICE MANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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SAFETY  
ELECTRIC SHOCK can kill.  
ARC RAYS can burn.  
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.  
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.  
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.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.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.  
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  
3.g. Never dip the electrode in water for cooling.  
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.  
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.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.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.  
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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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
the welding sparks from starting a fire.  
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.  
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.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
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.  
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.  
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.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
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.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
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.  
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.h. Also see item 1.c.  
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.  
Jan ‘07  
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SAFETY  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
PRÉCAUTIONS DE SÛRETÉ  
prévenir tout risque d’incendie dû aux étincelles.  
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 suiv-  
antes:  
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.  
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 met-  
allique 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 defonc-  
tionnement.  
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.  
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.  
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.  
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.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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:  
a. Utiliser un bon masque avec un verre filtrant approprié ainsi  
qu’un verre blanc afin de se protéger les yeux du rayon-  
nement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
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.  
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.  
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 debranch-  
er à l’interrupteur à la boite de fusibles.  
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, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur place.  
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.  
Mar ‘93  
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v
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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 com-  
plete 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 equip-  
ment.  
Assessment of Area  
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-  
lems in the surrounding area. The following shall be taken into account:  
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the  
welding equipment;  
b) radio and television transmitters and receivers;  
c) computer and other control equipment;  
d) safety critical equipment, e.g., guarding of industrial equipment;  
e) the health of the people around, e.g., the use of pacemakers and hearing aids;  
f) equipment used for calibration or measurement  
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being  
used in the environment is compatible. This may require additional protection measures;  
h) the time of day that welding or other activities are to be carried out.  
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 recommenda-  
tions. 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 equip-  
ment 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 con-  
nection 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.  
_________________________  
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)  
product standard for arc welding equipment.”  
L10093  
3-1-96H  
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I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -  
X  
RETURN TO MAIN MENU  
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  
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A-1  
A-1  
TABLE OF CONTENTS - INSTALLATION SECTION  
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  
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  
POWER FEED® 25M  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS – POWER FEED® 25M K2536-1  
INPUT VOLTAGE and CURRENT  
INPUT VOLTAGE ± 10% INPUT AMPERES  
40 VDC  
4A  
RATED OUTPUT @ 104°F (40°C)  
DUTY CYCLE INPUT AMPERES  
60% rating  
500  
100% rating  
400  
GEARING - WIRE FEED SPEED RANGE-WIRE SIZE  
GMAW  
FCAW  
GEARING  
WIRE SIZES  
WFS RANGE  
WFS RANGE  
WIRE SIZES  
Normal Speed  
(factory setting)  
.023 – 1/16"  
(0.6 – 1.6mm)  
50 – 800 ipm  
(2.5 – 20.3m/min)  
50 – 800 ipm  
.030 – 5/64"  
(2.5 – 20.3m/min) (0.8 – 2.0mm)  
Extra torque  
.023 – 1/16"  
30 – 400 ipm  
30 – 400 ipm  
.030 – 3/32"  
(0.6 – 1.6mm)  
(1.3 – 10.4m/min)  
(1.3 – 10.4m/min) (0.8 – 2.4mm)  
PHYSICAL DIMENSIONS  
HEIGHT  
WIDTH  
DEPTH  
WEIGHT  
14.5 Inches  
(368 mm)  
8.5 Inches  
( 216 mm)  
23.5 Inches  
(597 mm)  
35 lbs  
(15.9 kg)  
Handle folded down  
Memory Panel Closed  
TEMPERATURE RANGE  
OPERATION:  
STORAGE:  
-40°F to 122°F (-40°C to 50°C)  
-40°F to 185°F (-40°C to 85°C)  
POWER FEED® 25M  
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A-3  
A-3  
INSTALLATION  
SAFETY PRECAUTIONS  
HIGH FREQUENCY PROTECTION  
CAUTION  
WARNING  
Locate the POWER FEED® 25M away from radio con-  
trolled machinery. The normal operation of the  
POWER FEED® 25M may adversely affect the opera-  
tion of RF controlled equipment, which may result in  
bodily injury or damage to the equipment.  
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 mainte-  
nance 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.  
Do not submerge the POWER FEED® 25M.  
The POWER FEED® 25M is rated IP23 and is suitable  
for outdoor use.  
The handle of the POWER FEED® 25M is intended  
for moving the wire feeder about the work place only.  
When suspending a wire feeder, insulate the hanging  
device from the wire feeder enclosure.  
POWER FEED® 25M  
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A-4  
A-4  
INSTALLATION  
DIGITAL CONTROL CABLE, K1543-XX  
(See Figure A.3)  
CONTROL CABLE CONNECTION:  
ArcLink/LincNet control cables are special high quality  
cables for digital communication. The cables are cop-  
per 5 conductor cable in a SO-type rubber jacket.  
There is one 20 gauge twisted pair for network com-  
munications. This pair has an impedance of approxi-  
mately 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 net-  
work. The fifth wire is 18 gauge and is used as an elec-  
trode sense lead.  
Digital Control Cable: Figure A.3  
Power Source  
ireFeeder  
W
E
E
A
D
D
A
B
B
C
C
Power Source  
Function  
Wire Feeder  
Pin  
A
Pin  
A
Function  
Digital I/O  
Digital I/O  
Digital I/O  
Use of non-standard cables may lead to system shut-  
downs, poor arc starting and wire feeding problems.  
B
Digital I/O  
B
C
D
"67" voltage sense  
40 VDC  
C
D
"67" voltage sense  
40 VDC  
The control cables connect the power source to the  
wire feeder, and the wire feeder to other wire feeders.  
E
Common  
E
Common  
Control cables may be connected end to end to extend  
their length. Use a maximum of 200 ft. (61.0m) of con-  
trol cable between components.  
CABLE CONNECTIONS  
There are three circular connectors on the front of the  
POWER FEED® 25M.  
FIGURE A.1  
Function  
PIN  
Wiring  
A
B
C
D
E
Trigger  
Not used  
Trigger, Common  
Dual Procedure Selection  
Dual, Common  
B
C
D
5 pin trigger con-  
nector for push-  
only guns.  
A
E
A
B
C
D
E
F
77 Remote potentiometer, 5K  
75 Remote potentiometer, common  
76 Remote potentiometer, wiper  
Switch, On/Off  
C
6 pin connector for  
remote control or  
foot/hand amptrol.  
D
B
E
A
Switch, common  
F
Not used  
A
B
C
D
E
F
Motor -  
Motor +  
C
7 pin connector for  
push-pull guns  
77 Remote potentiometer, 5K  
76 Remote potentiometer, wiper  
Switch, On/Off  
D
E
B
G
A
F
Switch, common  
G
75 Remote potentiometer, common  
There is one circular connector on the rear of the POWER FEED® 25M.  
FIGURE A.2  
Function  
PIN  
A
B
C
D
Wiring  
ArcLink  
ArcLink  
B
C
D
5 pin ArcLink con-  
nector.  
67 Electrode Voltage Sense  
40VDC  
A
E
E
40VDC, Common  
POWER FEED® 25M  
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A-5  
A-5  
INSTALLATION  
COAXIAL WELD CABLE  
WELD CABLE SIZE  
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.  
Table A.1 located below are copper cable sizes recom-  
mended for different currents and duty cycles. Lengths  
stipulated are the distance from the welder to work and  
back to the welder again. Cable sizes are increased for  
greater lengths primarily for the purpose of minimizing  
cable drop.  
Coaxial weld 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  
Work  
FIGURE A.5  
Electrode  
Work  
Power Source  
Work  
Electrode  
Coaxial Weld Cable  
Electrode  
Wire Feeder  
Work  
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 PERCENT  
0 to 50Ft.  
(0 to15M)  
50 to 100Ft.  
(15 to 30M)  
100 to 150 Ft.  
(30 to 46M)  
150 to 200 Ft.  
(46 to 61M)  
200 to 250 Ft.  
(61 to 76M)  
DUTY  
CYCLE  
2
2
3
3
3
2
1
1
1
2/0  
1/0  
2/0  
3/0  
2/0  
2
2
2
2
2
1
1
1
1
2/0  
2/0  
2/0  
3/0  
3/0  
200  
200  
225  
225  
250  
250  
250  
250  
300  
325  
350  
400  
400  
500  
60  
100  
20  
40 & 30  
30  
40  
60  
100  
60  
100  
60  
2
2
1
1
1
1
1
1
1
1
1/0  
2/0  
2/0  
3/0  
3/0  
3/0  
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  
4 or 5  
3
3
2
1
1
1
2/0  
1/0  
2/0  
3/0  
2/0  
60  
100  
60  
** 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).  
POWER FEED® 25M  
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A-6  
A-6  
INSTALLATION  
SHIELDING GAS CONNECTION  
ELECTRODE POLARITY  
WARNING  
The wire feeder is factory set for Electrode Positive  
welding.  
Most GMAW welding procedures use  
CYLINDER may explode if  
damaged.  
Electrode Positive welding. Most GTAW and some  
Innershield procedures use Electrode Negative weld-  
ing.  
• Keep cylinder upright and  
chained to support.  
CAUTION  
• 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.  
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.  
• BUILD UP OF SHIELDING GAS MAY  
HARM HEALTH OR KILL.  
• Shut off shielding gas supply when not in  
use.  
WARNING  
ELECTRIC SHOCK CAN KILL.  
• 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:  
• Turn the input power OFF at the weld-  
ing power source before changing  
electrode polarity.  
• Do not touch electrically live parts.  
• Only qualified personnel should per-  
form maintenance work.  
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 ATTACHTHE 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.  
Electrode Polarity  
Positive  
Negative  
DIP switch #7 setting  
OFF (Factory setting)  
ON  
Tools required:  
• 5/16" nut driver  
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  
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.  
connecting to 100% CO cylinder, insert regulator  
2
adapter between regulator and cylinder valve. If  
adapter is equipped with a plastic washer, be sure it is  
seated for connection to the CO cylinder.  
2
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.  
5. Install the cover and secure with the screws.  
6. Before opening the cylinder valve, turn the regulator  
adjusting knob counterclockwise until the adjusting  
spring pressure is released.  
7. Standing to one side, open the cylinder valve slowly a  
fraction of a turn. When the cylinder pressure gage  
stops moving, open the valve fully.  
8. The flow regulator is adjustable. Adjust it to the flow rate  
recommended for the procedure and process being  
used before making a weld.  
POWER FEED® 25M  
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A-7  
A-7  
INSTALLATION  
7. Remove the busbar by unscrewing the bolt using a 3/4"  
open end wrench.  
CHANGING THE DRIVE MOTOR GEAR RATIO  
WARNING  
8. With a 1/4" hex key wrench, loosen the socket head cap  
screw securing the gun bushing. Remove the gun bushing  
from the wire drive.  
• 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.  
9. With a 5/16" nut driver remove the five screws securing the  
wire drive panel. Lift out the wire drive panel and discon-  
nect the molex connections.  
10. Using a 5/16" nut drive, remove the four screws securing  
the cover.  
• When feeding with the gun trigger, the electrode  
and wire drive mechanism are "hot" to work and  
ground and could remain energized several sec-  
onds after the gun trigger is released.  
• Only qualified personnel should perform this  
operation.  
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.  
Extra  
Torque  
Gearing  
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.  
Normal  
Speed  
Gearing  
WFS  
800  
400  
15. Move DIP switch #8 on the Feed head board to the  
appropriate position.  
Gear Select  
Normal Speed  
Extra Torque  
DIP Switch #8 Setting  
ON  
OFF  
Range  
50 – 800 ipm  
30 – 400 ipm  
Extra Torque  
Gearing  
Normal Speed  
Gearing  
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.  
Tools required:  
• 1/4" hex key wrench  
• 3/4" open end wrench  
• 9/16" socket and ratchet wrench  
• 7/16" nut driver  
17. Reassemble the busbar and tighten the mounting hard-  
ware with a 3/4" open end wrench.  
• 5/16" nut driver  
• Phillips screw driver  
18. Place the new gear on the motor shaft. Secure the gear  
to the motor shaft with the collar, washer and screw.  
1. Remove the spool of electrode from the wire feeder.  
19. Reassemble the lower drive roll hub and lower drive roll  
hub retainer.  
2. Loosen the thumb screw at the wire drive and remove the  
welding gun.  
20. Reassemble the gear cover.  
3. Remove the outer wire guide, drive rolls and inner wire  
guide.  
21. Reassemble the inner wire guide, drive rolls and outer  
wire guide.  
4. Use a 7/16" nut driver to remove the gear cover.  
22. Place the welding gun into the gun bushing and secure  
with the thumb screw.  
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.  
POWER FEED® 25M  
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A-8  
A-8  
INSTALLATION  
WIRE DRIVE CONFIGURATION  
(See Figure A-6)  
8. Connect the shielding gas hose to the new gun  
bushing, if required.  
Changing the Gun Receiver Bushing  
9. Rotate the gun bushing until the thumb screw hole  
aligns with the thumb screw hole in the feed plate.  
Slide the gun receiver bushing into the wire drive  
and verify the thumb screw holes are aligned.  
10. Tighten the socket head cap screw.  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the  
11. Insert the welding gun into the gun bushing and  
tighten the thumb screw.  
welding power source before instal-  
lation or changing drive rolls and/or  
guides.  
PROCEDURE TO INSTALL DRIVE ROLLS  
AND WIRE GUIDES  
• Do not touch electrically live parts.  
• When inching with the gun trigger, electrode and  
drive mechanism are "hot" to work and ground  
and could remain energized several seconds  
after the gun trigger is released.  
• Only qualified personnel should perform mainte-  
nance work.  
WARNING  
• Turn the input power OFF at the weld-  
ing power source before installation  
or changing drive rolls and/or guides.  
• Do not touch electrically live parts.  
------------------------------------------------------------------------  
Tools required:  
• 1/4" hex key wrench.  
Note: Some gun bushings do not require the use of  
the thumb screw.  
• 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 mainte-  
nance 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.  
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.  
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.  
6. Remove the outer wire guide, and push the gun  
bushing out of the wire drive. Because of the preci-  
sion fit, light tapping may be required to remove the  
gun bushing.  
7. Disconnect the shielding gas hose from the gun  
bushing, if required.  
FIGURE A-6  
THUMB SCREW  
GUN RECEIVER BUSHING  
OUTER WIRE GUIDE  
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  
CONNECTOR BLOCK  
SOCKET HEAD  
CAP SCREW  
LOOSEN  
TIGHTEN  
POWER FEED® 25M  
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A-9  
A-9  
INSTALLATION  
REMOTE SENSE LEAD SPECIFICATIONS  
LOADING SPOOLS OF WIRE  
WARNING  
Welding with Multiple Arcs:  
( See Figure A.7)  
• Keep hands, hair, clothing and tools  
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  
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.  
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 fre-  
quency will be the same, helping to stabilize the arcs.  
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 spin-  
dle shows the orientation of the brake tab. Be cer-  
tain 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  
CONNECTALL SENSE  
LEADSAT THE END  
OF THE WELD  
DIRECTION  
OF TRAVEL  
CONNECT ALL  
WORK LEADSAT  
THE BEGINNING  
THE WELD  
OF  
POWER FEED® 25M  
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A-10  
A-10  
INSTALLATION  
TYPICAL SYSTEM CONFIGURATIONS  
• Brass-to-brass connections between the electrode  
connection and the gun minimize voltage drop varia-  
tions, resulting in consistent arc performance all day,  
every day.  
Standard Features  
Arc Performance  
• Push-Pull ready for welding aluminum with Pulse  
and Pulse-on-Pulse™ waveforms.  
• Powerful, quiet motor with integrated tachometer for  
accurate WFS regulation.  
• STT™ capable when used with STT™ equipped  
Power Waves.  
Extras:  
• Flowmeter with gas control valve  
• Waveform Control Technology™ for welds with good  
appearance and low spatter, even when welding  
nickel alloys.  
• Push-Pull ready.  
• Remote control / Foot amptrol ready.  
User Interface  
• 6 memories for easily selecting procedures.  
• Internal heater for keeping condensation off of the  
spool of wire.  
• MSP4 panel located behind the memory panel door  
for protection.  
• Internal lights for illuminating the wire drive compart-  
ment.  
• Full sequence control for tailoring the weld from start  
to end.  
Options  
• Water cooling kit for use with water cooled guns.  
• All welding controls located at the wire feeder, includ-  
ing process selection.  
Wire Drive  
Patented 2 roll drive system. MAXTRAC™ technology  
delivers great feeding because:  
• Patent pending drive rolls improve traction on solid  
wire by up to 20%.  
• The precision machined, rigid aluminum alloy frame  
results in maximum drive roll clamping pressure.  
• Patented split wire guides fully support the wire and  
virtually eliminate birdnesting.  
• No tools required to change the drive rolls and wire  
guides.  
• Patented dual spring pressure arms have sensitivity  
for feeding soft wires without crushing them, and  
have plenty of compression force for feeding solid or  
stiff wires.  
• All gear driven rolls for more feeding force.  
• Changeable gun bushings easily accept guns from  
other manufacturers.  
POWER FEED® 25M  
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B-1  
B-1  
TABLE OF CONTENTS - OPERATION SECTION  
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  
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  
POWER FEED® 25M  
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B-2  
B-2  
OPERATION  
GRAPHIC SYMBOLS THAT APPEAR ON  
SAFETY PRECAUTIONS  
READ AND UNDERSTAND ENTIRE SECTION  
BEFORE OPERATING MACHINE.  
THIS MACHINE OR IN THIS MANUAL  
INPUT POWER  
WARNING  
• ELECTRIC SHOCK CAN KILL.  
Unless using COLD FEED fea-  
ture, when feeding with gun trig-  
ger, the electrode and drive  
mechanism are always electri-  
cally energized and could  
remain energized several sec-  
onds 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.  
ON  
OFF  
WIRE FEEDER  
POSITIVE OUTPUT  
NEGATIVE OUTPUT  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
INPUT POWER  
---------------------------------------------------------------------  
• WELDING SPARKS can cause  
fire or explosion.  
DIRECT CURRENT  
• Keep flammable material away.  
OPEN CIRCUIT  
VOLTAGE  
U
0
----------------------------------------------------------------------  
ARC RAYS can burn.  
• Wear eye, ear and body protec-  
tion.  
U
U
I
INPUT VOLTAGE  
OUTPUT VOLTAGE  
INPUT CURRENT  
1
2
---------------------------------------------------------------------  
SEE ADDITIONAL WARNING INFORMATION  
UNDER ARC WELDING SAFETY PRECAUTIONS  
AND IN THE FRONT OF THIS OPERATING MANU-  
AL.  
----------------------------------------------------------------------  
1
I
OUTPUT CURRENT  
2
PROTECTIVE  
GROUND  
WARNING OR  
CAUTION  
POWER FEED® 25M  
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B-3  
B-3  
OPERATION  
GENERAL DESCRIPTION  
DEFINITION OF WELDING TERMS  
General Physical Description  
NON-SYNERGIC WELDING MODES  
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 situa-  
tions. 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.  
• 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  
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.  
CC  
• Constant Current  
CV  
• Constant Voltage  
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 suppres-  
sion components protect the POWER FEED® 25M  
from stray signals and keep the feeder from interfering  
with other digital equipment.  
GMAW  
• Gas Metal Arc welding  
GMAW-P  
• Gas Metal Arc welding-(Pulse Arc)  
GMAW-STT  
General Functional Description  
• Gas Metal Arc welding-(Surface Tension Transfer)  
The POWER FEED® 25M is best suited for applica-  
tions 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.  
SMAW  
• Shielded Metal Arc welding  
FCAW  
• Flux Core Arc Welding  
CAC  
DUTY CYCLE  
• Carbon Arc Cutting  
CAG  
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.  
• Carbon Arc Gouging  
For example, when welding at 500 amps, the POWER  
FEED® 25M may run 6 minutes and must idle for 4  
minutes.  
POWER FEED® 25M  
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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 sys-  
tems.  
• 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 compati-  
ble) back end.  
• No more than 2 wire feeders may be connected to  
one ArcLink® power source at a time.  
RECOMMENDED POWER SOURCES  
• Power Wave® 355M  
• Power Wave® 455M  
• Power Wave® 455M/STT  
• Power Wave® 655/R  
POWER FEED® 25M  
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B-5  
B-5  
OPERATION  
Connector for a remote control.  
CASE FRONT CONTROLS (See Figure B.1)  
14. 7- pin connector  
1. Left DISPLAY window  
Connector for a push-pull gun.  
15. Cover  
Shows WIRE FEED SPEED or AMPERAGE.  
Covers location for optional water cooling line.  
16. Set-Up  
2. Left KNOB  
Adjusts values in left display.  
Lights when feeder is set-up.  
17. Memory Panel Door  
3. Right Display window  
(See Memory Panel Operations in this Section)  
Shows VOLTAGE or TRIM.  
4. Right Knob  
FIGURE B.1  
Adjusts values in the right display.  
1
2
5
6
8
5. Status LED  
Illuminates a steady green when communicating to  
the power source properly.  
3
4
6. IR port  
Used to transfer information to palm computers, etc.  
7. MSP4 display window  
7
Shows detailed welding and diagnostic information.  
16  
9
8. Left Button  
Changes the MSP4 display to show the Weld Mode  
or Arc Control.  
10  
11  
12  
13  
9. Right Button  
Changes the MSP4 display to show Start Options or  
End Options.  
14  
15  
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  
17  
Fold Out  
Memory Panel  
POWER FEED® 25M  
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B-6  
B-6  
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 mainte-  
nance work.  
------------------------------------------------------------------------  
STATUS LED  
(See Table B.1)  
STAT US  
The status LED indicates system status. Normal oper-  
ation 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  
LED condition  
Definition  
Steady green  
System okay. The power source and wire feeder are communicating normally.  
Blinking green.  
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 set-  
ting on the wire feeders.  
Blinking green, fast  
Blinking green fol-  
lowed by blinking  
red.  
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.  
POWER FEED® 25M  
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B-7  
B-7  
OPERATION  
MAKING A WELD WITH WAVEFORM  
TECHNOLOGY POWER SOURCES  
FIGURE B.2 - SMAW (STICK) WELDING  
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WARNING  
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t
6
The serviceability of a product or structure utilizing  
the welding programs is and must be the sole respon-  
sibility 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 pro-  
cedure, plate chemistry and temperature, weldment  
design, fabrication methods and service require-  
ments. 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.  
5
5
3
E
V
A
W
R
E
W
O
P
A
R
N
I
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G
R
E
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O
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E
P
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N
4
3
----------------------------------------------------------------------------  
The steps for operating the Power Wave® will vary  
depending upon the user interface of the welding sys-  
tem. 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, diam-  
eter, shielding gas and process (GMAW, GMAW-P,  
GMAW-STT™, etc.)  
5
2
Second, find the program in the welding software that  
best matches the desired welding process. The stan-  
dard 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 repre-  
sentative.  
K2368-1  
K2202-1  
K2203-1  
Power Wave® 355M  
Power Wave® 455M  
Power Wave® 455M/STT™  
1
K2230-1  
K2234-1  
K2536-1  
POWER FEED® 10M, Bench  
Model  
POWER FEED® 10M Dual, Bench  
Model  
All adjustments are made on the user interface.  
Because of the different configuration options your sys-  
tem may not have all of the following adjustments.  
Regardless of availability, all controls are described  
below.  
2
POWER FEED® 25M  
3
4
K1543-xx  
Digital Control Cable  
K1842-xx  
K910-xx  
Weld Power Cable, Lug to Lug  
Ground Clamp  
SMAW (STICK) WELDING  
SMAW is most often used for outdoor construction,  
pipe welding and general repairs. The wire feeder con-  
trols Amperage, Output Control and Arc Force during  
SMAW welding.  
5
6
K909-xx  
K2176-1  
Electrode Holder  
Twist-Mate™ to Lug Cable  
Adapter  
During SMAW welding, the wire feeder sets the weld  
parameters and the wire drive remains idle.  
The “Volts”-”Trim” control is used to turn the power  
Source Output ON or OFF. (See Figure B.3)  
SMAW Welding (See Figure B.2)  
POWER FEED® 25M  
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B-8  
B-8  
OPERATION  
SMAW (Stick) Welding Display  
FIGURE B.3  
0
194  
n
WFS  
AMPS  
VOLTS  
TRIM  
LESS  
AMPS  
MORE  
AMPS  
OUTPUT  
ON  
OUTPUT  
OFF  
MSP4 OPERATION  
START OPTIONS  
FUNCTION  
START TIME:  
If no remote control is installed,  
this control sets the time for  
the weld output to ramp up or  
down from a preset Start cur-  
rent to the preset Weld current.  
Use the WFS/AMP knob to  
adjust Start current while the  
Start Options LED is displayed.  
0 to 10 seconds  
CC STICK MODES  
PROCESS  
MODE  
Stick Soft(7018)  
Stick Crisp(6010)  
1
2
WAVEFORM CONTROL TECHNOLOGY  
Stick  
I
I
IR PORT  
SETUP  
CC Stick Soft  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
SET  
ARC CONTROL  
DESCRIPTION  
ARC FORCE  
(Soft)-10.0 to  
(Crisp)+10.0  
END OPTIONS  
No arc ending options are active for  
Arc Force adjusts the short cir-  
cuit current for a soft arc, or for  
a forceful, driving arc. It helps  
to prevent sticking and shorting  
(Stick) welding modes.  
SMAW  
par  
electrodes,  
-
of organic coated  
ticularity globular transfer types  
such as stainless and low  
hydrogen. Arc Force is espe-  
cially effective for root pass on  
pipe with stainless electrode  
and helps to minimize spatter  
for certain electrodes and pro-  
cedure as with low hydrogen,  
etc.  
POWER FEED® 25M  
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B-9  
B-9  
Three non-synergic welding modes are available.  
OPERATION  
NON-SYNERGIC GMAW AND FCAW  
WELDING  
(See Figure B.4)  
Description  
Mode  
5
Used for:  
GMAW, Standard CV  
Best for traditional  
MIG welding.  
GMAW, Power  
FCAW  
40  
Specialized mode  
for short arc weld-  
ing and CV alu-  
minum welding.  
Best for cored  
electrodes, such  
as Innershield™  
and Outershield™.  
Non-synergic GMAW and FCAW welding mimics the  
welding controls of traditional welding power sources.  
Voltage and WFS are set as independent variables.  
6
FIGURE B.4  
6
3
4
1
2
5
K2368-1  
Power Wave 355M  
1
K2202-1  
Power Wave 455M  
K2203-1  
K2230-1  
K2234-1  
K2536-1  
Power Wave 455M/STT  
Power Feed 10M, Bench Model  
Power Feed 10M Dual, Bench Model  
Power Feed 25M  
2
KP1696-xx,  
KP1697-xx  
KP1505-xx,  
KP1507-xx  
K1543-xx  
K1842-xx  
K910-xx  
Drive Roll Kit, 2 Roll Feeder  
Drive Roll Kit, 4 Roll Feeder  
3
4
Digital Control Cable  
Weld Power Cable, Lug to Lug  
Ground Clamp  
5
6
See Magnum MIG gun  
Literature  
Deluxe Regulator for Mixed  
K586-1  
Shielding Gases  
Shielding Gas Hose  
POWER FEED® 25M  
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B-10  
B-10  
OPERATION  
Non-Synergic GMAW and FCAW Welding Display  
Modes 5 and 6:  
Mode 40:  
250  
54  
TRIM  
300  
25.3  
TRIM  
WFS  
AMPS  
VOLTS  
WFS  
AMPS  
VOLTS  
Less  
WFS  
More  
WFS  
Shorter  
Arc  
Longer  
Arc  
Less  
WFS  
More  
WFS  
Less  
Volts  
More  
Volts  
START OPTIONS  
MSP4 OPERATION  
EFFECT / RANGE  
DESCRIPTION  
Preflow Time  
Adjuststhetime  
shieldinggas  
that  
0 - 10 seconds  
pulled  
after the trigger is  
prior to feeding wire.  
flows  
and  
Run-In WFS:  
Run-In sets the wire feed  
Off, 50 to150 in/min. speed from the time the trigger  
is pulled until an arc is estab-  
lished.  
Start Procedure  
0 - 10 seconds  
The Start Procedure controls  
the WFS and Volts for a speci-  
fied 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.  
WELD MODE  
PROCESS  
WELD MODE  
GMAW, STANDARD CV  
GMAW, POWER MODE  
FCAW, STANDARD CV  
5
40  
6
WAVEFORM CONTROL TECHNOLOGY  
5
IR PORT  
SETUP  
STD CV MIG  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
SET  
END OPTIONS  
ARC CONTROL  
EFFECT / RANGE  
DESCRIPTION  
EFFECT / RANGE  
PINCH  
(Soft)-10.0 to  
(Crisp)+10.0  
DESCRIPTION  
Pinch controls the arc characte-  
-ristics when short-arc welding.  
Postflow Time  
0 to 10 seconds  
Adjusts the time that shielding  
gas flows after the welding out-  
put turns off.  
Crater Procedure  
Crater Procedure controls the  
0 TO 10.0 SECONDS 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.  
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.  
POWER FEED® 25M  
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B-11  
B-11  
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  
6
3
4
1
2
5
K2368-1  
K2202-1  
K2203-1  
Power Wave® 355M  
Power Wave® 455M  
Power Wave® 455M/STT  
1
2
K2230-1  
K2234-1  
K2536-1  
KP1696-xx,  
KP1697-xx  
KP1505-xx,  
KP1507-xx  
K1543-xx  
K1842-xx  
K910-xx  
Power Feed® 10M, Bench Model  
Power Feed® 10M Dual, Bench Model  
Power Feed® 25M  
Drive Roll Kit, 2 Roll Feeder  
Drive Roll Kit, 4 Roll Feeder  
3
4
Digital Control Cable  
Weld Power Cable, Lug to Lug  
Ground Clamp  
5
6
See Magnum MIG gun  
Literature  
Deluxe Regulator for Mixed  
K586-1  
Shielding Gases  
Shielding Gas Hose  
POWER FEED® 25M  
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B-12  
B-12  
OPERATION  
SYNERGIC CV VOLTAGE DISPLAY  
GMAW (MIG) Synergic Welding 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.  
Synergic CV programs feature an ideal voltage best  
suited for most procedures. Use this voltage as a start-  
ing point and adjust if needed for personal prefer-  
ences.  
• Preset voltage above ideal  
voltage. (upper bar displayed)  
220  
26.4  
TRIM  
WFS  
AMPS  
VOLTS  
• Preset voltage at ideal  
voltage. (no bar displayed)  
• Preset voltage below ideal  
voltage. (lower bar displayed)  
Less  
Deposition  
More  
Deposition  
Shorter  
Arc  
Longer  
Arc  
MSP4 OPERATION  
WELD MODE  
ELECTRODE AND GAS  
WIRE SIZE  
0.030 0.035 0.045 0.052  
START OPTIONS  
Steel  
Steel  
Stainless  
CO2  
---  
94  
61  
63  
---  
---  
10  
11  
31  
33  
148  
151  
20  
21  
41  
43  
71  
75  
24  
25  
---  
---  
---  
---  
EFFECT / RANGE  
DESCRIPTION  
Ar(Mix)  
Ar(Mix)  
Ar/He/CO2  
Ar  
Preflow Time  
thatshielding  
Adjusts thetime  
Stainless  
Aluminum 4043  
Aluminum 5356  
0 - 10 seconds  
gas  
flows after the  
is  
trigger  
prior to feeding.  
pulled and  
Run-In sets the wire feed  
Ar  
Run-in WFS:  
Off, 50 to150 in/min. speed from the time the trigger  
is pulled until an arc is estab-  
lished.  
Start Procedure  
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.  
WAVEFORM CONTROL TECHNOLOGY  
STEEL  
.035"  
IR PORT  
10  
SETUP  
CV CO2  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
SET  
END OPTIONS  
EFFECT / RANGE  
ARC CONTROL  
DESCRIPTION  
EFFECT / RANGE  
PINCH EFFECT  
(-10.0 to +10.0)  
DESCRIPTION  
Pinch controls the arc characte-  
-ristics when short-arc welding.  
Postflow Time  
0 to 10 seconds  
Adjusts the time that shielding  
gas flows after the welding out-  
put turns off.  
-
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 Procedure  
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.  
POWER FEED® 25M  
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B-13  
B-13  
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 applica-  
tions. 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  
Trim 1.50  
Arc Length Long  
Trim 1.00  
Arc Length Medium  
Trim .50  
Arc Length Short  
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 increas-  
ing the background current, for a soft arc good for out-of-position welding.  
FIGURE B.7  
Arc Control +10.0  
High Frequency, Focused  
Arc Control OFF  
Medium Frequency and Width  
Arc Control -10.0  
Low Frequency, Wide  
POWER FEED® 25M  
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B-14  
B-14  
OPERATION  
STAINLESS STEEL GMAW (MIG)WELDING  
FIGURE B.8  
6
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5
5
3
E
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1
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4
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K2368-1  
K2202-1  
Power Wave® 355M  
Power Wave® 455M  
1
2
K2203-1  
K2230-1  
K2234-1  
K2536-1  
KP1696-xx,  
KP1697-xx  
KP1505-xx,  
KP1507-xx  
K1543-xx  
Power Wave® 455M/STT  
POWER FEED® 10M, Bench Model  
POWER FEED® 10M Dual, Bench Model  
POWER FEED® 25M  
Drive Roll Kit, 2 Roll Feeder  
Drive Roll Kit, 4 Roll Feeder  
3
4
Digital Control Cable  
Coaxial Weld Power Cable, Lug to Lug  
Ground Clamp  
K1796-xx, K2593-xx  
K910-xx  
5
6
See Magnum  
Literature  
MIG gun  
Deluxe Regulator for Mixed  
Shielding Gases  
K586-1  
Shielding Gas Hose  
POWER FEED® 25M  
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B-15  
B-15  
OPERATION  
Steel and Stainless GMAW-P (Pulsed MIg)Display  
220  
1.06  
TRIM  
WFS  
AMPS  
VOLTS  
Less  
Deposition  
More  
Deposition  
Shorter  
Arc  
Longer  
Arc  
MSP4 OPERATION  
WELD MODE  
START OPTIONS  
DESCRIPTION  
WIRE SIZE  
0.030 0.035 0.045 0.052  
GAS  
ELECTRODE AND  
PREFLOW TIME  
0 - 10 seconds  
Steel(Crisp)  
95  
---  
12  
14  
36  
32  
34  
22  
19  
46  
42  
44  
201  
28  
---  
---  
---  
Ar(Mix)  
Ar(Mix)  
Ar/ CO2  
Ar/ CO2  
Ar/He/CO2  
Adjusts the time that shielding  
Steel(Soft)  
Stainless  
gas  
pulled  
flows after the trigger  
and  
is  
prior to feeding wire.  
66  
62  
---  
Stainless  
Stainless  
RUN-IN WFS:  
Off, 50 to150 in/min. Run-in sets the wire feed  
speed from the time the trigger  
is pulled until an arc is estab-  
lished.  
Start Procedure  
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.  
WAVEFORM CONTROL TECHNOLOGY  
STEEL  
.035"  
IR PORT  
12  
SETUP  
Pulse Crisp ArMix  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
SET  
END OPTIONS  
ARC CONTROL  
EFFECT / RANGE  
FUNCTION  
ARC  
DESCRIPTION  
FOCUS  
-10.0 (SOFT to  
10.0 (STIFF)  
Postflow Time:  
0 to 10 seconds  
Adjusts the time that shielding  
gas flows after the welding out-  
put 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.  
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.  
Burnback: 0 to .25  
Seconds  
Crater Procedure  
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.  
POWER FEED® 25M  
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B-16  
B-16  
OPERATION  
ALUMINUM SYNERGIC GMAW-P (PULSED  
MIG)AND GMAW-PP (PULSE ON PULSE)  
WELDING  
FIGURE B.11  
The POWER FEED® 25M and Power Wave welding  
power source combine to readily produce top quality  
aluminum welds with excellent appearance, little spat-  
ter and good bead shape. Push-pull guns are available  
for consistent feeding when welding a long distance  
away from the wire feeder.  
Frequency Modulation = 10  
Narrow weld and ripple spacing, fast travel speed.  
Pulse-on-Pulse Welding  
The POWER FEED® system offers both traditional  
pulse and Pulse-on-Pulse™. Pulse-on-Pulse (GMAW-  
PP) is an exclusive waveform for aluminum welding.  
Use it to make welds with a "stacked dime" appear-  
ance, similar to GTAW welds.  
FIGURE B.9  
The pulsing frequency is adjustable. Changing the fre-  
quency modulation (or arc control) of the waveform  
changes the ripple spacing. Faster travel speeds may  
be achieved by using higher values of frequency mod-  
ulation.  
FIGURE B.10  
Frequency Modulation = -10  
Wide weld and ripple spacing, slow travel speed.  
POWER FEED® 25M  
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B-17  
B-17  
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 applica-  
tions. 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  
Trim 1.50  
Arc Length Long  
Trim 1.00  
Arc Length Medium  
Trim .50  
Arc Length Short  
POWER FEED® 25M  
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B-18  
B-18  
OPERATION  
ALUMINUM GMAW-P AND GMAW-PP WELDING  
FIGURE B.14  
7
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5
5
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K2368-1  
Power Wave® 355M  
Power Wave® 455M  
Power Wave® 455M/STT  
POWER FEED® 10M, Bench Model  
Requires K1634-1 Spool cover  
POWER FEED® 10M Dual, Bench Model  
Requires K1634-1 Spool cover  
POWER FEED® 25M  
1
K2202-1  
K2203-1  
K2230-1  
K2234-1  
2
K2536-1  
KP1695-xx  
KP1507-xx  
K1543-xx  
K1796-xx, K2593-xx  
K910-xx  
Drive Roll Kit, 2 Roll Feeder  
Drive Roll Kit, 4 Roll Feeder  
Digital Control Cable  
Coaxial Weld Power Cable, Lug to Lug  
Ground Clamp  
Python Plus Gun, Air cooled  
Deluxe Regulator for Mixed  
Shielding Gases  
3
4
5
6
K2447-xx  
7
K586-1  
Shielding Gas Hose  
POWER FEED® 25M  
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B-19  
B-19  
OPERATION  
Aluminum Pulse and Pulse-On-Pulse (Synergic) Weld Display  
220  
1.06  
TRIM  
WFS  
AMPS  
VOLTS  
Less  
Deposition  
More  
Deposition  
Shorter  
Arc  
Longer  
Arc  
MSP4 OPERATION  
WELD MODES  
START OPTIONS  
DESCRIPTION  
WIRE SIZE  
ELECTRODE AND GAS  
PREFLOW TIME  
0 - 10 seconds  
0.035 3/64 1/16  
149 72 74  
98 99 100  
152 76 78  
101 102 103  
ALUMINUM 4043  
ALUMINUM 4043  
ALUMINUM 5356  
ALUMINUM 5356  
Ar  
Ar  
Ar  
Ar  
Adjusts the time that shielding  
gas  
flows  
the trigger is  
after  
prior to feeding wire.  
pulled  
and  
RUN-IN WFS:  
Off, 50 to150 in/min. Run-in sets the wire feed  
speed from the time the trigger  
is pulled until an arc is estab-  
lished.  
WAVEFORM CONTROL TECHNOLOGY  
Start Procedure  
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.  
Aluminum  
3/64"  
IR PORT  
72  
SETUP  
4043 Pulse Ar  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
SET  
END OPTIONS  
EFFECT / RANGE  
FUNCTION  
ARC CONTROL  
DESCRIPTION  
PULSE  
Postflow Time:  
0 to 10 seconds  
Adjusts the time that shielding  
gas flows after the welding out-  
put turns off.  
FREQUENCY:  
(Low)-10.0 to  
(High)+10.0  
For Pulse  
modes, Arc Control  
changes the pulsing frequency.  
When the frequency changes,  
the Power Wave system auto-  
matically adjusts the back-  
ground current to maintain a  
similar heat input into the weld.  
Low frequencies give more con-  
trol over the puddle and high  
frequencies minimize spatter.  
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 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.  
Crater Procedure  
PULSE-ON-PULSE  
FREQ.MODULATION  
(Low)-10.0 to  
(High)+10.0  
For Pulse -On-Pulse modes,  
Arc controls changes the frequ-  
ency 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.  
POWER FEED® 25M  
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B-20  
B-20  
OPERATION  
GMAW-STT™ WELDING  
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% CO2 shielding gas, results in cost savings in gas  
and part clean-up.  
8
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.  
3
1
• Synergic STT™ modes keep the arc characteristics  
the same when the wire feed speed is changed.  
2
4
Note: STT™ is available only with specially equipped  
Power Wave power sources, like the POWER FEED®  
25M/STT.  
6
5
For best results:  
• Attach the work sense lead as close as possible to  
the welding arc.  
7
• Use only solid steel or silicon bronze electrodes.  
1
2
K2203-1  
K2230-1  
K2234-1  
K2536-1  
Power Wave® 455M/STT  
POWER FEED® 10M, Bench Model  
POWER FEED® 10M Dual, Bench Model  
POWER FEED® 25M  
KP1695-xx,  
KP1507-xx  
K1543-xx  
Drive Roll Kit, 2 Roll Feeder  
Drive Roll Kit, 4 Roll Feeder  
Digital Control Cable  
3
4
5
6
7
K1796-xx, K2593-xx Coaxial Weld Power Cable, Lug to Lug  
K910-xx  
K940-xx  
See Magnum MIG Gun  
Literature  
Ground Clamp  
Sense Lead Kit  
Deluxe Regulator for Mixed  
8
K586-1  
Shielding Gases  
Shielding Gas Hose  
POWER FEED® 25M  
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B-21  
B-21  
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.  
----  
220  
WFS  
AMPS  
VOLTS  
TRIM  
• Background Current - regulates the bead contour.  
• Tail-out - provides additional power in the arc.  
Less  
Deposition  
More  
Deposition  
There is no Voltage control when STT™ welding.  
MSP4 OPERATION  
WELD MODES  
WIRE SIZE  
0.035 0.045 0.052  
ELECTRODE AND GAS  
STEEL CO2 Ar/CO2  
110 126 126  
110 126 126  
STAINLESS  
He/Ar/CO2  
(with Hot Start)  
STEEL CO2 Ar/CO2  
123 124 124  
123 124 124  
STAINLESS  
He/Ar/CO2  
(SYNERGIC STT)  
111 117 120  
112 118 121  
STEEL CO2  
STEEL AR/CO2  
STAINLESS He/Ar/CO2  
START OPTIONS  
127 129  
---  
---  
PREFLOW TIME  
FUNCTION  
STAINLESS Ar/CO  
2
131 133  
SYNERGIC STT, OPEN ROOT  
STEEL CO2  
0 - 10 seconds  
Adjusts the time that shielding  
113 119 122  
135 137 ---  
gas  
is  
flows after the trigger  
2
STAINLESS He/Ar/CO  
prior to feeding wire.  
pulled and  
WAVEFORM CONTROL TECHNOLOGY  
Run-in sets the wire feed  
speed from the time the trigger  
is pulled until an arc is estab-  
lished.  
RUN-IN WFS:  
Off, 50 to150 in/min.  
Steel  
.035"  
IR PORT  
109  
SETUP  
Start Procedure  
The Start Procedure is not  
commonly used with STT  
procedures.  
STT  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
SET  
ARC CONTROL  
-
EFFECT / RANGE  
PEAK CURRENT  
DESCRIPTION  
END OPTIONS  
PARAMETER  
RANGE  
FUNCTION  
pinch  
arc  
Peak Current acts similar to an  
sets the arc length  
control. Peak Current  
Postflow Time:  
0 to 10 seconds  
Adjusts the time that shielding  
gas flows after the welding out-  
put turns off.  
good fusion.  
promotes  
Higher  
and  
current levels will cause  
while increasing arc length. If  
peak  
the arc to broaden  
momentarily  
set too high, globular transfer may occur.  
may cause instability  
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.  
Setting it too low  
stubbing.  
andwire  
Burnback: 0 to .25  
Seconds  
practice is to  
Best  
puddle  
adjust for minimum spatter and  
agitation.  
overall  
Background Current controls  
heat input in the weld.  
the  
B A C K G R O U N D  
CURRENT  
Crater is not commonly used  
in STT weld procedures.  
Crater Procedure  
power  
droplet becoming  
Tail out provides additional  
without the molten  
TAIL OUT  
STT ll MODES  
ONLY)  
(
too large.Increase as necessary to add  
arc length.  
heat input without increasing  
Often this results in faster travel speeds.  
as tail out increases, the peak  
Note that  
may need  
current and/or background current  
to be reduced.  
POWER FEED® 25M  
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B-22  
B-22  
OPERATION  
PEAK CURRENT (Figure B.16)  
Peak current controls the arc length, which also affects  
the shape of the root. When using 100% CO2, the peak  
current will be higher than when welding with blended  
shielded gases. A longer arc length is required with  
CO2 to reduce spatter.  
FIGURE B.16  
Peak  
Peak  
Peak  
Current  
Too High  
Current  
Optimum  
Current  
Too Low  
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% CO2 requires less  
background current than when welding with blended  
shielding gases.  
FIGURE B.17  
Background  
Current  
Too Low  
Background  
Current  
Optimum  
Background  
Current  
Too High  
TAILOUT  
Tailout provides additional heat into the weld without  
increasing the arc length or the droplet size. Higher tai-  
lout values improve wetting and may give faster travel  
speeds.  
POWER FEED® 25M  
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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 con-  
nect 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 dis-  
abled by parameter P.8 in the set-up menu found in this  
operations section.  
No Foot / Hand Amptrol  
With Foot / Hand Amptrol  
Touch Start TIG  
Weld Sequence  
1. Adjust the arc amperage with the left knob 1. Adjust the maximum arc amperage with  
on the display panel.  
the left knob on the display panel.  
2. Turn the right knob on the display panel 2. Touch the tungsten to the work piece.  
until the Output Control is ON. Gas will 3. Press the foot pedal or slide the hand  
start to flow.  
3. Touch the tungsten to the work piece.  
amptrol a slight amount. Gas will start to  
flow.  
4. Lift the tungsten to create an arc and weld. 4. Lift the tungsten to create an arc.  
TIG torches without  
built-in Gas Valves.  
5. Stop welding by turning the Output Control 5. Regulate the arc current with the foot  
to OFF, or by pulling away the tungsten  
from the work.  
6. Gas flow will continue for a short time and  
then shut-off.  
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 arc amperage with the left knob 1. Adjust the maximum arc amperage with  
on the display panel.  
the left knob on the display panel.  
2. Turn the right knob on the display panel 2. Touch the tungsten to the work piece.  
until the Output Control is ON.  
3. Open the gas valve on the TIG torch.  
4. 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.  
TIG torches with  
built-in Gas Valves.  
5. Lift the tungsten to create an arc and weld. 5. Lift the tungsten to create an arc.  
6. Stop welding by turning the Output Control 6. Regulate the arc current with the foot  
to OFF, or by pulling away the tungsten  
from the work.  
7. Close the gas valve on the TIG torch.  
pedal or hand amptrol.  
7. Stop welding by releasing the foot pedal or  
hand amptrol, or by pulling the tungsten  
away from the work.  
8. Close the gas valve on the TIG torch.  
POWER FEED® 25M  
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B-24  
B-24  
OPERATION  
GTAW (TIG) WELDING  
Maximum  
Amperage  
8
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VOLTS TRIM  
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AMPS  
5
5
3
E
V
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Output  
ON  
Output  
OFF  
1
3
WELD MODE  
MODE  
5
TOUCH START  
3
4
2
START OPTIONS  
START PROCEDURE  
The Start Procedure controls the Amperage at a  
fixed level for the set amount of time.  
7
WAVEFORM CONTROL TECHNOLOGY  
3
IR PORT  
SETUP  
Touch Start TIG  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
6
SET  
END OPTIONS  
No Arc End Options are  
active for Touch Start TIG  
ARC CONTROL  
No Arc Controls are active  
for Touch Start TIG.  
K2368-1  
K2202-1  
K2203-1  
K2230-1  
K2234-1  
K2536-1  
K1543-xx  
Power Wave® 355M  
Power Wave® 455M  
1
2
Power Wave® 455M/STT™  
POWER FEED® 10M, Bench Model  
POWER FEED® 10M Dual, Bench Model  
POWER FEED® 25M  
Digital Control Cable  
Electrode Cable  
3
4
5
6
K910-xx  
Ground Clamp  
K1782-xx, K1783-xx PTA-17, PTA-26 TIG torch  
(shown with valve)  
7
8
K870  
3100211  
Foot Amptrol  
Harris Argon Flow Regulator  
POWER FEED® 25M  
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B-25  
B-25  
OPERATION  
Change the value of the blinking parameter by rotating  
the SET knob.  
SET-UP FEATURES MENU  
The Setup Menu gives access to the set-up configura-  
tion. Stored in the set-up configuration are user para-  
meters that generally need to be set only at installation.  
The parameters are grouped as follows:  
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.  
• P.1 through P.99  
adjustable)  
• P.101 through P.199 Diagnostic Parameters (always  
read only)  
• P.501 through P.599 Secured Parameters (accessi-  
ble only though a p.c. or palm application.)  
Unsecured Parameters (always  
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 set-  
up 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.  
To access the set-up menu, press the right and left but-  
tons of the MSP4 panel simultaneously. Note that the  
set-up menu cannot be accessed if the system is weld-  
ing, or if there is a fault (The status LED is not solid  
green).  
TABLE B.1  
POWER FEED® POWER  
10M (All Models) FEED® 25M  
POWER  
FEED® 10A  
Unsecured Parameters  
PARAMETER  
DESCRIPTION  
Exit set-up menu  
WFS Units  
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
P.0  
P.1  
P.2  
P.4  
P.5  
P.6  
P.7  
P.8  
Arc Display Mode  
Trigger Memory Recall  
Trigger Procedure Change  
Stall Factor Adjustment  
Gun Offset Adjustment  
TIG Gas Control  
℘
℘
℘
P.11  
P.12  
P.13  
P.80  
P.99  
Set Timers  
Travel Options  
Adjust Arc Force  
Sense From Studs  
Show Test Modes  
℘
℘
℘
℘
℘
Diagnostic Parameters  
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
℘
P.100  
P.101  
P.102  
P.103  
P.104  
P.105  
P.106  
P.107  
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  
POWER FEED® 25M  
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B-26  
B-26  
OPERATION  
P.0  
Press the left button to exit the set-up menu.  
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 fac-  
tor can be reduced to stall more easily and  
possibly prevent bird nesting.  
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.  
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.  
P.4  
Trigger Memory Recall  
Enable = Selecting memories 2 through 6 with  
quick trigger pulls is enabled when the option-  
al dual procedure/memory panel is installed.  
To recall a memory with the gun trigger, quick-  
ly 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 memo-  
ry recall can only be performed when the sys-  
tem is not welding. Disable = Memory selec-  
tion is performed only by the buttons on the  
optional dual procedure/memory panel.  
(default)  
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.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.  
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.  
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.  
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.  
3. "Integral Trigger Procedure" (the optional value  
2), the machine will only change the selected pro-  
cedure 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 re-  
selected when the trigger is quickly and com-  
pletely 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.  
• 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 nec-  
essary, decrease the calibration setting to  
slow the pull motor, or increase the calibra-  
tion 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  
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B-27  
B-27  
OPERATION  
P.8  
TIG Gas Control (Two Settings)  
P.13  
Adjust Arc Force  
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 sec-  
onds.  
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 but-  
ton 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.  
• 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 tung-  
sten 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 flow-  
ing when the output is turned on and stop flowing  
after the postflow period after the output is turned  
off.  
P.80  
Sense From Studs (two settings)  
1. "False", the voltage sense lead is automat-  
ically selected based on the DIP switch con-  
figuration and the selected weld mode. This  
is the default value that is used every time  
the machine is powered up. Note that set-  
ting P.80 to "False" does not preclude volt-  
age 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).  
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.  
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 trou-  
bleshooting purposes. P.80 will automatical-  
ly be set back to "False" the next time the  
equipment is powered up or can be manual-  
ly changed back to "False" via the setup  
menu.  
P.12  
Travel Options  
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 mea-  
sured 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)  
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.  
Remote voltage sensing (anything other than  
"studs") is used to obtain a more accurate volt-  
age measurement since the sense lead is  
closer to the arc. Remote voltage sensing can  
involve external wiring and DIP switch configu-  
ration, there is a potential for incorrect voltage  
measurement which can lead to poor arc con-  
trol or wire burn back.  
POWER FEED® 25M  
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B-28  
B-28  
OPERATION  
P.99  
Show Test Modes  
P.106 Ethernet IP Address  
Many weld tables include special modes for  
testing and servicing the welding system. Set  
this parameter to YES to show all test modes.  
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.  
When the power source is turned off, the Show  
Test Modes parameter automatically reverts  
back to "NO".  
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.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.  
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 soft-  
ware 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 ver-  
sion loaded into the module. Press the left  
MSP4 button to exit.  
P.104 Hardware Version  
Press the right MSP4 button to view the hard-  
ware 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 ver-  
sion loaded into the module. Press the left  
MSP4 button to exit.  
P.105 Welding Software  
Press the right MSP4 button to view the weld-  
ing software version inside the power source.  
Press the left MSP4 button to exit.  
POWER FEED® 25M  
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B-29  
B-29  
OPERATION  
PROCEDURE/MEMORY PANEL OPERA-  
TION  
USER MEMORIES  
Recall a memory with memory buttons  
The Dual Procedure/Memory Panel performs three  
functions:  
To recall a user a memory, press one of the six user  
memory buttons.The memory is recalled when the but-  
ton is released. Do not hold the button for more than  
two seconds when recalling a user memory.  
• Weld procedure selection  
• Memory save and recall  
• Limits setting  
Recall a memory with the gun trigger  
There are two procedure memories (A and B) and six  
user memories (1-6).  
If desired, memories 2 through 6 can be recalled with  
the gun trigger. For example, to recall memory 3, quick-  
ly pull and release the gun trigger 3 times without weld-  
ing.  
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.  
Note: the POWER FEED® Wire Feeders are factory  
set with this feature disabled. Use the SETUP menu  
and change P.4 to enable memory recall with the gun  
trigger.  
Save a memory with memory buttons  
User memories work by copying the weld procedure  
from one of the six memories into either the A or B pro-  
cedure. Weld procedures are saved into the memories  
only when the operator chooses.  
To save a memory, press and hold the desired memo-  
ry 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 but-  
ton for more than 5 seconds when saving a user mem-  
ory.  
USER  
MEMORIES  
PROCEDURE  
MEMORY  
M
M
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.  
PROCEDURE  
A
GUN  
B
1
4
2
3
HOLD 2 SECONDS TO SAVE  
5
6
RECALL  
PRESS 1  
SECOND  
SAVE  
PRESS 2  
SECONDS  
Using Procedure Memories  
M
M
MEMORY  
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 proce-  
dure 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.  
PROCEDURE  
A
GUN  
B
1
4
2
3
6
HOLD 2 SECONDS TO SAVE  
5
M
M
MEMORY  
PROCEDURE  
A
GUN  
B
1
4
2
3
6
HOLD 2 SECONDS TO SAVE  
5
PRESS TO  
SELECT  
PROCEDURE OR  
QUICK TRIGGER-  
WHILE  
WELDING  
POWER FEED® 25M  
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B-30  
B-30  
To set limits, press the desired memory button 1-6  
and hold for 5 seconds. Release the memory button  
when the LED begins to blink rapidly and the MSP4  
displays "Memory X Set Limits" as shown below.  
OPERATION  
LIMITS  
Limits allow the welder to adjust the welding procedure  
only within a defined range.  
Each user memory may have a different set of limits.  
For example, memory 1 can be set to limit the WFS to  
200 through 300 in/min, and memory 2 can be set to  
limit the WFS to 275 through 310 in/min, while memo-  
ry 3 may not have any WFS limits.  
Set Limits:  
Press 5  
seconds  
M
M
MEMORY  
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.  
PROCEDURE  
A
GUN  
B
1
4
2
3
6
HOLD 2 SECONDS TO SAVE  
5
Machine limits are:  
MSP4 DISPLAY  
Range  
Weld mode dependent  
and gear box ratio  
dependent  
Parameter  
Wire Feed  
Speed  
Units  
in/min  
WAVEFORM CONTROL TECHNOLOGY  
Memory 1  
IR PORT  
Weld mode dependent  
0.50 to 1.50  
-10.0 to 10.0  
0.0 to 2.5  
Voltage  
Trim  
Volts  
--  
SETUP  
Set Limits  
Arc Control  
Preflow  
Weld mode dependent  
Seconds  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
SET  
0.0 to 10.0  
Start Time  
Run-In WFS  
Crater Time  
Burnback Time  
Postflow Time  
Seconds  
Off, 50 to 150  
0.0 to 10.0  
in/min  
Seconds  
0.00 to 0.25  
0.0 to 10.0  
Seconds  
Seconds  
Limits may be set for:  
• Wire Feed Speed/Amperage • Start Time  
• Voltage/Trim  
• Burnback Time  
• Arc Control  
• Preflow Time  
• Run-In Speed  
• Start Wire Feed Speed  
• Start Voltage/Trim  
• Crater Wire Feed Speed  
• Crater Voltage/Trim  
• Crater Time  
• Postflow Time  
Weld modes cannot be selected through the Limits  
Setup menu, and must be chosen and saved to mem-  
ory before entering the Limits Setup Menu.  
POWER FEED® 25M  
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B-31  
B-31  
OPERATION  
The memory value must always be less than or equal  
to the high limit, and greater than or equal to the low  
limit.  
Four items show on the MSP4 panel.  
• 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 but-  
ton (YES) to save and enable the limits and exit. Press  
the right MSP4 button (NO) to exit and leave limits  
unchanged.  
• 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.  
High Limit  
Low Limit  
Memory Value  
WAVEFORM CONTROL TECHNOLOGY  
Enabling/Disabling Limits  
Hi  
= 200  
Enable/Disable  
Limits: Press  
10 seconds  
Lo = 180  
200  
IR PORT  
SETUP  
Weld WFS  
M
M
MEMORY  
WELD MODE  
START OPTIONS  
END OPTIONS  
PROCEDURE  
A
ARC CONTROL  
GUN  
B
1
4
2
3
6
SET  
HOLD 2 SECONDS TO SAVE  
Parameter Name  
5
The Limits Setup menu shows a list of all parameters  
available for the weld mode stored in the memory cho-  
sen. For example, if limits are being set for a stick  
(SMAW) mode, parameters such as Run-in WFS and  
Postflow will not appear.  
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:  
WAVEFORM CONTROL TECHNOLOGY  
To lock a parameter to a specific value that cannot  
be changed, set the high and low limits to the same  
value.  
Memory 1  
IR PORT  
Limits  
SETUP  
Enable/Disable  
WAVEFORM CONTROL TECHNOLOGY  
WELD MODE  
START OPTIONS  
END OPTIONS  
Hi  
ARC CONTROL  
= 200  
Lo = 180  
200  
IR PORT  
SET  
SETUP  
Weld WFS  
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.  
WELD MODE  
START OPTIONS  
ARC CONTROL  
END OPTIONS  
SET  
WAVEFORM CONTROL TECHNOLOGY  
Enable  
Limits?  
IR PORT  
Rotate to  
Change  
Value.  
SETUP  
Press to  
select item  
to change.  
Yes  
No  
WELD MODE  
START OPTIONS  
END OPTIONS  
ARC CONTROL  
SET  
POWER FEED® 25M  
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B-32  
B-32  
OPERATION  
INTERNAL CONTROLS  
4
5
6
3
2
1
COLD  
FEED  
ON  
ON  
HEATER  
OFF  
OFF  
GAS  
PRUGE  
8
7
9
ITEM  
DESCRIPTION  
1
2
3
4
5
2 Step / 4 Step Trigger Switch  
Cold Feed / Purge Switch  
Wire Drive Pressure Arm  
Internal Light Switch  
Internal Heater Switch  
6
Spindle Brake  
7
8
Gun Bushing  
Thumb Screw for securing the welding Gun  
9
Socket Head Cap Screw for securing the Gun Bushing  
to the Electrode Connection  
POWER FEED® 25M  
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B-33  
B-33  
OPERATION  
NOTE: All switches described on this page will func-  
tion only when power source is ON.  
2 STEP - 4 STEP - TRIGGER OPERATION  
COLD FEED/GAS PURGE SWITCH  
COLD FEED  
The 2 Step - 4 Step switch changes the  
function of the gun trigger. 2 Step trig-  
ger operation switches the welding out-  
put ON-OFF in direct response to the  
trigger. 4 Step trigger operation pro-  
vides 'trigger interlock' capability and  
gives the ability to control the amount of  
time spent in the arc start and arc crater  
steps.  
Cold Feed and Gas Purge are combined  
into a single spring centered toggle  
switch.  
4 STEP  
GAS PURGE  
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.  
Place the toggle switch in the UP posi-  
tion for 4 Step operation and in the  
DOWN position for 2 Step operation.  
2-STEP  
Hold with toggle switch in the DOWN position to acti-  
vate 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.  
The 2 Step - 4 Step trigger has no effect when weld-  
ing 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.  
LIGHT SWITCH  
ON  
Turn the internal light switch ON to  
illuminate the inside of the POWER  
FEED® 25M.  
LIGHT  
OFF  
4 Step Trigger  
HEATER SWITCH  
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 inter-  
lock.  
Turn the heater switch ON to warm  
the inside of the POWER FEED®  
25M. The heater is useful for reduc-  
ON  
HEATER  
ing condensation build-up on the  
spool of wire.  
OFF  
POWER FEED® 25M  
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B-34  
B-34  
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 con-  
tinue 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  
2 Step Trigger  
Start= OFF  
Crater = OFF  
Burnback = OFF  
Idle  
Preflow  
Strike  
Weld  
Postflow  
Idle  
On  
Off  
Shielding  
Gas  
Weld  
Power  
Source  
Output  
1.5 sec max.  
Off  
Weld  
WFS  
Run-in  
Off  
POWER FEED® 25M  
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B-35  
B-35  
OPERATION  
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)  
UPSLOPE:  
Once the wire touches the work and an arc is estab-  
lished, 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,  
WELD:  
PREFLOW:  
After upslope, the power source output and the wire  
feed speed continue at the weld settings.  
Shielding gas begins to flow immediately when the gun  
trigger is pulled.  
BURNBACK:  
STRIKE:  
As soon as the trigger is released, the wire feed speed  
is turned OFF and the machine output continues for  
the 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 estab-  
lished within 1.5 seconds, the power source output and  
wire feed speed skips to the weld settings.  
POSTFLOW:  
Next, the machine output is turned OFF and shielding  
gas continues until the post flow timer expires.  
FIGURE B.20  
2 Step Trigger  
Start = ON  
Crater = OFF  
Burnback = ON  
Idle  
Preflow  
Strike  
Upslope  
Weld  
Burnback  
Postflow  
Idle  
On  
Off  
g
Shieldin  
Gas  
Start  
time  
Weld  
Power  
Source  
Output  
1.5 sec max.  
Burnback Time  
Start  
Off  
Weld  
WFS  
Run-in  
Off  
POWER FEED® 25M  
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B-36  
B-36  
OPERATION  
EXAMPLE 3 - 2 STEP TRIGGER: Customized Arc  
Start, Crater and Arc End. Sometimes it is advanta-  
geous to set specific arc start, crater and arc ending  
parameters for the ideal weld. Many times when weld-  
ing 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)  
WELD:  
After upslope, the power source output and the wire  
feed speed continue at the weld settings.  
CRATER:  
As soon as the trigger is released, the wire feed speed  
and power source output ramp to the crater settings  
throughout the crater time. The time period of ramping  
from the weld settings to the crater settings is called  
DOWNSLOPE.  
For this sequence,  
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  
burnback time.  
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 estab-  
lished within 1.5 seconds, the power source output and  
wire feed speed skips to the weld settings.  
POSTFLOW:  
Next, the machine output is turned OFF and shielding  
gas continues until the post flow timer expires.  
UPSLOPE:  
Once the wire touches the work and an arc is estab-  
lished, 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  
2 Step Trigger  
Start = ON  
C rat er = ON  
Burnback = ON  
Idle  
Preflow  
Strike  
Upslope  
Weld  
Downslope Burnback  
Postflow  
Idle  
On  
Off  
Shielding  
Gas  
Starttime  
Crater ti me  
Weld  
1.5 sec max .  
Burnback Time  
Power  
Source  
Output  
Start  
Crater  
Off  
Weld  
WFS  
Crater  
Run-in  
Off  
POWER FEED® 25M  
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B-37  
B-37  
OPERATION  
EXAMPLE 4 – 4 STEP TRIGGER: Trigger Interlock  
The 4 step trigger can be configured as a trigger inter-  
lock. 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 estab-  
lished 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 con-  
tinue 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  
4 Step Trigger  
Start = OFF  
Crater = OFF  
Burnback = OFF  
Idle  
Preflow Strike  
Wel  
Burnb ack Postflow  
Idl e  
d
On  
Off  
Shielding  
Gas  
We ld  
1. 5 s e c ma x.  
Power  
Source  
Output  
Start  
Crater  
Off  
We ld  
WFS  
Crater  
Run-in  
Off  
POWER FEED® 25M  
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B-38  
B-38  
OPERATION  
UPSLOPE:  
EXAMPLE 5 - 4 STEP TRIGGER: Manual control of  
Start and Crater times with Burnback ON. The 4 step  
trigger sequence gives the most flexibility when the  
Start, Crater and Burnback functions are active. This is  
a popular choice when welding aluminum because  
extra heat may be needed during Start and less heat  
desired during crater. With 4 step trigger, the welder  
chooses the amount of time to weld at the Start, Weld  
and Crater settings by using the gun trigger. Burnback  
reduces the occurrence of wire to sticking into the weld  
pool at the end of a weld and conditions the end of the  
wire for the next arc start. ( See Figure B.23)  
During upslope, the power source output and the wire  
feed speed ramp to the weld settings throughout the  
start time. The time period of ramping from the start  
settings to the weld settings is called UPSLOPE.  
WELD:  
After upslope, the power source output and the wire  
feed speed continue at the weld settings.  
DOWNSLOPE:  
As soon as the trigger is released, the wire feed speed  
and power source output ramp to the crater settings  
throughout the crater time. The time period of ramping  
from the weld settings to the crater settings is called  
DOWNSLOPE.  
In this sequence,  
PREFLOW:  
Shielding gas begins to flow immediately when the gun  
trigger is pulled.  
CRATER:  
During CRATER, the power source continues to supply  
output at the crater WFS and voltage.  
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 estab-  
lished 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:  
POSTFLOW:  
The power source welds at the start WFS and voltage  
until the trigger is released.  
Next, the machine output is turned OFF and shielding  
gas continues until the post flow timer expires.  
FIGURE B.23  
4 Step Trigger  
Start = ON  
Crater = ON  
Burnback = ON  
Idle  
Preflow Strike  
Start  
Upslope  
Weld  
Down slope  
Crater  
Burnback Postflow  
Idle  
On  
Off  
Shielding  
Gas  
Wel d  
Start  
1 .5 sec max .  
BurnbackTime  
Po wer  
So urce  
Output Crater  
Off  
Wel d  
St ar t  
WFS  
Crater  
Strike  
Off  
POWER FEED® 25M  
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B-39  
B-39  
OPERATION  
REAR CONTROLS:  
1
2
3
4
5
ITEM  
DESCRIPTION  
1
2
3
4
5
Flow Meter  
Shielding Gas Inlet  
5-Pin Arclink Cable Connector  
Electrode Cable  
Cover for Optional Water Line Connector  
POWER FEED® 25M  
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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 CO2, Ar, and CO2/Ar blends. It is not calibrated and  
is for reference purposes only. The middle of the ball  
indicates the flow rate of shielding gas.  
Adjust 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 condi-  
tions may effect the amount of shielding gas required.  
SCFH  
10  
Liter/Min.  
4.7  
20  
9.4  
30  
40  
50  
60  
70  
80  
14.2  
18.9  
23.6  
28.3  
33.1  
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.  
POWER FEED® 25M  
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C-1  
C-1  
TABLE OF CONTENTS - ACCESSORIES SECTION  
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  
POWER FEED® 25M  
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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).  
ELECTRODE SIZE  
.023-.030 (0.6-0.8mm)  
.035 (0.9mm)  
KP KIT  
WIRE TYPE  
Steel Wires:  
KP1696-030S  
KP1696-035S  
KP1696-045S  
KP1696-052S  
Includes: 2 V groove  
drive rolls and inner  
.045 (1.2mm)  
.052 (1.4mm)  
1/16 (1.6mm)  
.035,.045 (0.9, 1.2mm)  
.040 (1.0mm)  
KP1696-1/16S wire guide.  
KP1696-1  
KP1696-2  
.030-.035" (0.8-0.9mm) KP1697-035C  
.040-.045" (1.0-1.2mm)  
.052" (1.4mm)  
1/16" (1.6mm)  
.068-.072" (1.7-1.8mm)  
5/64" (2.0mm)  
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  
Cored Wires:  
Includes: 2 Knurled  
drive rolls and inner  
wire guide.  
3/32” (2.4mm)  
.035" (0.9 mm)  
.040" (1.0mm)  
3/64" (1.2mm)  
1/16" (1.6mm)  
Includes: 2 polished  
U groove drive rolls,  
outer wire guide and  
inner wire guide.  
Aluminum Wires:  
POWER FEED® 25M  
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C-3  
C-3  
ACCESSORIES  
Includes: 1 "T" adapter for  
K2429-1  
ArcLink "T" Cable Adapter  
Remote Output Control  
Remote Output Control  
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.  
K857  
Includes: 1 remote output con-  
trol pendant with a 100’ cable.  
Used most often with SMAW  
welding.  
K857-1  
Includes: a complete alu-  
minum case. Decals, skids,  
insulation and latches are all  
preassembled.  
K2596-1  
K2596-2  
K2593-xx  
K1796-xx  
Aluminum Case  
Plastic Case  
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.  
#1 Co-Axial Power Cable  
Co-Axial Power Cable  
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  
K1803-1  
Work and Feeder Cables Package 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  
K1840-xx  
K1842-xx  
Weld Power Cable, Twist-Mate to  
Lug  
Ground Clamp, and Twist-  
Mate to Lug 2/0 Cable 9'  
(2.7m) long.  
Weld Power Cable, Lug to Lug  
Includes: Twist-Mate to Lug,  
1/0 cable of length "xx".  
POWER FEED® 25M  
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C-4  
C-4  
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.  
K1543-xx  
Digital Control Cable  
K910-1  
Ground Clamp  
Includes: One 300 Amp  
Ground Clamp.  
K910-2  
Ground Clamp  
Includes: One 500 Amp  
Ground Clamp.  
Gun Receiver Bushing (for guns  
with K466-1 Lincoln gun connec-  
tors; Innershield and Subarc guns)  
Includes: Gun receiver bush-  
ing, set screw and hex key  
wrench.  
K1500-1  
Gun Receiver Bushing (for guns  
with K466-2, K466-10 Lincoln gun Includes: Gun receiver bush-  
connectors; Magnum 200/300/400 ing with hose nipple, set screw  
K1500-2  
(Included  
with PF25M)  
guns and compatible with Tweco®  
#2-#4)  
and hex key wrench.  
Gun Receiver Bushing (for guns Includes: Gun receiver bush-  
with K613-7 Lincoln gun connec- ing with hose nipple, set screw  
K1500-3  
tors; Magnum 550 guns and com-  
patible with Tweco® #5)  
and hex key wrench.  
Gun Receiver Bushing (for gun  
Includes: Gun receiver bush-  
K1500-4  
with K466-3 Lincoln gun connec- ing with hose nipple, set screw  
tors; compatible with Miller®  
guns.)  
and hex key wrench.  
POWER FEED® 25M  
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C-5  
C-5  
ACCESSORIES  
Includes: Gun receiver bushing  
Gun Receiver Bushing (compatible with hose nipple, 4 guide tubes,  
with Oxo® guns.) set screw and hex key wrench.  
K1500-5  
K489-7  
Gun Receiver Bushing (for Lincoln Includes: Gun receiver bushing  
Fast-Mate guns.)  
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.  
K2339-1  
Push-Pull Gun Connection Kit  
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.  
K590-6  
K435  
Water Connection Kit  
Spindle Adapter, for mounting 14 Includes: Spindle Adapter made  
lb. (6.4 kg) Innershield Coils on 2 from 2 coil retainers. (Electrode  
in (51 mm) spindles.  
not included.)  
Spindle Adapter, for mounting 8in  
(203mm) diameter spools on 2 in  
(51 mm) spindles.  
Includes: 2 Spindle Adapters,  
one for 2" wide spools and the  
other for 3" wide spools.  
K468  
Includes: Gas Guard Regulator  
and adjustment key.  
K659-1  
3000290  
K586-1  
Gas Guard Regulator  
Adjustable Gas Regulator  
Includes: Gas Regulator for  
Mixed Gases and 10' (3.0m)  
Hose.  
Includes: Deluxe Gas Regulator  
for Mixed Gases, Adapter for  
CO2 and 10' (3.0m) Hose.  
Deluxe Adjustable Gas Regulator  
POWER FEED® 25M  
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C-6  
C-6  
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.  
INSTALLATION OF THE K590-6 WATER  
COOLING KIT  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the dis-  
connect 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 compati-  
ble with the water cooler and the gun.  
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.  
Tools required:  
• 3/8" wrench  
• 5/16" nut driver  
• medium flat bladed screw driver  
• cutting tool  
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.  
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  
3. Remove the module from the case by lifting the front  
of the module approximately .25" (6 mm) and then  
sliding forward.  
8. Slide the hose clamps on to the hoses. Trim the  
hoses to length so that they lay flat on the case bot-  
tom. Slide the hoses on to the fittings on the case  
rear and secure with the hose clamps.  
POWER FEED® 25M  
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C-7  
C-7  
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 K590-  
6 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  
THUMB  
SCREW  
CONDUIT  
ELECTRODE  
CABLE  
WATER  
HOSE  
GUN  
BUSHING  
WATER  
HOSES  
POWER FEED® 25M  
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C-8  
C-8  
NOTES  
POWER FEED® 25M  
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D-1  
D-1  
TABLE OF CONTENTS - MAINTENANCE SECTION  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
Calibration Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
POWER FEED® 25M  
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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 pro-  
cedure that gives steady "spray" transfer in the arc.  
• While a weld is being made, measure the voltage from the feed plate  
to work with a calibrated volt meter.  
• The displayed voltage on the POWER FEED® 25M should be within  
2% of the measured value.  
POWER FEED® 25M  
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E-1  
E-1  
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  
VOLTAGE  
SENSE  
LEAD #67A  
PUSH PULL  
LEAD #67  
DAUGHTER  
DRIVE  
MOTOR  
GEAR BOX  
AND  
CONDUCTOR  
BLOCK  
CONTROL BOARD  
FEEDHEAD  
TO POWER  
SOURCE  
FEEDBACK  
STATUS LED  
TACH  
GUN TIGGER AND  
DUAL PROCEDURE  
RECEPTACLE  
DIP SWITCHES  
INPUT  
NETWORK  
RECEPTACLE  
2-STEP/  
4-STEP  
HEATER LIGHT  
CONNECTOR  
FOOT AMPTROL  
GAS  
SOLENOID  
COLD  
INCH/  
GAS  
PURGE  
POWER FEED® 25M  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 - GENERAL PHYSICAL DESCRIPTION  
VOLTAGE  
SENSE  
LEAD #67A  
PUSH PULL  
LEAD #67  
DAUGHTER  
DRIVE  
MOTOR  
GEAR BOX  
AND  
CONDUCTOR  
BLOCK  
CONTROL BOARD  
FEEDHEAD  
TO POWER  
SOURCE  
FEEDBACK  
STATUS LED  
TACH  
GUN TIGGER AND  
DUAL PROCEDURE  
RECEPTACLE  
DIP SWITCHES  
INPUT  
NETWORK  
RECEPTACLE  
2-STEP/  
4-STEP  
HEATER LIGHT  
CONNECTOR  
FOOT AMPTROL  
GAS  
SOLENOID  
COLD  
INCH/  
GAS  
PURGE  
GENERAL DESCRIPTION  
GENERAL FUNCTIONAL  
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 togeth-  
er and to the Power Wave power source.  
• 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 para-  
meters and set-up variables.  
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 indus-  
try 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.  
• The POWER FEED® 25M Wire Feeder is provided  
with an infrared red (IR) port. Transferring welding  
settings is accomplished with a common palm com-  
puter.  
• When the POWER FEED® 25M Wire Feeder is cou-  
pled to a Power Wave welding power source, the  
result is a welding system with absolutely superior  
arc performance.  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
POWER FEED® 25M  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 - GAS SOLENOID CONTROLS  
VOLTAGE  
SENSE  
LEAD #67A  
LEAD #67  
PUSH PULL  
DAUGHTER  
DRIVE  
MOTOR  
GEAR BOX  
AND  
CONDUCTOR  
BLOCK  
CONTROL BOARD  
FEEDHEAD  
TO POWER  
SOURCE  
FEEDBACK  
STATUS LED  
TACH  
GUN TIGGER AND  
DUAL PROCEDURE  
RECEPTACLE  
DIP SWITCHES  
INPUT  
NETWORK  
RECEPTACLE  
2-STEP/  
4-STEP  
HEATER LIGHT  
CONNECTOR  
FOOT AMPTROL  
GAS  
SOLENOID  
COLD  
INCH/  
GAS  
PURGE  
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 POWER FEED® 25M is a two roll, high perfor-  
mance, 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.  
The STATUS LED is designed to blink a red and  
green code if a fault should occur.  
Network communications, intelligence, PC board input  
power, and arc voltage feedback is received and  
transmitted through the input network receptacle.  
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.  
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.  
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.  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
POWER FEED® 25M  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 - CONTROL BOX  
DISPLAY AND  
ENCODER PANEL  
(STANDARD)  
STATUS  
LED  
SMALL  
PANEL  
MEMORY  
LARGE  
PANEL  
MSP4  
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.  
POWER FEED® 25M  
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E-5  
E-5  
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.  
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.  
STATUS LIGHT STATES  
LED State  
Power Source LED  
LED on any other nodes (components);  
Wire Feeder, Control Box Etc.  
Off  
Power Source is not turned ON or is not function- The system component is not receiving input  
ing correctly. power or is faulty.  
Green LED blink- It should only blink for a few seconds while It should only blink for a few seconds until the  
ing at a “normal” the system is mapping (identifying compo- system component (node) has been recog-  
rate  
nents). If blinking continues every group may nized. If the blinking continues at least one  
have a mapping error. (DIP switches may be node in the group has a mapping error (DIP  
set incorrectly).  
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.  
Red LED blinking Indicates a recoverable communication fault. Indicates a recoverable communication fault  
at a “normal” rate The power source should automatically most likely caused by one of the following.  
recover: If it cannot recover the LED will be • More than one control box (UI) in the group.  
solid red.  
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 equip-  
ment 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.  
Red/Green LED Indicates a recoverable hardware fault such Indicates a recoverable hardware fault such  
blinking at a “nor- as over temperature, overload shutdown etc. as over temperature, overload shutdown etc.  
mal” rate  
Could also be an open shutdown circuit at the  
feed head (leads 570, 572 with tab terminals)  
typically used for water flow shutdown switch-  
es.  
POWER FEED® 25M  
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E-6  
E-6  
TROUBLESHOOTING  
STATUS LIGHT STATES (CON’T)  
LED State  
Power Source LED  
LED on any other nodes (components);  
Wire Feeder, Control Box Etc.  
Red LED blinking Power source needs to be reprogrammed. System component (node) needs to be  
at a fast rate Contact your Local Authorized Lincoln Field reprogrammed. Contact your Local  
Service Facility. Authorized Lincoln Field Service Facility.  
Red LED ON and Power source has a non-recoverable hard- System component (node) has a non-recov-  
steady ware fault. Contact your Local Authorized erable hardware fault. Contact your Local  
Lincoln Field Service Facility.  
Authorized Lincoln Field Service Facility.  
Green LED ON System normal and functional.  
and steady  
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.  
POWER FEED® 25M  
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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  
POWER FEED® 25M  
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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.  
---------------------------------------------------------------------------------------------------------------------------  
Step 3. RECOMMENDED  
COURSE OF ACTION  
The last column labeled “Recommended  
This Troubleshooting Guide is provided to  
help you locate and repair possible machine  
malfunctions. Simply follow the three-step  
Course of Action” lists the most likely com-  
procedure listed below.  
ponents that may have failed in your  
machine. It also specifies the appropriate  
test procedure to verify that the subject com-  
ponent is either good or bad. If there are a  
number of possible components, check the  
components in the order listed to eliminate  
one possibility at a time until you locate the  
cause of your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM  
(SYMPTOMS)”. This column describes pos-  
sible symptoms that the machine may exhib-  
it. Find the listing that best describes the  
symptom that the machine is exhibiting.  
Symptoms are grouped into the following  
categories: output problems, function prob-  
lems, wire feeding problems, and welding  
problems.  
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.  
Step 2. PERFORM EXTERNAL TESTS.  
The second column labeled “POSSIBLE  
AREAS OF MISADJUSTMENT(S)” lists the  
obvious external possibilities that may con-  
tribute to the machine symptom. Perform  
these tests/checks in the order listed. In  
general, these tests can be conducted with-  
out removing the case wrap-around cover.  
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.  
-----------------------------------------------------------------------------------------------------------------------------------  
POWER FEED® 25M  
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F-3  
F-3  
TROUBLESHOOTING AND REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
- 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-shield-  
ing bag.  
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.  
- 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 prop-  
er failure analysis.  
CAUTION  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
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.  
1. Determine to the best of your technical ability  
that the PC board is the most likely component  
causing the failure symptom.  
NOTE: Allow the machine to heat up so that all  
electrical components can reach their operating  
temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and  
substitute it with the original PC board to  
recreate the original problem.  
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:  
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.  
PC board can be damaged by static electricity.  
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.  
- Remove your body’s static  
charge before opening the static-  
shielding bag. Wear an anti-static  
wrist strap. For safety, use a 1 Meg  
ohm resistive cord connected to a  
grounded part of the equipment  
6. Always indicate that this procedure was  
followed when warranty reports are to be  
submitted.  
frame.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
- If you don’t have a wrist strap,  
touch an un-painted, grounded,  
part of the equipment frame. Keep  
touching the frame to prevent  
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.  
Workstations  
static build-up. Be sure not to  
touch any electrically live parts at  
the same time.  
- Tools which come in contact with the PC board must  
be either conductive, anti-static or static-dissipative.  
POWER FEED® 25M  
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F-4  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-4  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The ammeter on the POWER  
FEED® 25M does not function  
properly even though the STATUS  
LEDs are steady green.  
1. Perform the Current Transducer  
Test in the Power Source  
Service Manual.  
1. Make sure the DIP switches are  
configured correctly for the weld-  
ing process and polarity used.  
See Setting DIP Switches in  
the Wire Drive in the  
2. The control board, located in the  
power source, may be faulty.  
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 suspected potentiometer  
and/or switches for correct resis-  
tances and operation.  
1. Check for loose or faulty connec-  
tions between the encoder panel  
and the Control Box control  
board.  
The display and/or indicator LEDs  
do not change when their corre-  
sponding switches and or knobs  
are activated or turned.  
2. Refer to machine schematics for  
lead numbers and voltages.  
2. Check for loose or faulty connec-  
tions between the appropriate  
switches and the Control Box  
control board.  
3. The Control Box control board  
may be faulty.  
The mode and/or settings change  
while welding under normal condi-  
tions.  
1. Contact “powerwave software.com”  
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.  
POWER FEED® 25M  
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F-5  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-5  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The wire feed speed is consistent  
and adjustable, but runs at the  
wrong speed.  
1. The feed head control board  
may be faulty.  
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.  
2.The wrong gear may be installed.  
1. If there are no restrictions in the  
wire feeding path, the drive  
1. The drive motor may be over-  
loaded due to a mechanical  
restriction in the wire feeding  
path. See Operation section of  
this manual.  
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.  
motor or gear box may be faulty.  
2. The feed head control board  
may be faulty.  
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.  
POWER FEED® 25M  
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F-6  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-6  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The feeder does power up - no dis-  
play, no cold feed.  
1. Turn the POWER FEED® 25M  
power switch ON.  
1. The POWER FEED® 25M power  
switch is OFF.  
2. Turn ON the Power Wave power  
source.  
2. The Power Wave power source is  
OFF.  
3. Reset the circuit breakers.  
4. Tighten, repair or replace the  
control cable.  
3. The circuit breaker for the wire  
feeder on power source have  
tripped.  
5. Replace the power switch.  
4. The control cable may be loose or  
damaged.  
5. The power switch is damaged.  
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.  
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 connec-  
tion or the solenoid has failed.  
No shielding gas.  
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 1. Keep the gun cable as straight as  
twisted  
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.  
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 3. Blow dirt out of the liner with low  
or has spatter.  
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.  
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.  
5. Replace the contact tip.  
6. Verify the proper parts are  
installed.  
7. Adjust the tension arm per the  
Instruction Manual. Most elec-  
trodes feed well at a tension arm  
setting of "3".  
8. Replace the drive rolls if worn or  
filled with dirt.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
POWER FEED® 25M  
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F-7  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-7  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Variable or "hunting" arc.  
1. Replace the contact tip.  
1. Wrong size, worn and/or melted  
contact tip.  
2. Worn work cable or poor work  
connection.  
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 recom-  
mended procedure.  
4. Adjust the gas nozzle and short-  
en the stickout to 3/8 to 1/2 inch-  
es.  
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.  
5. Check gas flow and mixture.  
Remove or block sources of  
drafts.  
1. See "Gas Metal Arc Welding  
Guide" (GS-100).  
1. Improper procedures or tech-  
niques.  
Poor arc starts with sticking or  
"blast-offs", weld porosity, narrow  
and ropy looking bead.  
The wire feed speed/amperage  
and voltage/trim display work dur-  
ing preset but show nothing during  
welding.  
1. The software in the POWER 1. Contact the local authorized  
FEED® 25M must be upgraded.  
Lincoln Field Service Shop.  
2. Download update from power-  
wavesoftware.com  
Can only select mode 12 or other  
(Factory Reset) setting - or unit  
returns to the factory setting  
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.  
POWER FEED® 25M  
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F-8  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-8  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
Major physical or electrical damage  
is evident when the sheet metal  
cover(s) are removed.  
1. Contact the Lincoln Electric  
Service Department, 1-888-  
935-3877.  
1. Contact your local authorized  
Lincoln Electric Field Service  
Facility for assistance.  
1. Check the continuity of leads  
from the gun trigger receptacle  
to plug J85. See wire drive  
wiring diagram.  
1. The gun trigger may be faulty.  
Check or replace.  
No wire feed, solenoid or arc volt-  
age. The STATUS LED’s are  
steady green.  
2. Check panel connections and  
switch(s) for proper operation.  
2. The wire drive feedhead board  
may be faulty.  
1. Perform the Tach Feedback  
1. Check P9 plug and set at feed-  
head control.  
No control of wire feed speed. All  
STATUS LEDs are steady green.  
The preset wire feed speed is  
adjustable on the front panel.  
Test.  
2. The wire drive feedhead board  
may be faulty.  
1. Make certain the Power Wave  
power source is functioning  
correctly. (Green Status LED)  
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.  
No welding arc voltage when the  
gun trigger is activated. The wire  
feeds normally and the gas sole-  
noid functions properly. The STA-  
TUS LEDs are steady green on the  
wire drive unit.  
2. Check weld + work cable rout-  
ing.  
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 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.  
1. Perform the Current Transducer  
Test in POWERWAVE® service  
manual.  
2. If the run in wire feed speed can-  
not be adjusted, perform the  
Tach Feedback Test and also  
the Drive Motor Test.  
3. The wire drive feedhead board  
may be faulty.  
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.  
POWER FEED® 25M  
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F-9  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-9  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
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.  
1. If the COLD INCH/GAS PURGE  
switch is operating correctly and  
the associated leeds are OK.  
The feedhead board may be  
faulty.  
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. If the COLD INCH/GAS PURGE  
switch is operating correctly and  
the associated leads are OK.  
The feedhead board may be  
faulty.  
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.  
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.  
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 1. Check leads #513 and #514 from  
configured correctly for the weld-  
ing polarity being used. See  
Setting Dip Switches in theWire  
Drive in the Installation section  
of this manual.  
J85 on the feedhead board to the  
voltage sense PC board. Verify  
placement in proper cavities.  
2. Perform the Voltage Sense  
Board Test.  
2. Check the #67 lead on the wire  
drive unit. Make sure it is connect-  
3. The display board may be faulty.  
ed to the motor gear box and also 4. The feedhead control board may  
the voltage sense PC board. be faulty.  
3.Check the work sensing leads on 5. The Control Box control board  
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 4-  
pin receptacle on the front of the  
POWERWAVE® and the work-  
place.  
may be faulty.  
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.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-10  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The displays are blank (not lit). The  
wire feeds when the gun trigger is  
activated.  
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.  
1. Check for loose or faulty connec-  
tions 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 daugh-  
ter board to the feed head board.  
2. If the 5VDC is low or not present,  
check for loose or faulty connec-  
tions 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.  
1. Make certain the LED indicator on  
the Dual Procedure Panel is in the  
middle position. This enables the  
gun remote dual procedure  
switch.  
The dual procedure is not function-  
al when using the remote Dual  
Procedure switch. The STATUS  
LEDs are steady green on the  
power source, and wire drive units.  
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.  
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.  
POWER FEED® 25M  
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F-11  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-11  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ArcLink System Error Codes  
Fault Code  
Possible Adjustments  
Description  
Err 81 Motor overload, long term.  
1. Check that the electrode slides  
easily through the gun and  
cable.  
1. The wire drive motor has over-  
heated.  
2. Remove tight bends from the  
gun and cable.  
3. Check that the spindle brake is  
not too tight.  
4. Verify a high quality electrode is  
being used.  
5. Wait for the error to reset and the  
motor to cool (approximately 1  
minute).  
1. Check that motor can turn freely  
when idle arm is open.  
2. Verify that the gears are free of  
debris and dirt.  
1. The wire drive motor current draw  
has exceeded limits, usually  
because the motor is in a locked  
rotor state.  
Err 82 Motor overload, short term.  
1. See the power source Instruction  
Manual for load welding pro-  
grams.  
1. The power source does not have  
any welding programs loaded.  
Err 263 No usable weld modes.  
Err 53 Voltage sense loss.  
Verify that leads 67 and 21 is  
enabled and connected. See  
enhanced schematic.  
1. The system detected that one  
of the voltage sense lead  
cables was disconnected from  
the welding circuit during a  
weld.  
Err 95 Spool gun or pull gun  
motor overload.  
1. The drive motor in the spool  
gun or push-pull gun is  
Check spool gun brake or feeding  
for binding. Replace spool gun  
circuit board.  
drawing too much current.  
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.  
POWER FEED® 25M  
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F-12  
F-12  
NOTES  
POWER FEED 25M  
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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 trou-  
bleshooting 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 volt-  
age sensing information.  
MATERIALS NEEDED  
3/8" in. nut driver  
Volt-Ohm Meter  
POWER FEED® 25M  
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F-14  
F-14  
TROUBLESHOOTING AND REPAIR  
VOLTAGE SENSE PC BOARD TEST (continued)  
FIGURE F.1 – PLUG J1 AND J2 LOCATIONS  
J2  
2 3  
5
J1  
NOTE: Inspect the molex plug con-  
2
4
nector pins on the Voltage Sense  
Board. If any of them are gold plat-  
ed the P.C. board should be  
replaced.  
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 pre-  
sent, check the continuity of lead 67 from the  
conductor block to plug J1 pin 3 on the voltage  
sense PC board.  
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.  
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.  
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 connec-  
tions between the feedhead board (plug J85  
and plug J1 on the voltage sense PC board.  
This voltage is polarity sensitive.  
7. If the 12 VDC IS present in step #4 and the arc  
voltage IS present in step #5 but the arc volt-  
age 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  
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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 trou-  
bleshooting 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  
POWER FEED® 25M  
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F-16  
F-16  
TROUBLESHOOTING AND REPAIR  
TACH FEEDBACK TEST (continued)  
FIGURE F.2 – PLUG J84 LOCATION  
RED  
BLUE  
Black  
J84  
PROCEDURE  
5. With the gun trigger activated and the motor  
1. Remove input power from the wire feeder unit.  
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.  
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.  
6. Remove input power from the wire feeder unit.  
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 connec-  
tions.  
7. Install the wire feeder cover with the 3/8 in. nut  
driver.  
POWER FEED® 25M  
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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 trou-  
bleshooting 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 capa-  
ble of running properly.  
MATERIALS NEEDED  
3/8" in. nut driver  
Volt-Ohmmeter  
POWER FEED® 25M  
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F-18  
F-18  
TROUBLESHOOTING AND REPAIR  
DRIVE MOTOR TEST (continued)  
FIGURE F.3 – QUICK CONNECTOR #550 AND #551 LOCATIONS  
#550  
#551  
4
1
5
2
6
3
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.  
PROCEDURE  
1. Remove input power to wire feed unit.  
2. Using the 3/8 in. nut driver, remove the  
cover from the wire feeder.  
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.  
3. Locate the two quick connectors in the two  
motor armature leads. Refer to Figure F.3.  
Do NOT disconnect the leads.  
4. Apply the correct input power (from the  
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.  
7. Install the wire feeder cover using the 3/8  
in. nut driver.  
POWER FEED® 25M  
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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 trou-  
bleshooting 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  
POWER FEED® 25M  
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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  
THUMB  
SCREW  
Control Box Cover  
CONDUIT  
ELECTRODE  
CABLE  
WATER  
HOSE  
GUN  
BUSHING  
WATER  
HOSES  
7. Using the needlenose pliers, disconnect the  
gas hose from the brass gun connector  
block.  
PROCEDURE  
1. Remove input power to wire feed unit.  
8. Using the 7/16 in. socket wrench, remove  
the four mounting bolts, lock washers, and  
flat washers from the plastic base insulator.  
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.  
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.  
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.  
6. Using the Phillips head screwdriver, remove  
the #67 lead from the conductor block.  
POWER FEED® 25M  
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F-21  
F-21  
TROUBLESHOOTING AND REPAIR  
GEAR BOX REMOVAL AND DRIVE MOTOR  
REMOVAL AND REPLACEMENT PROCEDURE (continued)  
“top” of the drive motor to the gear box.  
TO REMOVE THE DRIVE MOTOR  
FROM THE GEAR BOX:  
6. Install the mounting screw located inside  
the gearbox using the 5/16 in. wrench.  
10. Using the slot head screwdriver, remove the  
gear box inspection cover nearest to the drive  
motor.  
7. Install the gear box inspection cover and  
secure it with slot head screws.  
11. Using the 5/16 in. wrench, remove the  
motor mounting screw located inside the  
gear box.  
8. Properly place insulation in the bottom of  
the wire feeder case.  
12. Using the slot head screwdriver, remove  
the two screws mounting the “top” of the  
motor to the gear box.  
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.  
13. Carefully remove the motor from the gear  
box assembly. Note motor lead  
placement for reassembly.  
10. Mount the gear box and drive motor  
assembly to the wire feeder case using  
the four mounting bolts, lock washers ad  
flat washers.  
TO REMOVE THE WIRE DRIVE  
ASSEMBLY FROM THE GEAR  
BOX:  
14. Using the 3/16 in. Allen wrench, loosen the  
two Allen type screws at the bottom of the  
wire drive unit.  
11. Connect the gas hose to the brass gun  
connector block.  
12. Connect drive motor leads #550 and #551  
to their quick disconnects.  
15. Remove lead #67 from the conductor block.  
16. Carefully slide and remove the wire drive  
assembly from the gear box assembly.  
13. Thread plug J4 and associated leads  
through the vertical baffle and attach it to  
the control board. Install cable ties as  
necessary.  
REPLACEMENT PROCEDURES  
14. Install the wire feeder cover using the 3/8  
in. nut driver.  
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  
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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 proce-  
dure.  
3. With the use of a load bank and the utility, all functions of the feeder can be tested.  
POWER FEED® 25M  
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G-1  
G-1  
TABLE OF CONTENTS - DIAGRAM SECTION  
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  
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.  
POWER FEED® 25M  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - COMPLETE MACHINE - CODE 11313 (G5585)  
59  
0
AC  
-
N.D.  
S4  
S5  
640A  
BRIDGE  
RECTIFIER  
1
2
3
4
5
6
7
8
9
10  
DISPLAY  
P.C BOARD  
AC  
530A  
540E  
59  
0
.
R1  
B
475  
HEATER  
LIGHT  
LED  
640  
554  
579C  
542A 540C  
541A 500D  
53  
4
53  
52  
5
6
53  
55  
0
1
55  
55  
2
3
55  
640A  
4
531  
7
51  
55  
400E  
400D  
400E  
8
570E  
570C  
N.D.  
N.D.  
570F  
S2  
S3  
570F  
532E  
543A  
1
2
3
FLEX FLEX  
P7  
579B  
579C  
579B  
COLD N  
I
CH  
/
579A  
586A  
535A  
579A  
57  
57  
53  
58  
9
1
2
3
4
5
6
7
8
9
1 2 3 4 5 6 7 8  
1 2 3 4 5 6  
1 2 3 4  
1 2 3 4  
2STEP/  
4STEP  
GASPURGE  
578A  
535A  
586A  
8
4
578A  
585C  
5
5
1
2
3
4
5
6
7
8
9
10  
ADAPTER  
400D  
400C  
MSP4  
P.C BOARD  
6
58  
587A  
54  
57  
580A  
581A  
582A  
6
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
J8  
4
J8  
3
J82  
J81  
400C  
400B  
.
518D  
53  
8
9
518B  
530A  
540E  
J85  
0
540C  
540B  
540D  
518B  
552  
(C  
BOX,  
O
NT  
TO  
R
OL  
P)  
ON  
10  
GAS  
400B  
L7  
1
2
B
W
W
B
51  
3
3
4
FEED  
PLATE  
OFF  
SOLENOID  
1
2
3
5
6
51  
4
7
8
553  
FLEX  
P9  
1W  
1B  
N.C.  
400F  
N.C.  
1
2
3
4
5
6
7
8
4
TACH  
L4  
LIGHTLEDS  
5
R
U
B
R
U
B
1
2
3
4
5
6
7
53  
53  
53  
1
M
OT  
O
R/  
MEMORY  
P.C BOARD  
S
HIELDED  
CABLE  
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
GEARBOX  
7
1
2
3
4
5
6
7
8
9
10  
.
4
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
L5  
.15uF  
400H  
J87  
(FRONT  
PANEL)  
B
W
55  
55  
1
0
W B  
ON  
FF  
P
89  
P86  
S
HIELDE  
D
CABLE  
O
J86  
8
9
400G  
400F  
J88  
10  
CONTROLP.C.BOARD  
10  
10  
1 2 3 4 5 6  
77  
1
2
3
4
5
6
7
8
518D  
B
W
RED /GREEN  
STATUSLED  
P8  
3218  
3214  
518  
W
B
58  
58  
58  
58  
58  
1W  
1B  
587A  
580A  
585C  
581A  
582A  
1
2
3
4
5
6
7
8
54  
8
N.C.  
J810  
76  
526  
3
2
1
58  
585A  
58  
7
CURRENT  
7
0
5
1
518C  
578  
59  
P1  
518C  
5
/
WFS  
0
SPOOL GUN  
DAUGHTE  
585  
ENCODER  
75  
R
VOLTAGE  
3
2
1
58  
585B  
58  
1
2
P
C BOARD  
P2  
/
TRIM  
2
64  
0
1
2
ENCODER  
J811  
595  
S1  
540B  
540A  
DIP SWITCH  
S
1
SETTING CHART  
POWER  
P4  
40  
R2  
N.C.PI  
LIGN  
GL  
OF  
N
NEAREST T  
IT HI  
SWITCHE  
ITH.  
H
E
T
FL  
LEA  
SHOW  
A
T
EDG  
OF  
FR  
E
OF  
LED  
L
E
D
LEN  
SOCKET.  
REA CONNECTIO  
S(ANODE)  
L3  
53  
570D  
54  
2
53  
570D  
2
A
B
C
D
E
VOLTAGESENSE  
SELECTP.C BOARD  
53  
0
A
S
E
W
H
W
E
S
D
TRIGGER N  
DUAL  
PROCEDURE N  
IPUT  
.
N.D.  
O
T
G
E
N
O
M
R
N
(CO  
NT  
ROL  
BOX, BOTTOM)  
51  
40  
67  
51  
3
1
2
3
4
5
6
3
543  
SI  
D
S
W
C
SPAR  
SPAR  
E
570G  
1
2
3
4
5
6
7
8
IPUT  
400  
0
520  
B
4
HEATER  
E
E
E
E
E
J1  
J2  
TRIGGER  
CONNECTOR  
SPAR  
SPAR  
SPAR  
SPAR  
L1  
500C  
G
ENER  
ELEC RIC  
LEAD CO  
- B AC  
R - RED  
U - BLU  
HITE  
A
L
INFORMATION  
40  
T
A
L
SYMBOLS PER E1537.  
500D  
500A  
1
2
R3  
L2  
67A  
LOR CODING  
K
A
B
3218  
3214  
77  
A
A
B
B
L
POLARITY  
POS  
NEG  
EXTRA  
TORQUE  
NORMAL  
SPEED  
C
D
E
F
G
E
FEED SPEED  
GEAR  
W
-
W
P6  
532B  
75B  
76B  
P10  
77B  
570B  
76B  
53  
570D  
54  
3218  
3214  
77  
76  
570A  
532A  
75  
2
532C  
570E  
543A  
3218  
3214  
77  
P11  
1
2
3
4
5
6
7
8
9
570B  
532B  
75A  
532A  
541A  
542A  
A
B
C
D
E
CAVITY NUMBERING SEQUENCE  
1
2
3
4
5
6
7
8
54  
1
54  
54  
67  
54  
50  
500B  
1
3
A
532E  
54  
2
2
(VIEWED FROM COMPONENT  
S
IDE OF P.C. BOARD)  
77  
A
570A  
76A  
ARCLINC  
RECEPTACLE  
67A  
67  
L6  
A
1
3
6
1
1
2
540A  
500A  
500C  
54  
0
0
J6, J  
8
1, J82  
J1, J  
8
3,J88  
75B  
J2, J811  
A
A
A
D
E
C
B
F
50  
0
0
4
2
3
76  
4
5
67  
B
500B  
570C  
532D  
75  
FOOTAMPTROL  
1
1
1
8
4
8
J8  
5
J8  
6
J84, J810  
PUSH-PULL  
P3  
INPUTELECTRODE  
CABLECONNECTION  
10  
16  
A
6
9
5
10  
P5  
A
R
CLEVELAND, OHIO U.S.A.  
G5585  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-3  
G-3  
ELECTRICAL DIAGRAMS  
SCHEMATIC - COMPLETE MACHINE - CODE 11313 (G5638)  
3 8 5 6 G  
R
ELEASE  
D
A.02 RFOM "X".  
E
NGI  
N
EERING CONTRO  
D
MANUFACTURER: NoLLE  
C
OM PONENT  
CAPACIT R: MFD/  
RESIST R: HMS/  
V
AL  
U
E
U
NITS:  
OLT  
ATT  
LE  
ADCOLORCODE:  
B-BLACK  
R-RED  
VOLTAGE SENSE  
SELECT P.C. BOARD  
O
V
S
C
AVITY NUMBERING SEQUENCE  
(COMPONENT  
S
IDE OF  
P.C. BOARD)  
O
O
W
S
(SCHEMATIC S24779)  
U-BLUE  
(LOCATED  
B
EHIND  
WIRE  
W-  
W
HITE  
CONNECT  
O
R
PIN  
NUMBERS:  
1
1
2
1
3
REEL  
COVER)  
1
4
8
J1,J83,J88  
J81,J82  
J2,J811  
J84,J810  
EX.12PINCONNECTO  
R
2
5
3
4
6
4
1
7
6
LABELS:  
OMM ON  
FRAM GROUND  
1
1
8
5
J8  
6
J85,J87  
C
10  
16  
9
12  
LATCH  
6
E
5 PIN A  
CONNECT  
POWER SOURCE  
OTE: WILL W RK WIT LINKNET  
POWER SOURCE BUT WILL  
R
CLINK  
VIEW OF CONNECTORONPCBOARD  
O
R T  
O
N
O
H
J2  
J1  
O
L
NLY SHOW A  
INKNET FEAT  
(LOCATED  
N
D
HAVE  
URES  
(BEHIND  
WIRE REEL COVER)  
P11  
AT  
REAR  
O
F
FEEDER)  
400  
A
1
2
3
541  
A
541  
C
OMMUNICATION  
(CONTROL  
BO BOTTOM)  
{
542  
542  
A
B
C
SEE ERROR TABLE  
IN IM MA UAL  
RED/ REE  
STATUS LED  
(TO FRONT)  
LED DISPLAY  
X
LED DISPLAY  
67  
67A  
LEDS  
P10  
N
S1 POWE  
R
D
E
540  
500  
4
5
6
7
8
540  
500  
500C  
A
540B  
25 TO 35  
NORMAL  
FL RATE  
G
N
40 VD  
C
{
(LEF  
T
LOWER CAS FRONT)  
E
500  
A
B
BALL FLOAT  
USE MI DLE  
BALL TO SET  
OW  
P
CONNECTS TO S4  
400  
E
(BEHIND  
W
IRE  
FEED MOTOR)  
R2 530  
HELPS KEEP MOISTURE  
D
OF  
540  
B
L
6
W
B
TOROID  
R3  
520  
530A  
7P7  
540  
S5 HEATER  
(ABOVE WI FEED MOTOR)  
E
8P7  
540D  
W
FS AMPS  
DISPLAY P. C. BOARD  
(S HEMATIC: L11756)  
(TO FRONT)  
RON PUL DOWN DOOR)  
PANEL ENCODERS  
VOLTS TRIM  
ARC VOLTAGE  
FEEDBACK  
40 O MS  
10 WATTS  
H
OFF  
OF  
WIRE  
R
E
C
500D  
ADJUST VALVE  
P
(BEHIND  
F
T
L
W
8
7
FLE  
X
B
VOLTS  
TRIM  
CURRENT  
FS  
INPUT ELECTRODE  
CABLE CONNECTION  
FLOW METER  
67B  
L
5
W
1 2 3  
3
1 2  
TOROID  
(OUTSI  
DE  
BACK OF CASE)  
P1  
P2  
P9  
GOO  
D
FOR A  
r, CO2,  
C
O2/A BLENDS  
r
(BAS  
BD.  
E
CONTROL  
PWM CONT  
R
OLLE  
GAS IS  
OIL  
D
ADAPTER  
A
REA)  
6.5 VD  
FLOWI  
C
N
W
G.  
HE  
C
N
ARCLINK OPTION USE  
1
2
4
3
5
7
6
8
FEED PLATE  
MOT  
OR  
F
RAME  
MEASURES 21 O  
12 VD OIL  
(LOCATED  
FEEDER)  
HMS.  
1
2
3
4
5
6
GAS  
580  
585  
IS HOT TO  
ELECTR  
C
C
MOT  
TYP: IPM  
50 - 800/IPM NO  
O
R
GEARBOX  
TACH  
587  
582  
3J81 4J81  
2J81 1J81  
14J85 13J85  
O
DE  
4J82  
3J82  
2J82 1J82  
A
T
REAR  
R
U
B
R
U
B
DIP SWITCH S9  
OF  
R
MAL SPEED  
XTRA TORQUE  
MOT  
MOT  
GAS SOLE  
GAS SOLE OI  
5VDC TA H SUPPLY  
TACH SI NAL  
TACH OM  
O
R
+
581  
NGLE HEAD)  
15J85  
16J85  
10J85  
7J85  
5J85  
12J85  
11J85  
1W  
1B  
580  
FLE  
X
30-400/IPM E  
1J83  
2J83  
3J83  
4J83  
550  
551  
553  
554  
SINGLE  
HEA  
O
R
N
-
OI  
SET SWIT  
AND SWIT  
AS SHOW  
C
C
N
H 1 "ON  
H 2 "ON  
DIP SWIT  
(LOCATED  
"
"
(SI  
FEEDER)  
H S9.  
1
2
FEEDE  
R
5-32 VDC  
FEED  
HEA  
D
D
O
N
P8  
A
D
+
(
P.C. BOARD  
(BEHIND COVER  
MOTOR REA)  
(S HEMATIC G3883)  
3.1 O  
13 SEC. AVERAGE CURRENT  
LIMIT 3.5  
(LIMIT IS SOFTWARE SET)  
HMS  
(BEHIND DISPLA  
Y
BOARD)  
587  
585C  
582  
581  
A
O
N
C
N
D
-
AND  
(ACCES  
CONNECTOR BY REMOVING  
THE WI DRIVE ASSEMBLY)  
S
THIS  
D
UAL  
BACK  
HEA  
A
O
N
=
A
(WI DRIVE FRON  
RE  
T
TOP)  
FUTURE  
D
C
G
C
R
E
SI  
DE OF  
BOARD)  
531  
537  
534  
1J84  
7J84  
4J84  
C
A
COLD INCH/  
LEDS  
A-GUN-B  
PUSHBUTTO  
COLD INCH  
A
GAS PURGE SWITCH  
0V TO  
SWIT  
P6  
C
OMMO  
N
WHEN  
N
(CONTROL  
BO TOP)  
+5VDC  
C
H
CLOSED  
(CAS  
E
FRONT)  
P4  
PERFORM  
INTERFACE, WI  
AND GA SOLENOI  
FUNCTIONS.  
S
AL  
L
RE  
USER  
DRIVE,  
L4 TOROID  
535A  
5J84  
6J85  
9J85  
535  
586  
579  
578  
3
4
1
2
X
L3 TO  
L1 TO  
R
OI  
D
D
S3  
400F  
TRIG  
GE  
GER A  
UAL PROCEDURE  
R
400G  
S
D
SIGNAL  
+15VDC  
GAS PURGE  
A
C
D
E
B
532  
532  
532C  
532  
570F  
543  
E
1
2
3
2J85  
1J85  
3J85  
586  
A
A
CONTRO  
L
TRI  
UAL  
GGER  
SUPPLY FOR TRI  
G
ND  
DUAL  
{
{
570  
E
570D  
543  
570D  
543  
MEMORY P.C. BOARD  
400D  
S4  
579  
D
(S  
UL  
(BEHIND UL  
C
HEMATIC: L11897)  
DOWN DOOR RONT)  
DOWN DOOR RONT)  
(BEHIND CAS  
E
FRONT)  
A
543  
A
D
400C  
S2  
SEE DIPSWIT  
CH S1  
ROI  
(ON  
P
L
F
579  
B
PRO  
CEDURE  
578A  
4J88  
8J84  
SETTIN HART  
G
C
LIGHT LED SWITCH  
USED I DARK AREAS  
(ABOVE WI FEED MOTOR TOP)  
570G  
579C  
532  
570  
A
A
9
8
532D  
(
N
)
P
L
F
ON  
PR  
A = OPE  
OCEDURE  
1
3 S1  
570C  
SET UP  
LED  
2
R
E
N
4
5
6
7
2 STEP/4 STEP SWITCH  
590  
518  
OFF  
PUSH-PULL MOTOR  
B = CLOSE  
D
8
(WIRE  
DRIVE ARE  
A
FRON  
T
TOP)  
2 STEP  
INFRARED TRANSCEIVER  
WIRELESS COMMUNICATION)  
0VD  
24VD  
C
C
@
@
50 IN/MI  
700 IN/MIN  
N
7 PIN  
OPE  
N
=
4 STEP: CLOSE  
D
=
(
532  
A
PUSH-PULL  
MSP4 P.C. BOARD  
(S HEMATIC: G4456)  
J87  
N
OT USE  
CLEAN ROOM USE  
D
CAPACITOR  
518D  
AC  
1J88  
518C  
6
518  
B
W
B
W
WEL  
ERRO  
SEGMENTA  
NUMERIC DISPLAY  
D
MODE, WIRE SIZE,  
CODES, SEVEN  
D ALPHA  
GUN  
ONNECTION  
B
A
3214A  
3218A  
C
M
400H  
400  
B
R
PUS  
H
-PULL GU  
FEED SPEE  
N
WIRE  
C
(BEHIND CASE  
FRONT)  
P7  
N
J86 SPI USE  
D
CONTROL  
1J88  
8J84  
5K  
+40  
-
RE  
Q
UIRE  
D
FOR  
MOT  
RUN I  
OPEN, REVERSED,  
DISCONNECTE  
DE BRI GE  
(DIVIDER ANE  
ACCES DOOR SIDE)  
O
F
RS WILL  
DIODE IS  
NOT  
L2 TO  
ROID  
518  
5J83  
5J83  
5J88  
554  
START OPTIONS LE  
EN OPTIONS LE  
CONNECTS  
D
(CONTRO BO TOP)  
WEL MODE LE  
AR CONT OL LE  
SELECT  
PUSHBUTTO  
L
X
P5  
4 STEP MODE  
WIRE  
MOTOR  
USE  
PUS  
H
-PULL  
D
D
D
D
640  
A
E
F
D G  
C
16 DETENT  
ENCODE  
PUS  
BRAKE SIGNAL  
(0 VOLT MOTOR BRAKE  
H-PULL GUN  
O
R
D
GUN TRI  
GGE  
R
R1  
475 OHMS  
(BACK O WI  
B
C
R
D
CAPACIT  
OR  
R
570  
A
DI  
O
D
P
FROM PIN 10 F SHIELDE  
CABLE TO RAME GROUND.  
O
D
AMPHE  
NOL  
(LOWER CAS  
=
6J85  
6J84  
L
REAR  
SELECT PUSHBUTTO  
N
77B  
F
E
FRONT)  
F
RE  
DRIV  
E
N
S
570  
B
76B  
75B  
0-5V PUS  
POTENTIOMETER SI  
H
-PULL GUN  
PANEL - SOLDER  
SEE IM MANUAL FOR ERRO  
R
CODES  
WWW.POWERWAVESOFTWARE.COM  
R SE VICE AVIGATO DIAGNOSTI UTILITIES  
532  
B
6J810  
4J810  
3J810  
2J810  
5J810  
8J810  
1J810  
PUS  
77A  
526  
P6  
L
7
G
NAL  
ON  
B
RACKET)  
595  
2J811  
1J811  
548  
OR  
TO PUS  
H
-PULL  
76A  
75A  
TOROID  
3214A  
3218A  
76A  
5
4
7
10  
6
321  
321  
76  
75  
77  
4
8
321  
76  
4
640  
PROVIDE  
TH  
GUN MOTOR  
CONDITIO  
SIGNA FROM THE  
POTENTIOMETER.  
O
R
N
R
C
GUN  
MOT  
OR  
DRIVE  
321  
75  
8
SHIELDE CABLE  
D
S
BRAKING  
+40V  
PUS  
D
C SUPPLY FO  
R
OF  
E
PUSH-PULL  
ND  
THE  
75A  
77A  
SET  
UP  
M
ENU FEATURES  
it set up ode  
F
SE  
T
s the  
UP  
r
MENU  
ight and left push buttons  
C
B
E
D
A
P3  
H
-PULL GU MOTOR  
N
A
77  
P.0 = On/Off enter e  
x
m
P205  
P206  
=
=
C
C
C test 550A  
To acce  
ss, pre  
s
(NON-ISOLATED  
)
N
S
P1 =  
P2 = Left display a  
W
FS English/metri  
c
H
-PULL GUN  
on the MSP4 panel simultaneousl  
y
V test 10V to 30 V  
L1 TOROID  
PCT A  
ND  
RESISTORS  
L
6 PIN REMOTE FOOT  
AMPTROL CONNECTION  
DAUGHTE  
R
m
ps/w  
fs  
P207 = 1/0 test 25-600  
P208 ST test 170A  
P209 = 1 curve 0-600A  
PROTECTED ON  
DAUGHTER BOARD  
P.C. BOARD  
CHEMATIC L12008)  
P4 = T  
P5 = T  
r
r
igger me  
mory recall  
igger procedure change  
P6 = Stall facto  
P7 = Push pull gun offset  
P8 = Ne TIG solenoid feature  
P80-89 = Senses from studs on S25629-09  
S
et  
versi  
specific feature y  
are for reference.  
u
p featur  
ns. Must re  
e
numbers may v  
d small display to find your  
want. es numbers listed  
ary between software  
=
T
(S  
P89  
(LOWER CAS FRONT)  
E
o
a
r
ou  
T
h
e
P
P210  
P211  
P212  
=
=
=
Step resp background  
V cur e 0-70V 10-70V  
OCV test  
v
SEE IM MANUAL  
FO MORE  
DETAILS  
w
R
DIP SWITCH  
S
1
SETTING CHART  
P215 = Touch sense  
P255 Show weld file  
P99 = Sho  
P100 = Vie  
w
test mode 200.201  
diagnostics  
GENERAL  
STEEL  
S
TAINLESS  
=
w
GMA  
W
W
STD. CV  
WE  
STD. CV  
5
0.030 0.035 0.04  
5
0.030 0.035 0.045 0.052  
-
94  
95  
-
P102 = Fatal log  
P103 = Vie soft  
P104 = Hard are ver  
P105 = Welding soft  
P200 =  
P201 = CV test 10-35  
GMA  
GMA  
W
W
A
A
r (MIX)  
/He/  
61  
31  
33  
36  
32  
41  
43  
46  
42  
44  
CV GMA  
P
O
R
MODE 40  
GMA  
GMA  
W
W
C
O2  
MIX)  
MIX)  
MIX)  
/CO2  
/CO2  
--  
10  
11  
20  
21  
24  
25  
26  
w
w
ware  
sion  
w
r
C
O2 63  
F
CAW  
6
Ar  
(
(
PULSE Ar/  
PULSE Ar/O2  
PULSE Ar/He/  
CO2  
6
6
PULSE (CRISP  
PULSE (S FT  
O TAIL  
)
Ar  
Ar  
12  
14  
22  
19  
SPAR  
E
E
1
are  
STICK SOFT (7018  
TICK RISP (6010  
CC TIG TOUCH START  
GOUGE --  
)
1
2
3
9
62  
O
)
(
--  
28  
C
C test 25-600  
SERIAL N  
CODE NUMBER L  
BELOW WIRE FEE  
RIVE OLL AREA  
U
MBER AND  
SPAR  
S
C
)
2
3
4
5
6
7
C
C
C
O2 ---  
34  
STT (  
N
O
UT)  
C
O2 A  
O2 A  
r
r
109  
110 110  
109  
125  
126  
125  
126  
OCATE  
D
ST  
T
Ar/He/  
O2 109  
O2 110  
109  
110  
125  
126  
STTll  
C
SPAR  
E
E
P202 =  
P203 =  
P204 =  
CC test 10A  
CC test 355A  
CC test 455A  
D
-
STTll Ar/He/  
D
R
SPAR  
ALUMI UM  
N
METAL CORE  
GMA /CO2  
SPAR  
E
E
0.035 3/64 1/16  
Ar 148  
Ar 149  
0.045 0.052  
1
2
1/16  
85  
86  
0.035 3/64 1/16  
THIS DOCUMENT CONTAINS PROPRIETAR  
Y
INFORMATION OWNED B LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED  
TO OTHER PARTIES OR USED FOR AN PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
Y
GMAW  
71  
72  
99  
7
74  
10  
3
W
A
r
8
8
83  
84  
PROPRIETARY & CONFIDENTIAL:  
GMA  
W
Ar 151  
75  
77  
SPAR  
Y
PULSE Ar/ O2  
C
4043 PULSE  
PULSE ON PULSE  
5356 PULSE  
Ar 152  
76  
7
8
DESIG  
N
I
NFORMATION  
REFERENCE:  
G4440  
T
HE INFORMA  
PRIN ISOR RE  
ONLY. MPONEN  
CIRCUI RY MA BE DIFFERENT  
RO AN AC UAL ACHINE.  
T
IO  
ERENC  
AND  
N
F
ON  
THIS  
E
EQUIPMENT TYPE:  
PAGE _1__ OF _1__  
POWERFEED25M  
POLARITY  
FEED SPEED  
NEG  
POS  
LOW SPEE  
EXTRA TORQUE  
A
r
98  
0
PULSE ON PULSE Ar 101  
102 103  
T
F
JIMJ/KJ  
ENYEDY  
DRAWN BY:  
DOCUMENT  
REVISION:  
DO  
CUMENT  
O
C
TS  
D
SUBJECT:  
NORMAL  
SPEED  
MACHINESCHEMATIC  
NUMBER:  
ENG  
INEER:  
SCALE:  
8
G
EAR  
T
Y
MATERIAL  
APPROVAL  
DATE:  
PROJECT  
NUMBER:  
G5638  
F
M
T
M
C
RM38268  
A
ION:NA  
APPROVED  
:
9/13/2060  
NONE  
DISPOSIT  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-4  
G-4  
ELECTRICAL DIAGRAMS  
SCHEMATIC - 42 VAC & ARCLINK FEEDER PC BOARD #1 (G3883-2)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-5  
G-5  
ELECTRICAL DIAGRAMS  
SCHEMATIC - 42 VAC & ARCLINK FEEDER PC BOARD #2 (G3883-2)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
SCHEMATIC - MSP4 OPTIONAL DISPLAY PC BOARD (G4456)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
SCHEMATIC - SPI DISPLAY PC BOARD - (L11756)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - SPI DISPLAY - (L11757-1)  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-9  
G-9  
ELECTRICAL DIAGRAMS  
SCHEMATIC - VOLTAGE SENSE SELECT PC BOARD - (S24779)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-10  
G-10  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - VOLTAGE SENSE SELECT (M19540)  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-11  
G-11  
ELECTRICAL DIAGRAMS  
SCHEMATIC - SPOOL GUN PC BOARD (L12008)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-12  
G-12  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - SPOOL GUN (M20159)  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
POWER FEED® 25M  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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