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Lincoln Electric SVM185-A manual

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Table of contents for the manual

  • Page 1

    POWER FEED ® 25M SVM185-A July , 2008 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND T[...]

  • Page 2

    SAFETY i i i i Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-[...]

  • Page 3

    SAFETY i i i i i i i i Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FUMES AND GASES can be dangerous. 5.a. W elding may produce fumes and gases hazardous to health. A void breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to ke[...]

  • Page 4

    S S A A F F E E T T Y Y i i i i i i i i i i i i Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Jan ‘07 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b . Install equipment in accordance with the U .S. Nationa[...]

  • Page 5

    S S A A F F E E T T Y Y i i v v i i v v Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Mar ‘93 PRÉCAUTIONS DE SÛRETÉ P our votre propre protection lire et obser ver toutes les instr uctions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de s[...]

  • Page 6

    SAFETY v v Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M Electroma gnetic Compatibility (EMC) Conf or mance Products displa ying the CE mar k are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to elect[...]

  • Page 7

    SAFETY vi vi Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M Electr omagnetic 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 bey ond the boundari[...]

  • Page 8

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I PO WER FEED® 25M RETURN TO MAIN INDEX P age Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 9

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 T echnical Specific[...]

  • Page 10

    INST ALLA TION A-2 A-2 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC TEMPERA TURE RANGE OPERA TION: -40°F to 122°F (-40°C to 50°C) ST ORA GE: -40°F to 185°F (-40°C to 85°C) INPUT V OL T[...]

  • Page 11

    INST ALLA TION A-3 A-3 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SAFETY PRECA UTIONS ELECTRIC SHOCK CAN KILL. • T urn the input power OFF at the welding power source before installation o[...]

  • Page 12

    INST ALLA TION A-4 A-4 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC CONTROL CABLE CONNECTION: Digital Control Cable: Figure A.3 P o w er S ource A A B B C C D D E E W i re F eeder A A B B C C [...]

  • Page 13

    INST ALLA TION A-5 A-5 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC WELD CABLE SIZE T able A.1 located belo w are copper cab le sizes re com- mended f or diff erent currents and duty cycles . [...]

  • Page 14

    INST ALLA TION A-6 A-6 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SHIELDING GAS CONNECTION CYLINDER may explode if damaged. • Keep cylinder upright and chained to suppor t. • Keep cylind[...]

  • Page 15

    INST ALLA TION A-7 A-7 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC CHANGING THE DRIVE MO T OR GEAR RA TIO • T urn off input po wer at the welding power source bef ore installation or changi[...]

  • Page 16

    INST ALLA TION A-8 A-8 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC WIRE DRIVE CONFIGURA TION (See Figure A-6) Changing the Gun Receiver Bushing ELECTRIC SHOCK can kill. • T urn the input po[...]

  • Page 17

    INST ALLA TION A-9 A-9 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC REMO TE SENSE LEAD SPECIFICA TIONS W elding with Multiple Arcs: ( See Figure A.7) Special care must be tak en when more than[...]

  • Page 18

    INST ALLA TION A-10 A-10 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC TYPICAL SYSTEM CONFIGURA TIONS Standard Features Arc Perf ormance • Push-Pull ready f or welding aluminum with Pulse and[...]

  • Page 19

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Saf ety Precautions . . [...]

  • Page 20

    OPERA TION B-2 B-2 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ture, when feeding with gun trig- ger , the electrode and drive mechani[...]

  • Page 21

    OPERA TION B-3 B-3 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variab les t[...]

  • Page 22

    OPERA TION B-4 B-4 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC RECOMMENDED PROCESSES • GMA W (CV , Synergic CV , Pulse, STT™, P ower , Pulse on Pulse™, Push-Pull) • FCA W • SMA W ?[...]

  • Page 23

    OPERA TION B-5 B-5 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 1 3 2 5 4 6 9 14 15 16 8 11 12 13 10 7 FIGURE B.1 CASE FRONT CONTROLS (See Figure B.1) 1. Left DISPLA Y window Shows WIRE FEED S[...]

  • Page 24

    OPERA TION B-6 B-6 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC LED condition Steady green Blinking green. Blinking green, fast Blinking green f ol- lowe d by blin ki ng red. Definition System[...]

  • Page 25

    OPERA TION B-7 B-7 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC MAKING A WELD WITH W A VEFORM TECHNOLOGY PO WER SOURCES The serviceability of a product or structure utilizing the welding pr og[...]

  • Page 26

    OPERA TION B-8 B-8 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ST ART OPTIONS END OPTIONS SET SETUP IR PORT CC Stick Soft WA VEFORM CONTROL TECHNOLOGY Stick WELD MODE ARC CONTROL I I ARC FORC[...]

  • Page 27

    OPERA TION B-9 B-9 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NON-SYNERGIC GMA W AND FCA W WELDING (See Figure B.4) Non-synergic GMA W and FCA W welding mimics the welding controls of tradit[...]

  • Page 28

    OPERA TION B-10 B-10 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 300 25.3 WFS AMPS VOL TS TRIM Less WFS Less V olts More V olts More WFS 250 54 W FS AMPS VOL TS TRIM Less WFS S horter Arc L o[...]

  • Page 29

    OPERA TION B-11 B-11 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC GMA W (MIG) SYNERGIC WELDING Synergic welding allows for easy procedure setting. The WFS and V oltage change together to maint[...]

  • Page 30

    OPERA TION B-12 B-12 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Synergic CV programs f eature an ideal voltage best suited f or most procedures. Use this v oltage as a star t- ing point and [...]

  • Page 31

    OPERA TION B-13 B-13 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC STEEL AND ST AINLESS SYNERGIC GMA W -P (PULSED MIG) WELDING Synergic GMA W -P (Pulsed MIG) welding is ideal for low spatter , [...]

  • Page 32

    OPERA TION B-14 B-14 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ST AINLESS STEEL GMA W (MIG)WELDING K2368-1 P ower W av e® 355M 1 K2202-1 P ower W av e® 455M K2203-1 P ower W av e® 455M/S[...]

  • Page 33

    OPERA TION B-15 B-15 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Steel and Stainless GMA W -P (Pulsed MIg)Display 220 1.06 W FS AMPS VOL TS TRIM Less Deposition Shorter A rc L onger Arc More [...]

  • Page 34

    OPERA TION B-16 B-16 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ALUMINUM SYNERGIC GMA W -P (PULSED MIG)AND GMA W -PP (PULSE ON PULSE) WELDING The POWER FEED® 25M and P ower Wa ve welding po[...]

  • Page 35

    OPERA TION B-17 B-17 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ALUMINUM GMA W -P AND GMA W -PP ALUMINUM PULSE WELDING Synergic GMA W -P (Pulsed MIG) welding is ideal for low spatter , out o[...]

  • Page 36

    OPERA TION B-18 B-18 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ALUMINUM GMA W -P AND GMA W-PP WELDING K2368-1 P ower W av e® 355M 1 K2202-1 P ower W av e® 455M K2203-1 P ower W av e® 455[...]

  • Page 37

    OPERA TION B-19 B-19 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PULSE PULSE-ON-PULSE FREQUENCY: FREQ.MODULATION (Low)-10.0 to (High)+10.0 (Low)-10.0 to (High)+10.0 DESCRIPTION For Pulse -On-[...]

  • Page 38

    OPERA TION B-20 B-20 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC GMA W -STT™ WELDING Surface T ension T ransfer , or STT™ welding, is a break-through process offered e xclusively by the L[...]

  • Page 39

    OPERA TION B-21 B-21 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC GMA W -STT™ W aveform Control T echnology™ maximizes the ability to modify the arc for the perf ect weld. When STT™ weld[...]

  • Page 40

    OPERA TION B-22 B-22 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PEAK CURRENT (Figure B.16) P eak current controls the arc length, which also aff ects the shape of the root. When using 100% C[...]

  • Page 41

    OPERA TION B-23 B-23 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC No Foot / Hand Amptrol 1. Adjust the arc amperage with the left knob on the displa y panel. 2. T ur n the right knob on the di[...]

  • Page 42

    OPERA TION B-24 B-24 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 8 4 3 2 7 1 5 6 W A R N I N G W A R N I N G A V I S O D E P R E C A U C I O N A T T E N T I O N ! ! ! ! L o r e m i p s u m d [...]

  • Page 43

    OPERA TION B-25 B-25 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SET -UP FEA TURES MENU The Setup Menu gives access to the set-up configura- tion. Stored in the set-up configuration are user [...]

  • Page 44

    OPERA TION B-26 B-26 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC P .0 Press the left button to exit the set-up menu. P .1 WFS units Metric = m/min wire f eed speed units English = in/min wire[...]

  • Page 45

    OPERA TION B-27 B-27 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC P .8 TIG Gas Control (T wo Settings) 1. "V alve (manual)" , the internal solenoid will not actuate while TIG welding[...]

  • Page 46

    OPERA TION B-28 B-28 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC P .99 Show T est Modes Many weld tables include special modes f or testing and ser vicing the welding system. Set this paramet[...]

  • Page 47

    OPERA TION B-29 B-29 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC USER MEMORIES Recall a memory with memor y buttons T o recall a user a memor y , press one of the six user memor y buttons . T[...]

  • Page 48

    OPERA TION B-30 B-30 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC T o set limits, press the desired memor y button 1-6 and hold f or 5 seconds. Release the memor y button when the LED begins t[...]

  • Page 49

    OPERA TION B-31 B-31 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC F our items show on the MSP4 panel. • Memor y V alue • High Limit • Low Limit • P arameter Name One of these items wil[...]

  • Page 50

    OPERA TION B-32 B-32 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC INTERNAL CONTROLS 2 - S TE P 4 S TE P 1 2 Step / 4 Step T rigger Switch 2 Cold F eed / Purge Switch 3 Wire Drive Pressure Arm [...]

  • Page 51

    OPERA TION B-33 B-33 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC COLD FEED/GAS PURGE SWITCH Cold F eed and Gas Purge are combined into a sin gle s pr ing cent ered togg le s witch. T o activa[...]

  • Page 52

    OPERA TION B-34 B-34 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC EXAMPLE 1 - 2 STEP TRIGGER: Simple operation The simplest trigger operation occurs with a 2 Step trigger and the Star t, Crate[...]

  • Page 53

    OPERA TION B-35 B-35 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC EXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Star t and Arc End. T ailor ing the arc star t and arc end is a common method for red[...]

  • Page 54

    OPERA TION B-36 B-36 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC WELD: After upslope, the power source output and the wire f eed speed continue at the weld settings. CRA TER: As soon as the t[...]

  • Page 55

    OPERA TION B-37 B-37 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Shield in g Ga s I d le Preflo w St ri ke W e l d B ur nb ac k P os t f low I dl e WFS On Of f Ru n- in Of f We l d Of f We l [...]

  • Page 56

    OPERA TION B-38 B-38 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC EXAMPLE 5 - 4 STEP TRIGGER: Manual control of Star t and Crater times with Burnback ON. The 4 step trigger sequence gives the [...]

  • Page 57

    OPERA TION B-39 B-39 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC REAR CONTROLS: 1 Flow Meter 2 Shielding Gas Inlet 3 5-Pin Arclink Cable Connector 4 Electrode Cable 5 Cover for[...]

  • Page 58

    OPERA TION B-40 B-40 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FLO W METER The flo wmeter sho ws the flow rate of shielding gas and has a valv e to adjust the flow . The flow meter is scale[...]

  • Page 59

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 F actor y Installed Equip[...]

  • Page 60

    ACCESSORIES C-2 C-2 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC WIRE TYPE Steel Wires: Cored Wires: Aluminum Wires: ELECTRODE SIZE .023-.030 (0.6-0.8mm) .035 (0.9mm) .045 (1.2mm) .052 (1.4mm)[...]

  • Page 61

    ACCESSORIES C-3 C-3 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC K2429-1 K857 K857-1 K2596-1 K2596-2 K2593-xx K1796-xx K1803-1 K1840-xx K1842-xx ArcLink "T" Cable Adapter Remote Outp[...]

  • Page 62

    ACCESSORIES C-4 C-4 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC K1543-xx K910-1 K910-2 K1500-1 K1500-2 (Included with PF25M) K1500-3 K1500-4 Digital Control Cable Ground Clamp Ground Clamp Gu[...]

  • Page 63

    ACCESSORIES C-5 C-5 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC K1500-5 K489-7 K2339-1 K590-6 K435 K468 K659-1 3000290 K586-1 Gun Receiver Bushing (compatible with Oxo® guns.) Gun Receiver B[...]

  • Page 64

    ACCESSORIES C-6 C-6 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC INST ALL A T ION OF THE K590- 6 W A TE R COOLING KIT ELECTRIC SHOCK can kill. • T urn the input power OFF at the dis- connect[...]

  • Page 65

    ACCESSORIES C-7 C-7 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ELECTRIC SHOCK can kill. • T urn the input power OFF at the disconnect switch before working on this equipment. • Do not to[...]

  • Page 66

    Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NOTES C-8 C-8 PO WER FEED® 25M[...]

  • Page 67

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Saf ety Precautions . . . .[...]

  • Page 68

    MAINTENANCE D-2 D-2 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ELECTRIC SHOCK can kill. • Do not operate with co vers removed. • T urn off power source before installing or servicing. ?[...]

  • Page 69

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Physical Descr [...]

  • Page 70

    VO LTA G E SENSE LEAD #67A LEAD #67 PUSH PULL DAUGHTER DRIVE MOTOR GEAR BOX AND CONDUCTOR BLOCK FEEDBACK T ACH ST A TUS LED GUN TIGGER AND DUAL PROCEDURE RECEPT ACLE 2-STEP/ 4-STEP CONTROL BOARD FEEDHEAD DIP SWITCHES TO POWER SOURCE INPUT NETWORK RECEPT ACLE HEA TER LIGHT CONNECTOR FOOT AMPTROL COLD INCH/ GAS PURGE GAS SOLENOID THEOR Y OF OPERA TIO[...]

  • Page 71

    THEOR Y OF OPERA TION E-3 E-3 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M The PO WER FEED® 25M is a two roll, high perfor- mance, digitally controlled, modular wire f eeder[...]

  • Page 72

    THEOR Y OF OPERA TION E-4 E-4 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC CONTROL BOX (USER INTERF ACE) The PO WER FEED® 25M wire feeders do not hav e User Interface Boards in the control bo[...]

  • Page 73

    TROUBLESHOOTING E-5 E-5 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC COMPONENT ST A TUS LIGHTS Each network component has a single status light. The light is a bicolor , Green/Red, LED . The p[...]

  • Page 74

    TROUBLESHOOTING E-6 E-6 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ST A TUS LIGHT ST A TES (CON’T) LED State Red LED blinking at a f ast rate Red LED ON and steady Green LED ON and steady [...]

  • Page 75

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting G[...]

  • Page 76

    TROUBLESHOOTING AND REP AIR F-2 F-2 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply f o[...]

  • Page 77

    TROUBLESHOOTING AND REP AIR F-3 F-3 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Sometimes machine failures appear to be due to PC board failures . These problems can sometimes be traced to po[...]

  • Page 78

    FUNCTION PROBLEMS Obser ve Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any r eason y ou do not understand the test procedure s or are unab le to perform the tests/repairs saf ely , contact the Lincoln Electr ic Service Depar tment f or technic[...]

  • Page 79

    FUNCTION PROBLEMS Obser ve Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any r eason y ou do not understand the test procedure s or are unab le to perform the tests/repairs saf ely , contact the Lincoln Electr ic Service Depar tment f or technic[...]

  • Page 80

    OUTPUT PROBLEMS Obser ve Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any r eason y ou do not understand the test procedure s or are unab le to perform the tests/repairs saf ely , contact the Lincoln Electr ic Service Depar tment f or technical[...]

  • Page 81

    OUTPUT PROBLEMS Obser ve Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any r eason y ou do not understand the test procedure s or are unab le to perform the tests/repairs saf ely , contact the Lincoln Electr ic Service Depar tment f or technical[...]

  • Page 82

    FUNCTION PROBLEMS Obser ve Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any r eason y ou do not understand the test procedure s or are unab le to perform the tests/repairs saf ely , contact the Lincoln Electr ic Service Depar tment f or technic[...]

  • Page 83

    FUNCTION PROBLEMS Obser ve Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any r eason y ou do not understand the test procedure s or are unab le to perform the tests/repairs saf ely , contact the Lincoln Electr ic Service Depar tment f or technic[...]

  • Page 84

    FUNCTION PROBLEMS Obser ve Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any r eason y ou do not understand the test procedure s or are unab le to perform the tests/repairs saf ely , contact the Lincoln Electr ic Service Depar tment f or technic[...]

  • Page 85

    ArcLink System Error Codes Obser ve Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any r eason y ou do not understand the test procedure s or are unab le to perform the tests/repairs saf ely , contact the Lincoln Electr ic Service Depar tment f o[...]

  • Page 86

    Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NOTES F-12 F-12 PO WER FEED 25M[...]

  • Page 87

    Ser vice and repair should be perf or med b y only Lincoln Electric f actor y trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine oper ator and will in validate your f actor y warranty . F or your saf ety and to av oid electrical shock, please obser ve all safety notes and precaution[...]

  • Page 88

    23 4 5 2 J1 J2 FIGURE F .1 – PLUG J1 AND J2 LOCA TIONS VOL T AGE SENSE PC BOARD TEST (continued) PROCEDURE 1. Remov e input power from the wire feed unit. 2. Using the 3/8 in. nut driver , remov e the cov er from behind the wire reel. 3. Locate the volt age sense PC board and plugs J1 and J2. Do not remove the plugs from the voltage sense pc boar[...]

  • Page 89

    Ser vice and repair should be perf or med b y only Lincoln Electric f actor y trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine oper ator and will in validate your f actor y warranty . F or your saf ety and to av oid electrical shock, please obser ve all safety notes and precaution[...]

  • Page 90

    BLUE Black RED J84 FIGURE F .2 – PLUG J84 LOCA TION T ACH FEEDBACK TEST (continued) TROUBLESHOOTING AND REP AIR F-16 F-16 PO WER FEED® 25M Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PROCEDURE 1. Remov e in[...]

  • Page 91

    Ser vice and repair should be perf or med b y only Lincoln Electric f actor y trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine oper ator and will in validate your f actor y warranty . F or your saf ety and to av oid electrical shock, please obser ve all safety notes and precaution[...]

  • Page 92

    1 4 2 5 6 3 #550 #551 FIGURE F .3 – QUICK CONNECTOR #550 AND #551 LOCA TIONS DRIVE MOTOR TEST (continued) PROCEDURE 1. Remov e input power to wire feed unit. 2. Using the 3/8 in. nut driver , remov e the cov er from the wire feeder . 3. Locate the two quick connectors in the two motor ar mature leads. Refer to Figure F .3. Do NOT disconnect the l[...]

  • Page 93

    Ser vice and repair should be perf or med b y only Lincoln Electric f actor y trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine oper ator and will in validate your f actor y warranty . F or your saf ety and to av oid electrical shock, please obser ve all safety notes and precaution[...]

  • Page 94

    THUMB THUMB S CREW SCREW CONDUIT CONDUIT E LECTRODE ELECTRODE CABLE CABLE G UN GUN BUSHING BUSHING WATER WATER HOSES HOSES WATER WATER HOSE HOSE FIGURE F .4 – GEAR BOX AND DRIVE MOTOR REMOV AL AND REPLACEMENT GEAR BOX REMOV AL A ND DRIVE MOTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-20 F-20 PO WER FEED® 25M R[...]

  • Page 95

    GEAR BOX REMOV AL AND DRIVE MOTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TO REMOVE THE DRIVE MOTOR FROM THE GEAR BOX: 10. Using the slot head screwdriver , remov e the gear box inspection cov er nearest to the dr ive motor . 11. Using the 5/16 in. wrench, remov e the motor mounting screw located inside the gear box. 12. Using the slot head [...]

  • Page 96

    Return to Section T OC Return to Section T OC Retur n to Section T OC Retur n to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NOTES F-22 F-22 PO WER FEED® 25M RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remov e any par t which[...]

  • Page 97

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PO WER FEED® 25M Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram Entire Machine Code [...]

  • Page 98

    ELECTRICAL DIA GRAMS G-2 PO WER FEED® 25M WIRING DIA GRAM - COMPLETE MA CHINE - CODE 11313 (G5585) - + PO W ER AR C L I NC RE CEP T A CL E A B C D E 54 1 L6 54 0B 54 0A 6 4 0 A BR I DG E RE CT I FI ER 5 5 4 AC AC RE D / GRE E N ST ATUS LE D A P4 53 2 TR I GGE R CO NNECT O R L3 P1 0 S1 57 0G W B 2 3 1 58 1 58 5B 58 2 VO L TAG E / TR I M EN C O DE R[...]

  • Page 99

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIA GRAMS G-3 PO WER FEED® 25M SCHEMA TIC - COMPLETE MA CHINE - CODE 11313 (G5638) E N- 1 7 0 S O L I D E D G E G5638 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT URE [...]

  • Page 100

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIA GRAMS G-4 PO WER FEED® 25M SCHEMA TIC - 42 V A C & ARCLINK FEEDER PC BO ARD #1 (G3883-2) G-4 NO TE: This diagram is for ref erence only . It may not be accura[...]

  • Page 101

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIA GRAMS G-5 PO WER FEED® 25M SCHEMA TIC - 42 V A C & ARCLINK FEEDER PC BO ARD #2 (G3883-2) G-5 NO TE: This diagram is for ref erence only . It may not be accura[...]

  • Page 102

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIA GRAMS G-6 PO WER FEED® 25M SCHEMA TIC - MSP4 OPTIONAL DISPLA Y PC BO ARD (G4456) G-6 NO TE: This diagram is for ref erence only . It may not be accurate f or all [...]

  • Page 103

    ELECTRICAL DIA GRAMS G-7 PO WER FEED® 25M SCHEMA TIC - SPI DISPLA Y PC BO ARD - (L11756) y ( y y ) g R i i A S STANDARD This print is Current G-7 NO TE: This diagram is for ref erence only . It may not be accurate f or all machines covered b y this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Retu[...]

  • Page 104

    NO TE: Lincoln Electric assumes no responsibility for liablilities resulting from board le vel troubleshooting. PC Board repairs will inv alidate your factory warranty . Individual Printed Cir cuit Board Components are not av ailable from Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electric discourages board le ve[...]

  • Page 105

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIA GRAMS G-9 PO WER FEED® 25M SCHEMA TIC - V OL T A GE SENSE SELECT PC BO ARD - (S24779) G-9 NO TE: This diagram is for ref erence only . It may not be accurate f or[...]

  • Page 106

    NO TE: Lincoln Electric assumes no responsibility for liablilities resulting from board le vel troubleshooting. PC Board repairs will inv alidate your factory warranty . Individual Printed Cir cuit Board Components are not av ailable from Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electric discourages board le ve[...]

  • Page 107

    ELECTRICAL DIA GRAMS G-11 PO WER FEED® 25M SCHEMA TIC - SPOOL GUN PC BO ARD (L12008) G-11 NO TE: This diagram is for ref erence only . It may not be accurate f or all machines covered b y this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master T[...]

  • Page 108

    NO TE: Lincoln Electric assumes no responsibility for liablilities resulting from board le vel troubleshooting. PC Board repairs will inv alidate your factory warranty . Individual Printed Cir cuit Board Components are not av ailable from Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electric discourages board le ve[...]