Lincoln-electric IM10077 POWER FEED 25M User Manual

Operator’s ManualPOWER FEED ™25MRegister your machine: www.lincolnelectric.com/registerAuthorized Service and Distributor Locator: www.lincolnelectr

A-3INSTALLATION POWER FEED™ 25MA-3Figure A.3ABCDEABCDEPOWER SOURCEWIRE FEEDERPower SourcePin FunctionA ArcLinkB ArcLinkC "67" voltage sens

A-4INSTALLATION POWER FEED™ 25MA-4WELD CABLE SIZETable A.1 located below are copper cable sizes recommended fordifferent currents and duty cycles.

CHANGING THE DRIVE MOTOR GEAR RATIO• Turn off input power at the weld-ing power source before installa-tion or changing drive roll and/orwire guides.

A-6INSTALLATION POWER FEED™ 25MA-68. Remove the busbar by unscrewing the bolt using a 3/4"open end wrench.9. With a 1/4" hex key wrench, l

A-7INSTALLATION POWER FEED™ 25MA-7WIRE DRIVE CONFIGURATION(See Figure A-6)Changing the Gun Receiver BushingELECTRIC SHOCK can kill.• Turn the input

A-8INSTALLATION POWER FEED™ 25MA-8REMOTE SENSE LEAD SPECIFICATIONSWelding with Multiple Arcs:( See Figure A.7)Special care must be taken when more t

A-9INSTALLATION A-9TYPICAL SYSTEM CONFIGURATIONSStandard FeaturesArc Performance• Push-Pull ready for welding aluminum with Pulseand Pulse-on-Pulse™

B-1OPERATIONPOWER FEED™ 25MB-1• ELECTRIC SHOCK CAN KILL.Unless using COLD FEED fea-ture, when feeding with gun trig-ger, the electrode and drivemechan

B-2OPERATIONB-2POWER FEED™ 25MDEFINITION OF WELDING TERMSNON-SYNERGIC WELDING MODES• A Non-synergic welding mode requires all weldingprocess variables

B-3OPERATIONB-3RECOMMENDED PROCESSES• GMAW (CV, Synergic CV, Pulse, STT™, Power,Pulse on Pulse™, Push-Pull)• FCAW• SMAW • GTAW (Lift Start only)• Soli

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELYWhen this equipment is ship

B-4OPERATIONB-4POWER FEED™ 25M11323141617101112155879618194FIGURE B.1CASE FRONT CONTROLS(SEE FIGURE B.1)1. Left DISPLAY windowShows WIRE FEED SPEED or

B-5OPERATIONB-5POWER FEED™ 25MLED conditionSteady greenBlinking green.Blinking green, fastBlinking green fol-lowed by blinkingred.DefinitionSystem oka

B-6OPERATIONB-6POWER WAVE SYSTEM OPERATIONThe serviceability of a product or structure utilizingthe welding programs is and must be the soleresponsibi

B-7B-7POWER FEED™ 25MOPERATIONSMAW (STICK) WELDINGSMAW is most often used for outdoor construction,pipe welding and general repairs. The wire feederc

B-8OPERATIONB-8SET-UP, PHYSICAL, NON-SYNERGICGMAW AND FCAW WELDING(See Figure B.4)Non-synergic GMAW and FCAW welding mimics thewelding controls of tr

B-9OPERATIONB-9POWER FEED™ 25MWFSAMPSVOLTS TRIM30025.3WFSAMPSVOLTS TRIM2505.7EFFECT / RANGECrater ProcedureBurnback: DESCRIPTIONCrater Procedure contr

B-10OPERATIONB-10POWER FEED™ 25MGMAW (MIG) SYNERGIC WELDINGSynergic welding allows for easy procedure setting.The WFS and Voltage change together to m

B-11OPERATIONB-11Synergic CV programs feature an ideal voltage bestsuited for most procedures. Use this voltage as astarting point and adjust if nee

B-12OPERATIONB-12POWER FEED™ 25MSTEEL AND STAINLESS SYNERGIC GMAW-P (PULSED MIG) WELDINGSynergic GMAW-P (Pulsed MIG) welding is ideal for low spatter,

B-13OPERATIONB-13POWER FEED™ 25MSYNERGIC GMAW-P (PULSED MIG) WELDINGK2202-1 Power Wave 455M1 K2203-1 Power Wave 455M/STTK2823-xx Power Wave S350K2230-

SECTION A:WARNINGS CALIFORNIA PROPOSITION 65 WARNINGSDiesel EnginesDiesel engine exhaust and some of its constituents are known to the State of Calif

B-14OPERATIONB-14POWER FEED™ 25MWFSAMPSVOLTS TRIM2201.06ARC FOCUS-10.0 (SOFT to10.0 (STIFF)DESCRIPTIONArc Focus adjusts the arc froma wide, soft arc g

B-15OPERATIONB-15POWER FEED™ 25MALUMINUM SYNERGIC GMAW-P (PULSEDMIG)AND GMAW-PP (PULSE ON PULSE)WELDINGThe POWER FEED™ 25M and Power Wave weldingpower

B-16OPERATIONB-16POWER FEED™ 25MALUMINUM GMAW-P AND GMAW-PP WELDINGK2368-1 Power Wave®355M1 K2202-1 Power Wave®455MK2203-1 Power Wave®455M/STTK2230-1

B-17OPERATIONB-17POWER FEED™ 25MPULSEPULSE-ON-PULSEFREQUENCY:FREQ.MODULATION(Low)-10.0 to(High)+10.0(Low)-10.0 to(High)+10.0DESCRIPTIONFor Pulse -On

B-18OPERATIONB-18POWER FEED™ 25MGMAW-STT™ WELDINGSurface Tension Transfer, or STT™ welding, is abreak-through process offered exclusively by theLincol

B-19OPERATIONB-19GMAW-STT™Waveform Control Technology™ maximizes theability to modify the arc for the perfect weld. WhenSTT™ welding, the parameters

B-20OPERATIONB-20PEAK CURRENT (Figure B.16)Peak current controls the arc length, which alsoaffects the shape of the root. When using 100% CO2,the pea

No Foot / Hand Amptrol1. Adjust the arc amperage with the left knobon the display panel.2. Turn the right knob on the display paneluntil the Output Co

B-22OPERATIONB-22POWER FEED™ 25M84327156WARNINGWARNINGAVISO DEPRECAUCIONATTENTION!!!!Lorem ipsum dolor sit amet consectetuer adipiscingLorem ipsum dol

B-23OPERATIONB-23POWER FEED™ 25MSET-UP FEATURES MENU(See Figure B.17b)1. To access the set-up menu, press the right and leftbuttons of the user interf

ELECTRIC SHOCK CAN KILL.3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts wi

B-24OPERATIONB-24POWER FEED™ 25MParameter DefinitionP.0 Exit Setup MenuThis option is used to exit the setup menu. When P.0 is displayed, press the Le

B-25OPERATIONB-25POWER FEED™ 25MUSER DEFINED PARAMETERSParameter DefinitionP.5 Procedure Change MethodThis option selects how remote procedure selecti

B-26OPERATIONB-26POWER FEED™ 25MParameter DefinitionP.7 Gun Offset AdjustmentThis option adjusts the wire feed speed calibration of the pull motor of

B-27OPERATIONB-27POWER FEED™ 25MParameter DefinitionP.14 Reset Consumable WeightUse this option to reset the initial weight of the consumable package.

B-28OPERATIONB-28POWER FEED™ 25MParameter DefinitionP.18 Wire Drive Gear RatioThis option selects the Wire Drive Gear Ratio that will be used. The po

B-29OPERATIONB-29POWER FEED™ 25MParameter DefinitionP.80 Sense From StudsUse this option for diagnostic purposes only. When power is cycled, this opti

B-30OPERATIONB-30POWER FEED™ 25MParameter DefinitionP.103 View Software Version InformationUsed for viewing the software versions for each board in th

B-31OPERATIONB-31POWER FEED™ 25MParameter DefinitionP.503 Memory Button DisableDisables the specified memory button(s). When a memory is disabled, wel

B-32OPERATIONB-32POWER FEED™ 25MUSER MEMORIESRecall a memory with memory buttonsTo recall a user a memory, press one of the six usermemory buttons. Th

To set limits, press the desired memory button 1-8and hold for 5 seconds. Release the memory buttonwhen the LED begins to blink rapidly and the useri

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the

B-34OPERATIONB-34POWER FEED™ 25MIf the passcode does not equal zero (0000), enter thepasscode now. If the passcode has been forgotten, ap.c. computer

B-35OPERATIONB-35POWER FEED™ 25MINTERNAL CONTROLS1 Cold Feed / Gas Purge Switch2 Wire Drive Pressure Arm3 Internal Light Switch4 Internal Heater Swi

B-36OPERATIONB-36COLD FEED/GAS PURGE SWITCHCold Feed and Gas Purge are com-bined into a single spring centered tog-gle switch.To activate Cold Feeding

B-37OPERATIONB-37POWER FEED™ 25M2- STEP 4- STEP- TRIGGER OPERATIONThe 2-Step - 4-Step switch changes the function ofthe gun trigger. 2-Step trigger

B-38OPERATIONB-38EXAMPLE 1 - 2 STEP TRIGGER: Simple operationThe simplest trigger operation occurs with a 2 Steptrigger and the Start, Crater and Burn

B-39OPERATIONB-39POWER FEED™ 25MEXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Startand Arc End. Tailoring the arc start and arc end is acommon method for r

B-40OPERATIONB-40POWER FEED™ 25MWELD:After upslope, the power source output and the wirefeed speed continue at the weld settings.CRATER:As soon as the

B-41OPERATIONB-41POWER FEED™ 25MShieldingGasIdle Pr eflow Str ike WeldBur nback Postflow IdleWFSOnOffRu n- inOffWe ldOffWe ldAr c Est abl i shedTr i

B-42OPERATIONB-42POWER FEED™ 25MEXAMPLE 5 - 4 STEP TRIGGER: Manual control ofStart and Crater times with Burnback ON. The 4 steptrigger sequence gives

B-43OPERATIONB-43REAR CONTROLS:POWER FEED™ 25M1 Flow Meter2 Shielding Gas Inlet3 ArcLink Cable Connector4 Electrode Cable5 Cover for Optional Water L

ELECTROMAGNETICCOMPATIBILITY (EMC)CONFORMANCEProducts displaying the CE mark are in conformity with EuropeanCommunity Council Directive of 3 May 1989

B-44OPERATIONB-44FLOW METERThe flowmeter shows the flow rate of shielding gasand has a valve to adjust the flow. The flow meter isscaled for CO2, Ar,

C-1ACCESSORIESC-1POWER FEED™ 25MFACTORY INSTALLED EQUIPMENT• K1500-2 Gun Receiver Bushing.• See Parts PagesDRIVE ROLL KITS USEDK2429-1K857-2K2596-2K25

C-2ACCESSORIESC-2POWER FEED™ 25MK1543-xxK2683-xxK910-1K910-2K1500-1K1500-2K1500-3K1500-4Digital Control CableHeavy Duty ArcLink Control CableGround Cl

C-3ACCESSORIESC-3POWER FEED™ 25MK1500-5K489-7K2339-1K590-6K435K468K659-13000290K586-1Gun Receiver Bushing (compatiblewith Oxo® guns.)Gun Receiver Bush

C-4ACCESSORIESC-4POWER FEED™ 25MINSTALLATION OF THE K590-6 WATERCOOLING KITELECTRIC SHOCK can kill.• Turn the input power OFF at the dis-connect switc

C-5ACCESSORIESC-58. Secure the module to the case with the screws.9. Install the fittings to the rear of the case. 10. Slide the hose clamps on to the

C-6ACCESSORIESC-6WATER COOLED GUNSELECTRIC SHOCK can kill.• Turn the input power OFF at the dis-connect switch before working onthis equipment.• Do n

D-1MAINTENANCED-1POWER FEED™ 25MELECTRIC SHOCK can kill.• Do not operate with coversremoved.• Turn off power source beforeinstalling or servicing.• Do

E-1TROUBLESHOOTINGE-1POWER FEED™ 25MIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

E-2TROUBLESHOOTINGE-2POWER FEED™ 25MObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

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E-3TROUBLESHOOTINGE-3POWER FEED™ 25MObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-4TROUBLESHOOTINGE-4POWER FEED™ 25MObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

F-1DIAGRAMSF-1POWER FEED™ 25MNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specifi

F-2DIMENSION PRINTF-2POWER FEED™ 25MDimensions for Aluminum Case Code 1174323.2116.913.912 X 18 In. Ellipse16 In. Circle16.9214.548.55.4

F-3DIAGRAMSF-3POWER FEED™ 25MDimensions for Plastic Case Code 1174412 X 18 In. Ellipse16 In. Circle23.117.214.88.75.717.214.8

POWER FEED™25MP-662P-662PARTS LIST FORPower Feed™25MThis parts list is provided as an informative guide only.It was accurate at the time of printing.

POWER FEED™25MOct-13P-662-A221435ILLUSTRATION OF SUB-ASSEMBLIESP-662-A

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page andcolumn the desired part is located on for your

POWER FEED™25MOct-13P-662-CP-662-CFront Panel Assembly1233A3A22A22A11G11G18A18A18B18B19B19B1717121210109986523237A7A7B7B11A11A11B11B13A13A12A12A13B13B

Front Panel Assembly (G5635-3), Includes: NSS 1X1 Case Front G5577-3 1 X2 Nameplate (L15878-1) (Part of L15878) NSS 1X3 LED, Lens, Includes: S23093-1

A-1INSTALLATION A-1POWER FEED™ 25MTEMPERATURE RANGEOPERATION: -40°F to 122°F (-40°C to 50°C)STORAGE: -40°F to 185°F (-40°C to 85°C)INPUT VOLTAGE an

Oct-13POWER FEED™25MP-662-DP-662-DControl Box Assembly7A7A7B7B3A3A3B3B142A2A2C2C25A25A25B25B11D11D19A19A16A16A16C16C13B13B13C13C19E19E1212101019B19B19

Control Box Assembly (G5634-3), Includes: NSS 1X1 Control Box G5584-4 1 X2A Control Box Decal M22570 1 X2B Mast Decal (Not Shown) M22570-1 1 X2C Insul

Oct-13POWER FEED™25MUse only the parts marked “x” in the column under theheading number called for in the model index page.# Indicates a change this p

POWER FEED™25MNOTES

Oct-13POWER FEED™25MP-662-EP-662-ESpindle & Mast Assembly1788910101111121223A3A3B3B15155

Spindle & Mast Assembly (G5572-2), Includes: NSS 1X1 Spindle Mast G5571-2 1 X2 Spindle Shaft M20990-1 1 X3A Thread Forming Screw S9225-102 2 X3B E

POWER FEED™25MOct-13P-662-FP-662-FWire Drive Assembly3A3A1515373712A12A2121222212B12B12626292923233D3D3E3E20202B2B16A16A16B16B30A30A30B30B16C16C11A11A

Wire Drive Assembly, Includes: M21079-7 1 X1 Wire Drive Panel G5569-2 1 X2A Feed Plate Assembly, Includes: M19932 1 X2B Connection Bar M19611-1 1 X2C

36 Pinion Gear (Low Speed) M18967-1 1 X37 Plug Button T10397-3 1 XOct-13POWER FEED™25MUse only the parts marked “x” in the column under theheading num

POWER FEED™25MNOTES

A-2INSTALLATION POWER FEED™ 25MA-2SAFETY PRECAUTIONSELECTRIC SHOCK CAN KILL.• Turn the input power OFF at thewelding power source beforeinstallation

Oct-13POWER FEED™25MP-662-GP-662-GCase Assembly2525242415151A1A20A20A131320A20A17A17A10A10A10B10B10C10C23A23A151523B23B118183A3A1616121222222

Case Assembly (G5633-1), Includes: NSS 1X•Case Assembly (G5661-2), Includes: NSS 1•X1 Case Welded Assembly (M20976) NSS 1X•1A Plastic Case Asbly (G566

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cu