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Lincoln Electric IM892-C User's Manual

1. AMON Section Re elle Me EE 1 2 onte DEL 2 High Frequency e Le EE 2 Arclink eene Ree EE 3 Cable Connections sise A 3 Weld cable EE A 4 Coaxial Weld Ree A 4 Electrode Polarity EE A 5 Shielding Gas ul EE A 5 Changing The Drive Motor Gears iii A 6 Wire Drive GoOntiQu ration A 7 Procedure to Install Drive Rolls and Wire Guides A 7 Remote Sense Lead Specifications A 8 l oading Spools Of TEE A 8 Typical System GonfiguratiOlis en penc A 9 ie njm Section B Safety D TEE B 1 Graphic Symbols that appear on this Machine or in this B 1 Definition of Welding Terms General Description BIAGIO Recommended Processes Equipment Limitations Recommended Power Sources B 3 Case Front GOonttols B 4 B 5 ON ON SWIT ices EE B 6 Making a Weld with Waveform Technology Power B 7 thru B 24 Set Up Feature Menu for Parameters and Definition B 25 thru B 32 Procedure Memory Panel Operation B 33 thru B 35 D
2. Wu HOWL Od Sa311H911 alvid 0333 ub ON ON E 1 8819 e 75 T es GIONS10S TT 579 926 E x o S a 933 43MOd PECES L Q4vog od vds 93157 18315 amp ER gt NER AVIdSiq POWER FEED 25M LINCOLN E LL DIAGRAMS F 2 L Jequunu epoo jueuudinbe 10 2919S 0 e qiDej si ou j sjeued y JO euo uo eui episui pejsed si epoo 10 siy Aq 104 eq jou Aew 68GG2 gerer ir zer 4er 24 40 30S LN3NOdWOO 5 ALIAVO SLIHM M ama n
3. Enable Disable Limits Press 10 seconds MEMORY HOLD 2 SECONDS SAVE 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 display shows the following WAVEFORM CONTROL TECHNOLOGY IR PORT Memory 1 Limits Enable Disable WELD MODE C Q START OPTIONS ARC CONTROL e END OPTIONS SET If the passcode does not equal zero enter the passcode now If the passcode is zero 0000 SETUP will light and the MSP4 displays the following WAVEFORM CONTROL TECHNOLOGY Enable Limits No PORT Yes WELD MODE START OPTIONS ARC CONTROL G ENDorTions Press the left 5 4 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 POWER FEED 25M LINCOLN P 36 DUAL PROCEDURE MEMORY OPERATION For Code 11456 and Higher The Dual Procedure Memory buttons performs three functions Weld procedure selection Memory save and recall Limits setting There are two procedure memories A and B and eight user memories 1 8 Procedure Memory vs User Memory Procedure memory is used while welding Changes to the weld procedur
4. Parameter Name If the passcode has been set to zero 0000 SETUP will illuminate on the panel and the display will show the following Four items show on the panel Memory Value High Limit Low Limit Parameter Name One of these items will flash to indicate which item will change when the MSP4 encoder is rotated Press the right button on the panel to select the item to change HI 200 LO 180 WELD WFS WELD MODE START OPTIONS ARC CONTROL 7 END SS Rotate to Press to Change select item Value to change The Limits Setup menu shows a list of all parameters available for the weld mode stored in the memory chosen For example if limits are being set for a stick SMAW mode parameters such as Run in WFS and will not appear To lock a parameter to a specific value that can not be changed set the high and low limits to the same value B 38 The memory value must always be less than or equal to the high limit and greater than or equal to the low limit After setting limits press the memory button with the flashing LED The MSP4 will ask to save or discard the limit changes just made Press the left MSP4 for button YES to save and enable the limits and exit Press the right MSP4 button NO to exit and leave limits unchanged Enabling Disabling Limits Enable Disable Limits Press
5. CAUTION When changing the electrode polarity the weld cables must be changed at the power source studs and the DIP switch inside the wire feeder must be properly set Operation with the DIP switch in the wrong position will cause erratic arc performance AWARNING ELECTRIC SHOCK CAN KILL 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 Electrode Polarit DIP switch 7 setting Positive OFF Factory setting Tools required 5 16 nut driver To change the DIP switch from Electrode Polarity 1 Turn power off at the welding power source 2 Remove the spool of wire from the feeder 3 Remove the 4 screws holding the cover cover out of the feeder 4 Move DIP switch 7 on the feed head board to the appropriate position 5 Install the cover and secure with the screws Lift the INSTALLATION A 5 SHIELDING GAS CONNECTION WARNING CYLINDER may explode if damaged Keep cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live electrical circuits BUILD UP OF SHIELDING GAS MAY 3 HARM HEALTH OR KILL 4 Shut off shielding gas supply when not in
6. set menu parameter without first entering the passcode even if the passcode is non zero default Yes The operator must enter the passcode if the passcode is non zero in order to change any setup menu parameters This parameter can only be accessed using Power Wave Manager Set User Interface Passcode Prevents unauthorized changes to the equipment The default passcode is zero which allows full access A nonzero passcode will prevent unauthorized changes to memory limits saving to memory if P 502 Yes changes to setup parameters if P 505 Yes This parameter can only be accessed using Power Wave Manager POWER FEED 25M LINCOLN P 32 OPERATION B 32 USER DEFINED PARAMETERS P 507 UI Clear All Memories Allows the operator to quickly set all memories to the default weld mode and welding parame ters Presently this option does not exist in any setup menu UI Master Lockout Locks all user interface controls preventing the operator from making any changes This para meter can only be accessed using Power Wave Manager POWER FEED 25M LINCOLN P 33 PROCEDURE MEMORY PANEL TION For Code 11313 The Dual Procedure Memory Panel performs three functions e Weld procedure selection e Memory save and recall Limits setting There are two procedure memories A and B and six user memories 1 6 Procedure Memory vs User Memory Procedure memory is used
7. Parameter __ Range Unis Wire Feed Speed Weld mode and wire in min feeder dependent ES Limits be set for Wire Feed Speed Amperage Voltage Trim Arc Control Preflow Time Run In Speed Start Wire Feed Speed Start Voltage Trim Crater Time Seconds Start Time Burnback Time Crater Wire Feed Speed Crater Voltage Trim Crater Time Postflow Time Weld modes cannot be selected through the Limits Setup memu and must be chosen and saved to mem ory before entering the Limits Setup Menu OPERATION B 37 Set Limits limits press the desired memory button 1 8 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 MSP4 DISPLAY Memory 2 Set Limits WELD MODE 7 ARC CONTROL 7 Q SET START OPTIONS END OPTIONS POWER FEED 25M LINCOLN P 38 If the passcode does not equal zero 0000 enter the passcode now If the passcode has been forgotten a p c computer application or Palm O S application is required to change the passcode OPERATION Memory TN Low Limit High Limit 200 2200 10 180 WELD WES START OPTIONS END OPTIONS WELD MODE ARC CONTROL
8. Improper gun liner tip drive 5 6 Verify the proper parts are and or inner wire guide installed Incorrect tension arm pressure on 7 Adjust the tension arm per the the drive rolls Instruction Manual Most elec trodes feed well at a tension arm setting of 3 Worn drive roll 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 your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 25M LINCOLN 8 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Output Problems Wire feed speed consistently 1 The wire feeder gear setting is not 1 Verify the POWER FEED 15 ates at the wrong value properly set software setting matches the gear mounted See the Instruction Manual for setting the gear speed Variable or hunting arc Wrong size worn and or melted 1 Replace the contact tip contact tip Worn work cable or poor work 2 Verify all work and electrode con connection nections are tight and that the cables are in good condition Clean replace as necessary Wrong polarity Adjust polarity to the recommend ed procedure The gas nozzle is extended 4 Adjust the gas nozzle and shor
9. POWER FEED 25M For use with machines having Code Number 11313 11456 11557 11714 11715 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 opera tion on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful IP23 IEC 60974 5 OPERATOR S MANUAL 150 9001 E 2 wi ABS Quality Eval to ISO 9001 Re 5 CERTIFICATE NUMBER 30273 Copyright Lincoln Global Inc LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 216 486 1751 WEB SITE www lincolnelectric com Design a SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines
10. 5 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 6 Disconnect the shielding gas hose from the gun bushing if required 7 For water cooled guns a Install the hose assembly from K590 6 to the rear of the POWER FEED 25M case b Remove the rear panel of the POWER FEED 25M Route the water hoses from the rear of the case in between the inner module and the case Assemble the rear panel with the water hoses routed in the bottom cut out of the panel c Install Adapter 5 8 L H Fitting to the Push Pull Bushing 8 Slide the Push Pull Bushing into the wire drive Align the thumb screw with one of the threaded holes on the bushing 9 Insert the conduit from the push pull gun into the push pull bushing until the conduit is flush to the inner wire guide Secure the conduit with the thumb screw 10 Tighten the socket head cap screw to hold the push pull bushing tightly to the wire drive 222 2 11 Assemble Adapter Fitting to the front of the pull bushing Attach the electrode cable from gun to the adapter fitting 12 Use the adapter fittings to attach one of the water hoses to the adapter 13 Attach the other water hose to the water hose of the of push pull gun using the Hose Nipple 14 Connect the control cable from the push pull gun to the
11. ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 5 Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until
12. KP1696 030S KP1696 035S KP1696 045S KP1696 052S KP1696 1 16S KP1696 1 KP1696 2 KP1697 035C KP1697 045C KP1697 052C KP1697 1 16C KP1697 068 KP1697 5 64 KP1697 3 32 KP1695 035A KP1695 040A KP1695 3 64A KP1695 1 16A LINCOLN 8 Includes 2 V groove drive rolls and inner wire guide Includes 2 Knurled drive rolls and inner wire guide Includes 2 polished U groove drive rolls outer wire guide and inner wire guide POWER FEED 25M C 1 C 2 ACCESSORIES c2 Includes 1 T adapter for ArcLink T Cable Adapter connecting two wire feeders to one power source Includes 1 remote output con Remote Output Control trol pendant with a 25 cable Used most often with SMAW welding Includes 1 remote output con Remote Output Control trol pendant with a 100 cable Used most often with SMAW welding Includes a complete alu minum case Decals skids insulation and latches are all preassembled Aluminum Case Includes a complete engineered plastic case Decals and latches are all preassembled Plastic Case Includes AWG 1 Coaxial weld cable of length xx Ends of the K2593 xx 1 Co Axial Power Cable weld cable have lug connections Use for Pulse or STT welding Includes 1 0 Coaxial weld cable of length xx Ends of K1796 xx 1 0 Co Axial Power Cable the weld cable have lug con nections Use for Pulse or STT welding Includes
13. Shows WIRE FEED SPEED or AMPERAGE 2 Left KNOB Adjusts values in left display 3 Right Display window Shows VOLTAGE or TRIM 4 Right Knob Adjusts values in the right display 5 Status LED llluminates a steady green when communicating to the power source properly 6 IR port Used to transfer information to palm computers etc 7 MSP4 display window Shows detailed welding and diagnostic information 8 Left Button Changes the MSP4 display to show the Weld Mode or Arc Control 9 Right Button Changes the MSP4 display to show Start Options or End Options 10 Set Knob Changes the value on the MSP4 display 11 ON OFF switch Controls power to the POWER FEED 25M 12 5 pin connector Trigger connector for a push only gun 13 6 pin connector Connector for a remote control 14 7 pin connector Connector for a push pull gun 15 Cover Covers location for optional water cooling line 16 Set Up Lights when feeder is set up 17 Memory Panel Door See Memory Panel Operations in this Section FIGURE B 1 Fold Out Memory Panel POWER FEED 25M LINCOLN P CASE FRONT CONTROLS CODE 11456 higher See Figure B 1a 10 11 12 13 14 15 16 17 Left DISPLAY window Shows WIRE FEED SPEED or AMPERAGE Left KNOB Adjusts values in left display Status LED Illuminates a steady green when commu
14. 1 0 Coaxial weld cable of length xx Ends of 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 Weld Power Cable Twist Mate to Ground Clamp and Twist Lug Mate to Lug 2 0 Cable 9 2 7m long K1842 xx Weld Power Cable Lug to Lug Includes Twist Mate to Lug 1 0 cable of length xx POWER FEED 25M LINCOLN 8 3 ACCESSORIES 3 Includes 5 to 5 wire feeder to power source control K1543 xx Digital Control Cable cable Cables may be con nected end to end to make a longer cable Includes 5 pin to 5 pin wire feeder power source to control cable Cables may be connected end to end to make a longer cable The male con nector is stainless steel and the female connector is brass Recommended for outdoor applica tions 910 2 Ground Clamp ee Amp 2683 Heavy Duty ArcLink Control Cable Gun Receiver Bushing for guns o h with K466 1 Lincoln gun connec Includes Gun 4 ges 1500 1 tors Innershield Subarc EE angi nex Rey guns wrench Gun Receiver Bushing for guns _ with K466 2 466 10 Lincoln gun Ncludes Gun receiver bush K1500 2 connectors Magnum ing RE ae 200 300 400 guns and compatible SE with Tweco 2 4 Includes Gun bush Gun Receiver Bushing for guns ing with hose nipple set screw
15. 18 Ellipse POWER FEED 25M LINCOLN F 4 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese ZS BIR Do not touch electrically live parts electrode with skin or wet clothing Insulate yourself from work and ground toque las partes los electrodos bajo carga con la piel a Aislese del trabajo de tierra laissez la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra o E PORTED iAH E 9 7 5 gt amp RAE ATAH 2452 84 uu e Ae AXE W el la Quali Y 0 dr i AS d ril gs STE DE dan die pg Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda do
16. 5 secmax Source sau orici Output WFS Crater ti me Burback Time POWER FEED 25M LINCOLN P 46 Idle 1 Shielding 97 Gas 1 Weld 1 Power Source Starti Output Craters 1 1 1 Weld 1 ee 1 WFS Crater Run in i Trigger Pulled 1 1 Preflow Strike 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 RUN IN After preflow time expires the power source regulates to the welding output and wire is advanced towards the work piece at the Run In WFS If an arc is not established within 1 5 seconds the wire feed speed will jump to the welding wire feed speed WELD The power source output and the wire feed speed continue at the weld settings 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 e
17. H9V18 4 NIQO9 45913 H3d S IOBWAS 1VOIH1O3T3 NOLLVINHOGNI TVH3N39 30 3015 NOLLO3NNOO NMOHS S3HOLIMS 319901 ON 7147905 097 40 SLIHM 5 AGONY 40 3903 1V71 IHL 1S38V3N Nid ON NOLLO3NNOO 37872 300910313 LAdNI 829 1419141934 ROSCH Old 3nouol 1880 aaaas 0334 SOd 4 3uvds 5 3uvds 3uvdS ECKE 1 ONLLL3S 15 HOLIMS Ajuo 10 S 4141 310 Tind Hshd Ed OHLdNY 1004 8S4 9 i 007 24103158 SSNAS 10HLNOO m es o 028 8055 d 8025 3 1 0 sl E H t v 1 H3991H1L 0 3 ES sl A td 4399 41 uer 455 H31HONva NN9 10095 GION310S Svo QuvO8 24 OH IN ED gt 8 gt 1 gt gt 9 9 80 8 ur ON CH
18. SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL 1 Uo Uy U2 l4 l2 AN POWER FEED 25M LINCOLN 8 NEGATIVE OUTPUT INPUT POWER DIRECT CURRENT OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION 2 OPERATION B 2 DEFINITION OF WELDING TERMS NON SYNERGIC WELDING MODES Non synergic welding mode requires all welding process variables to be set by the operator SYNERGIC WELDING MODES Synergic welding mode offers the simplicity of single knob control The machine will select the cor rect voltage and amperage based on the wire feed speed WFS set by the operator WFS Wire Feed Speed CC Constant Current Constant Voltage GMAW Gas Metal Arc welding GMAW P Gas Metal Arc welding Pulse Arc GMAW STT Gas Metal Arc welding Surface Tension Transfer SMAW Shielded Metal Arc welding FCAW e Flux Core Arc Welding CAG e Carbon Arc Gouging GENERAL DESCRIPTION General Physical Description The POWER FEED 25M is a premium portable wire feeder for use with the Power Wave products The wire feeder features a 2 roll MAXtrac drive coupled to a powerful motor for driving wire through difficult sit uations The easy to use MSP4 interface provides ready access to all welding modes in the Power
19. Wave A memory panel is included with the POWER FEED 25M and allows quick recall of favorite weld procedures Two cases are available An engineered aluminum case with replaceable skids or an impact resistant polycarbonate plastic case The heart of the POWER FEED 25M is the MAXtrac drive The patented features on the wire drive offer tool less changing of the drive rolls and the wire guides for quick spool changes Plus the drive can be configured for extra torque when feeding large diameter flux cored electrodes The POWER FEED 25M continues Lincoln s lead role of environmental protection for electronics P C boards are potted in epoxy and electrical connections are protected with dielectric grease Noise suppres sion components protect the POWER FEED 25M from stray signals and keep the feeder from interfering with other digital equipment General Functional Description The POWER FEED 25M is best suited for 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 diffi cult to weld materials Easy to use controls make it a great feeder for consistent results with mild steel applications too DUTY CYCLE The POWER FEED 25M is rated for 500 amps 60 duty cycle and 400 amps 100 duty The duty cycle is based on a 10 minute cycle For example when welding at 500 amps the POWER FEED 25M may run continu
20. a slight amount Gas will start to torches without Touch the tungsten to the work piece flow built in Gas Valves 4 Lift the tungsten to create an arc and weld 4 Lift the tungsten to create an arc Stop welding by turning the Output Control 5 Regulate the arc current with the foot to OFF or by pulling away the tungsten pedal or hand amptrol from the work Stop welding by releasing the foot pedal Gas flow will continue for a short time and hand amptrol or by pulling the tung then shut off sten away from the work Gas will continue for a short time and then shut off 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 Turn the right knob on the display panel 2 Touch the tungsten to the work piece until the Output Control is ON Press the foot pedal or slide the hand TIG torches with 3 Open the gas valve on the TIG torch amptrol a slight amount built in Gas Valves 4 Touch the tungsten to the work piece Open the gas valve on the TIG torch Lift the tungsten to create an arc Regulate the arc current with the foot to OFF or by pulling away the tungsten pedal or hand amptrol from the work Stop welding by releasing the foot pedal Close the gas valve on the TIG torch or hand amptrol or by pulling the tung sten away from the work Close the gas valve on the TIG torch POWER FEED 25M
21. c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 du corps PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER SCH TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises
22. case 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 Aluminum Case Plastic Case 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 SSN POWER FEED 25M LINCOLN 8 C 6 ACCESSORIES C 6 WATER COOLED GUNS 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 e Only qualified personnel should install use or service this equipment Python Waiter Cooled Guns 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 To install the K2339 1 Push Pull Gun Connection Kit the POWER FEED 25M 1 Turn power off at the welding power source 2 Remove the gun from the wire feeder if attached 3 Remove the wire spool from the feeder if present 4 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
23. de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN 8 for selecting QUALITY product by Lincoln Electric We want you You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advic
24. is no Voltage control when STT welding MSP4 OPERATION WELD MODES ELECTRODE AND GAS WIRE SIZE 0 035 0 045 0 052 STEEL 110 STAINLESS 110 with Hot Start STEEL CO Ar CO 12 STAINLESS He Ar CO 123 SYNERGIC STT STEEL CO STEEL AR CO START OPTIONS STAINLESS AGO PREFLOW TIME FUNCTION YNERGIC STT OPEN ROOT STEEL b 0 25 0 seconds Adjusts the time that shielding STAINLESS He Ar CO2 gas flows after the trigger is pulled and prior to feeding wire IR PORT WAVEFORM CONTROL TECHNOLOGY RUN IN WES Run in sets the wire feed Off 30 10150 speed from the time the trigger Steel 035 lished SETUP Start Procedure The Start Procedure is not procedures ARC CONTROL EFFECT RANGE DESCRIPTION END OPTIONS is pulled until an arc is estab commonly used with STT WELD MODE 7 56 CH START OPTIONS ARC CONTROL OPTIONS PEAK CURRENT PARAMETER Peak Current acts similar to an arc pinch FUNCTION control Peak Current sets the arc length and promotes good fusion Higher peak current levels will cause the arc to broaden momentarily while increasing arc length If set too high globular transfer may occur Setting it too low may cause instability and wire stubbing Best practice is to adjust for minimum spatter and puddle Adjust the
25. omsnivis 8 M N33H89 G3H 90 in 1007 NOUS d01 TOULNOO 9 5431 LHI ae LJ 20 5 4 30 5 t a9HNd svo 4109 2007 G3sn LON N8IS 9625 p 0629 0007 HIH 30 or8 iim J Mes K n 3005 L 268 LO 065 E Od AN 14510 QHONVHN3 Todd 1594 SLZLL 46611 96711 63000 HOS 0334 WVH9VIG ONIHIM POWER FEED 25M LINCOLN E 3 Dimensions for Code 11313 ke DIMENSION PRINT e ELECTRIC LINTONN Le Circle 12 x 18 Ellipse POWER FEED 25M LINCOLN F 3 F 4 Dimensions for Codes 11456 11557 DIMENSION PRINT ELEGTRIG 12 x
26. on both feed heads This parameter can only be accessed using Weld Manager or Power Wave Manager software Mode Select Panel Lock Selects between several Mode Select Panel lockout preferences When a Mode Select Panel selection is locked and an attempt is made to change that parameter a message will be dis played on the Mode Select Panel indicating the parameter is locked All MSP Options Unlocked All adjustable parameters on the Mode Select Panel are unlocked All MSP Options Locked All knobs and buttons on the Mode Select Panel are locked Start amp End Options Locked The Start and End parameters on the Mode Select Panel are locked all others are unlocked Weld Mode Option Locked The weld mode cannot be changed from the Mode Select Panel all others Mode Select Panel settings are unlocked Wave Control Options Locked The Wave Control parameters on the Mode Select Panel locked all others are unlocked Start End Wave Options Locked The Start End and Wave Control parameters on the Mode Select Panel are locked all others are unlocked Start End Mode Options Locked The Start End and Weld Mode Select parameters on the Mode Select Panel are locked all others are unlocked This parameter can only be accessed using Power Wave Manager Setup Menu Lock Determines if the setup parameters can be modified by the operator without entering a pass code The operator can change
27. 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 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 5f LINCOLN 8 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 Also see item 1 b Jan 09 SAFETY WELDING and CUTTING gt SPARKS 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 Remember that welding sparks 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 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 When not welding make certain no part of the electrode circuit is touching the work or grou
28. read only P 501 through P 599 Secured Parameters only accessible through a p c or palm application SET UP FEATURES MENU See Figure B 17b and B 17c for specific Codes 1 access the set up menu press the Right and Left buttons of the MSP4 panel simultaneously Note that the set up menu cannot be accessed if the system is welding or if there is a fault The sta tus LED is not solid green Change the value of the blinking parameter by rotat ing the SET knob 2 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 3 To exit the set up menu at any time press the Right and Left buttons of the MSP4 panel simulta neously Alternately 1 minute of inactivity will also exit the set up menu FIGURE B 17b SETUP MENU FIGURE B 17c SETUP MENU Only parameters below can be accessed in Code 11313 All parameters can be accessed in Code 11456 and higher 0 p P 100 thru P 107 P 1 P 8 P 2 P 11 P 3 P 12 P 4 P 13 P 5 P 80 Mode Select P 6 P 99 Panel MSP4 Jn HI SHEHE 9 5 EHEH j AEEA Q O1 LED Oe 9 Mode Select Indicator Panel MSP4 uni LED Indicator 80 13 R
29. sec iBurback Time Soure set Output Off WES POWER FEED 25M LINCOLN P 48 REAR CONTROLS ITEM DESCRIPTION POWER FEED 25M LINCOLN P 49 FLOW The flowmeter shows the flow rate of shielding gas and has a valve to adjust the flow The flow meter is scaled for Ar and blends It is not cali brated 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 for sufficient shielding gas coverage Gun angle nozzle diameter joint configuration and wind conditions may effect the amount of shielding gas required When using a wire feeder with a flow meter adjust the regulator at the shield gas bottle or supply to a flow rate that is higher than the flow rate indicated on the feeder flow meter Note that most regulators are cali brated based upon having low restrictions on the out let The valve on the feeder flow meter creates a high restriction and may cause errors in the readings at the supply regulator the gas flow rate using the feeder flow meter reading and not the supply regulator reading Only use a pressure regulator like K586 1 at the gas bottle or supply Do not use
30. the arcs LOADING SPOOLS OF WIRE A WARNING Keep hands hair clothing and tools away from rotating equipment Do not wear when threading wire or changing wire spool Only qualified personnel should install use or service this equipment Loading 10 to 15 Ib 4 5 6 8kg Spools A K468 spindle adapter is required for loading 2 51mm wide spools on 2 51mm spindles Use K468 spindle adapter for loading 2 1 2 64mm wide spools 1 Squeeze the release bar on the retaining collar and remove it from the spindle 2 Place the spindle adapter on the spindle aligning the spindle brake pin with the hole in the adapter 3 Place the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool An indicator mark on the end of the spindle shows the orientation of the brake tab Be certain the wire feeds off of the spool in the proper direction 4 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle FIGURE A 7 CONNECTALL SENSE LEADS AT THE END DIRECTION OF THE WELD WORK LEADS AT THE BEGINNING OF THE WELD OF e ALL POWER FEED 25M LINCOLN 8 9 INSTALLATION 9 TYPICAL SYSTEM CONFIGURATIONS Standard Features Arc Performance Push Pull ready for welding aluminum with Pulse and Pulse on Pulse waveforms
31. the circuit breakers feeder on power source have tripped The control cable may be loose 4 Tighten repair or replace the con damaged trol cable The power switch is damaged Replace the power switch No shielding gas gas supply is OFF or empty Verify the gas supply is ON and flowing The gas hose is cut or crushed Route the gas hose so it avoids sharp corners and make sure nothing is on top of it Repair or replace damaged hoses Dirt or debris is in the solenoid Apply filtered shop at 80psi to the solenoid to remove dirt There is a loose solenoid 4 Remove the cover and check that tion or the solenoid has failed all connections are in good condi tion The solenoid has failed Replace the solenoid Inconsistent wire feeding or wire 1 The gun cable is kinked 1 Keep the gun cable as straight as feeding but drive rolls turning twisted possible Avoid sharp corners or bends in the cable The wire is jammed in the gun and 2 Remove the gun from the wire cable feeder and pull the jammed wire out of the gun and cable The gun liner is dirty or worn Blow dirt out of the liner with low pressure 40 or less Replace the liner if worn The electrode is rusty or dirty Use only clean electrode Use quality electrode like L 50 or L 56 from Lincoln Electric The contact tip is partially melted 5 Replace the contact tip or has spatter
32. the passcode has been set to zero 0000 SETUP will illuminate on the MSP4 panel and the display will show the following Four items show on the MSP4 panel Memory Value High Limit Low Limit Parameter Name One of these items will flash to indicate which item will change when the encoder is rotated Press the right button on the panel to select the item to change 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 To lock a parameter to a specific value that cannot be changed set the high and low limits to the same value WAVEFORM CONTROL TECHNOLOGY 200 fso IR PORT 4 SETUP Weld WFS WELD MODE START OPTIONS ARC CONTROL CG END OPTIONS S SET Press to select item to change Rotate to Change Value OPERATION B 35 The memory value must always be less than or equal to the high limit and greater than or equal to the low limit After setting limits press the memory button with the flashing LED The MSP4 will ask to save or discard the limit changes just made Press the left MSP4 for button YES to save and enable the limits and exit Press the right MSP4 button NO to exit and leave limits unchanged Enabling Disabling Limits
33. time welding will to 120 0 Seconds continue even if the trigger is still pulled This option has no effect in 4 Step Trigger Mode Postflow Time 0 to 25 0 seconds Burnback 0 to 25 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 Tail out provides additional power STT MoDES Without the molten droplet becoming ONLY too large Increase as necessary to add heat input without increasing arc length Often this results in faster travel speeds Note that as tail out increases the peak current and or background current may need be reduced Crater is not commonly used in STT weld procedures Crater Procedure POWER FEED 25M LINCOLN 22 Low Background Current Too Low OPERATION Bc PEAK CURRENT Figure B 16 Peak current controls the arc length which also affects the shape of the root When using 100 CO the peak current will be higher than when welding with blended shielded gases A longer arc length is required with CO to reduce spatter FIGURE B 16 Peak Peak Current Current Optimum Too High BACKGROUND CURRENT Figure B 17 Backgroun
34. to 10 0 seconds default Off Used to skip the Crater sequence when making short tack welds If the trigger is released before the timer expires Crater will be bypassed and the weld will end If the trigger is released after the timer expires the Crater sequence will function normally if enabled Reset Consumable Weight Only appears in the list with systems using Production Monitoring Use this option to reset the initial weight of the consumable package Press the right Mode Select Button to reset the con sumable weight TIG Gas Control Allows control over which gas solenoid actuates while TIG welding Valve manual No solenoid will actuate while TIG welding gas flow is manually con trolled by an external valve Feeder Solenoid The internal feeder MIG solenoid will turn on and off automatically while TIG welding Power source Solenoid Any gas solenoid connected to the power source will turn on and off automatically while TIG welding Notes Preflow is not available while TIG welding Postflow is available the same postflow time will be used in MIG and TIG When machine output on off is controlled via the upper right knob gas flow will not start until the tungsten touches the work Gas flow will continue when the arc is broken until the POWER FEED 25M LINCOLN 29 OPERATION B 29 USER DEFINED PARAMETERS Push Pull Gun Knob Behavior Determines how the potentiometer on the Push Pu
35. use 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 Secure the cylinder to prevent it from falling 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve out let 4 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench Note if connecting to 100 CO cylinder insert regulator adapter between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seated for connection to the cylinder 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 Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting Spring pressure is released Standing to one side open the cylinder valve
36. while the engine is running 2 0 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side At Connect the work cable to the workpiece as close as possible to the area being welded 1 0 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 8 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Volta
37. while welding Changes to the weld procedure WFS voltage arc control etc immediately change the contents inside the selected procedure memory User memories work by copying the weld procedure from one of the six memories into either the A or B procedure Weld procedures are saved into the mem ories only when the operator chooses PROCEDURE MEMORY OPERATION MEMORY E HOLD 2 SECONDS TO SAVE Using Procedure Memories Procedure memories can be selected by choosing either A or procedure directly with the memory panel or by selecting GUN and using dual 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 B 33 USER MEMORIES Recall a memory with memory buttons To recall a user a memory press of the six user memory buttons The memory is recalled when the button is released Do not hold the button for more than two seconds when recalling a user memory Recall a memory with the gun trigger If desired memories 2 through 6 can be recalled with the gun trigger For example to recall memory 3 quickly pull and release the gun trigger 3 times without welding Note the POWER FEED Wire Feeders are factory set with this feature disabled Use the SETUP menu and change P 4 to enable memory recall with the gun tr
38. 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 HIGH FREQUENCY PROTECTION CAUTION Locate the POWER FEED 25M away from radio controlled machinery The normal operation of the POWER FEED 25M may adversely affect the oper ation of RF controlled equipment which may result in bodily injury or damage to the equipment POWER FEED 25M LINCOLN 8 3 INSTALLATION ARCLINK CONTROL CABLES Use of non standard cables may lead to system shut downs poor arc starting and wire feeding problems See Figure ArcLink Control Cables are available in two forms The control cables connect the power source to the K1543 xx series for most indoor or factory installa wire feeder and the wire feeder to other wire feeders tions K2683 xx series for outdoor use or when the equip Control cables may be connected end to end to ment is frequently moved extend their length Use a maximum of 200 ft 61 0m of control cable between components ArcLink LincNet control cables are special high quality Figure A 3 cables for digital communication The cables are c
39. with integrated tachometer for accurate WFS regulation Extras Flowmeter with gas control valve Push Pull reagy Remote control Foot amptrol ready Internal heater for keeping condensation off of the spool of wire Internal lights for illuminating the wire drive compart ment Options Water cooling kit for use with water cooled guns POWER FEED 25M LINCOLN 8 Do not with covers panels guards removed or open B 1 OPERATION B 1 SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON READ AND UNDERSTAND ENTIRE SECTION THIS MACHINE OR IN THIS MANUAL BEFORE OPERATING MACHINE WARNING lt INPUT POWER ELECTRIC 5 KILL Unless using COLD fea ON ture when feeding with gun trig ger the electrode and drive mechanism are always electri cally energized and could OFF remain energized several sec onds after the welding ceases Do not touch electrically live part or electrode WIRE with skin or wet clothing Insulate yourself from work and ground e Always wear dry insulating gloves POSITIVE OUTPUT 3 FUMES AND GASSES can be dangerous O Keep your head out of fumes Use ventilation or exhaust to Do remove fumes from breathing zone Sa WELDING SPARKS can cause fire or explosion e Keep flammable material away ARC RAYS can burn Wear eye ear and body protec QF tion
40. 10 seconds J8 34 Limits for each memory be enabled or disabled by pressing and hold the appropriate memory button for 10 seconds Release the memory button when the display shows the following GUN MEMORY 2 LIMITS ENABLE DISABLE WELD MODE 7 START OPTIONS ARC CONTROL END oprions C If the passcode does not equal zero enter the passcode now If the passcode is zero 0000 SETUP will light ENABLE LIMITS Y Yes No Y C C WELD MODE START OPTIONS ARC CONTROL END options and the MSP4 displays the following Press the left MSP4 button YES to enable limits or the right MSP4 button NO to disable limits Disabling limits does not change any limits values that may have been previously set POWER FEED 25M LINCOLN P 39 39 INTERNAL CONTROLS FOR CODE 11312 DI VO H GR OOOO m DESCRIPTION 2 Step 4 Step Trigger Switch Cold Feed Purge Switch Wire Drive Pressure Arm Internal Light Switch Internal Heater Switch Spindle Brake Gun Bushing Thumb Screw for securing the welding Gun Socket Head Cap Screw for securing the Gun Bushing POWER FEED 25M LINCOLN 40 40 INTERNAL CONTROLS FOR CODE 1
41. 1456 and higher ITEM DESCRIPTION Cold Feed Purge Switch Wire Drive Pressure Arm Internal Light Switch Internal Heater Switch Spindle Brake Gun Bushing Thumb Screw for securing the welding Gun Socket Head Cap Screw for securing the Gun Bushing N POWER FEED 25M LINCOLN 41 COLD FEED GAS PURGE SWITCH Cold Feed and Gas Purge are com 9 COLD FEED bined into a single spring centered tog gle switch To activate Cold Feeding hold the caseunee 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 feed ing or cold inching the electrode is useful for thread ing the electrode through the gun 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 LIGHT SWITCH Turn the internal light switch ON to ill
42. 7 pin circular connector on the front of the POWER FEED 25M POWER FEED 25M LINCOLN 8 D 1 MAINTENANCE SAFETY PRECAUTIONS ELECTRIC 5 kill not operate with covers removed Turn off power source before installing or servicing Do not touch electrically hot parts e Turn the input power to the welding power source off at the fuse box before working in the terminal strip e 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 e 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 e Adjust the wire feed speed to 300 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 To verify the voltage display Set the welding power source and POWER FEED 25M to a CV procedure that gives steady spray t
43. COLN 8 4 INSTALLATION 4 WELD CABLE SIZE Table 1 located below are copper cable sizes recommended for different currents and duty cycles Lengths stipulated are the dis tance 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 CABLE See Table A 2 Coaxial welding cables are specially designed welding cables for pulse welding or STT welding Coaxial weld cables feature low inductance allowing fast changes in the weld current Regular cables have a higher inductance which may distort the pulse or STT wave shape Inductance becomes more severe as the weld cables become longer Coaxial cables work best for high performance waveforms and when long cables are present the cables are housed in a metal tray 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 connec tion 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 To install 1 Turn the input power off at the welding power source 2 Connect one end of the center lead to the power source electrode connection and the other end to the wire feed er electrode connection 3 Connect the outer lead bu
44. LINCOLN 8 EST OPERATION B 24 GTAW TIG WELDING Figure B 17a Maximum FIGURE B 17a Amperage olo WFS OAMPS VOLTS Output Output ON OFF WELD ________ TOUCH START 3 START OPTIONS START PROCEDURE No Arc Contro are active for Touch Start TIG WAVEFORM CONTROL TECHNOLOGY IR PORT 3 Touch Start TIG WELD MODE START OPTIONS ARC CONTROL Q 5 SET Power Wave 355M 1 Power Wave 455M K2203 1 Power Wave 455M STT END OPTIONS ARC CONTROL During the Crater Time the 2 3 SETUP K2234 1 POWER FEED 10M Dual Bench Model 2536 1 2 3 POWER FEEDTM 25 No Arc Controls are active Amperagr will ramp up for Touch Start TIG down from the weld Amperage to the Crater Amperage 3 1543 K2683 xx Digital Control Cable 1 __________ K910 xx K1782 xx K1783 xx PTA 17 PTA 26 TIG torch M Foot Amptrol pr sem EL LES POWER FEED 25M LINCOLN P 25 OPERATION B 25 SETUP MENU FEATURES The Setup Menu gives access to the Setup Configuration Stored in the setup configuration are user parameters that generally only need to be set at installation The parameters are grouped as shown in the following table PARAMETER DEFINITION P 1 through P 99 Unsecured Parameters always adjustable P 101 through P 199 Diagnostic Parameters always
45. N 6 6 11 SWITCH Switch turns the wire feeder power off It does not control the power to the welding power source ELECTRIC 5 kill 09 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 L STATUS The status LED indicates system status Normal operation is a steady green light Note During normal power up the LED may flash red and or green as the equipment performs self tests TABLE B 1 LED condition Definition Steady green System okay The power source and wire feeder communicating normally 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 To clear the error turn the power source OFF and then back ON to reset
46. N on the memory panel 2 Start the weld by pulling the gun trigger The system will weld with procedure A settings 3 While welding quickly release then pull the gun trigger once The system will switch to procedure B settings Repeat to switch back to procedure A settings The procedure can be changed as many times as needed during the weld Release the trigger to stop weld ing The system will automatically return to procedure A settings Integral TrigProc When using a Magnum DS dual schedule gun or similar that incorpo rates a procedure switch in the gun trigger mechanism While welding in 2 step machine operation is identical to the External Switch selection When welding in 4 step additional logic prevents procedure A from being re selected when the trigger is released at step 2 of the 4 step weld sequence The machine will always operate in 2 step if a weld is made exclusive ly in procedure A regardless of the 2 4 step switch position this is intended to simplify tack welding when using a dual schedule gun in 4 step Stall Factor Adjustment Allows the adjustment of the stall factor in Push Pull operation The stall factor controls the stall torque of the push motor when using a push pull gun The wire feeder is factory set to not stall unless there is a large resistance to feeding wire The stall factor can be reduced to stall more easily and possibly prevent bird nesting However low stall factors can cause motor stalling d
47. O 3LIHM M ama n H9V18 4 30102 1 2891 3 STOSWAS 0878 NOILVWHOANI TVH3N39 HOLIMS 403015 NOLLO3NNOO HNH NMOHS SSHOLIMS 319901 ON 7133905 091 40 QV313LIHM HLIM SNOTTV GaoNv 091 40 3009 LV14 JHL 153 Nid O N NOILOANNOD T14V9 3004191413 2 8 9 104443244 Old SOd ALRVIOd 3nouol 91 0383 Ajuo 10 SI 4141 310 Sd Tina Hsnd td 1004 pes vds 3uvds vds Suvds EG 3uvds ONILLAS LS HOLIMS did SE gt 9 gt p vO8 9 d 10H HS 35185 39VL10 a E n W991 og L 1 s i wna 0 5 2 a ANdNI 899141 L ze Col 59 1 td 0 90 2815 Hier 2 2 YALHONVG zg NN9 10045 391101 m 5 4 018 RL WM uwen G4VO8 274 TOHLNOO v 9N CF ema 18389 G38 M dd TSOLON 8
48. OWER 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 avail able for consistent feeding when welding a long dis tance away from the wire feeder Pulse on Pulse Welding The Power Wave 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 appearance 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 10 Frequency Modulation 10 Wide weld and ripple spacing slow travel speed OPERATION B 16 FIGURE B 11 QC Frequency Modulation 10 Narrow weld and ripple spacing fast travel speed POWER FEED 25M LINCOLN 847 ______________ __ ETT ALUMINUM GMAW P 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 contro
49. STT capable when used with STT equipped Power Waves e Waveform Control Technology for welds with good appearance and low spatter even when weld ing nickel alloys User Controls code 11313 6 memories for easily selecting proce dures code 11456 and higher 8 memories for easily selecting procedures e MSP4 panel located behind the memory panel for protection Full sequence control for tailoring the weld from start to end All welding controls located at the wire feeder including process selection Wire Drive Patented 2 roll drive system MAXTRACTM 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 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 Powerful quiet motor
50. See Troubleshooting Section E POWER FEED 25M LINCOLN P 7 MAKING WELD WITH WAVEFORM TECHNOLOGY POWER SOURCES WARNING The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these pro grams These variables include but are not limited to welding procedure plate chemistry and tempera ture weldment design fabrication methods and vice requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selection The steps for operating the Power Wave will vary depending upon the user interface of the welding sys tem The flexibility of the Power Wave lets the user customize operation for the best performance First consider the desired welding process and the part to be welded Choose an electrode material diameter shielding gas and process GMAW GMAW P GMAW STTTM etc Second find the program in the welding software that best matches the desired welding process The stan dard software shipped with the Power Waves encom passes a wide range of common processes and will meet most needs If a special welding program is desired contact the local Lincoln Electric sales sentative All adjustments
51. UM 4043 __ 98 99 100 ALUMINUM 5356 152 76 78 ALUMINUM 5356 Ar 101 102 103 WAVEFORM CONTROL TECHNOLOGY 72 4043 Pulse Ar J OHU Aluminum 3 64 IR PORT WELD 7 ARC CONTROL _ START OPTIONS END OPTIONS SETUP ARC CONTROL 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 For Pulse On Pulse modes Arc controls changes the frequ ency modulation The freque 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 PULSE ON PULSE FREQ MODULATION Low 10 0 to High 10 0 PULSE DESCRIPTION FREQUENCY START OPTIONS DESCRIPTION Adjusts the time that shielding gas flows after the trigger is pulled and prior to feeding wire PREFLOW TIME 0 25 0 seconds RUN IN WFS Off 30 10150 in min Run in sets the wire feed speed from the time the trigger is pulled until an arc is estab lished The Start Procedure controls the WEG Trim at a specified time at the beginning of the weld Durin
52. Version Information Used for viewing the firmware versions for each board in the system Press the right MSP Button to enter the option Rotate Set knob to select the desired board to read Press the right button again to read the firmware version Press the left button to back out to select another board Rotate the SET knob to select another board or press the left button to exit this option View Hardware Version Information Used for viewing the hardware version for each board in the system Press the right MSP Button to enter the option Rotate Set knob to select the desired board to read Press the right button again to read the hardware version Press the left button to back out to select another board Press the left button again to exit this option View Welding Software Information Used for viewing the Weld Set in the Power Source Press the right MSP Button to read the Weld Set version Press the left button to back out and exit this option View Ethernet IP Address Used for viewing the Ethernet Network IP address if there is an Ethernet board present in the system Press the right MSP Button to read the IP Address Press the left button to back out and exit this option The IP address cannot be changed using this option View Power Source Protocol Used for viewing the type of power source the feeder is connected to Press the right MSP Button to identify the power source as either LincNet or ArcLink Press the left button to back o
53. a flow regulator 10 4 7 20 OPERATION B 49 OPERATION ON LINCNET POWER SOURCES The POWER FEED 25M is 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 the Set Up menu only parameters to P 99 are available POWER FEED 25M LINCOLN P 1 FACTORY INSTALLED EQUIPMENT ACCESSORIES K1500 2 Gun Receiver Bushing DRIVE ROLL KITS USED Drive Roll Kits Includes drive rolls and inner wire guide necessary to feed the identified wire size and type WIRE TYPE ELECTRODE SIZE KP KIT Steel Wires Aluminum Wires 023 030 0 6 0 8mm 035 0 9mm 045 1 2mm 052 1 4mm 1 16 1 6mm 035 045 0 9 1 2mm 030 035 0 8 0 9mm 040 045 1 0 1 2mm 052 1 4mm 1 16 1 6mm 068 072 1 7 1 8mm 5 64 2 0mm 035 0 9 mm 040 1 0mm 3 64 1 2mm 1 16 1 6mm
54. able Lug K910 xx Ground Clamp See MIG gun Literature Deluxe Regulator for Mixed K586 1 Shielding Gases Shielding Gas Hose POWER FEED 25M LINCOLN 12 GMAW Synergic Welding Display Synergic CV programs feature an ideal voltage best Use this voltage as a starting point and adjust if needed for personal prefer suited for most procedu ences res OPERATION When the voltage 220 olo WFS OAMPS Less More Deposition Deposition 26 4 VOLTS OTRIM Shorter Longer Arc Arc Preset voltage at MSP4 OPERATION WELD MODE WIRE SIZE ELECTROUE 0 030 0 035 0 045 0 052 Steel CO 10 20 24 Steel Ar Mix Stainless Aluminum 4043 Aluminum 5356 A Ar Mix tainless Ar He CO 63 33 43 r 5 94 11 31 Run in WFS WAVEFORM CONTROL TECHNOLOGY Start Procedure IR PORT STEEL 035 10 2 WELD MODE 7 ARC CONTROL 7 7 START OPTIONS END options ARC CONTROL EFFECT RANGE PINCH EFFECT 10 0 to 10 0 DESCRIPTION Pinch controls the arc characte ristics when short arc welding Spot Timer 0 to 120 0 Seconds Postflow Time 0 to 25 0 seconds Burnback 0 to 25 Seconds Crater Procedure POWER FEED 25M LINCOLN P Preset voltage above ideal voltag
55. always constrained by machine limits When memory limits are enabled the parameter will RS flash whenever attempt is made exceed the memory limit value The parameter will not flash if an set limits press the desired memory button 1 6 attempt is made to exceed the machine limit and hold for 5 seconds Release the memory button when the LED begins to blink rapidly and the MSP4 Machine limits are displays Memory X Set Limits as shown below MSP4 DISPLAY Parameter Range Unis Wire Feed Speed Weld mode dependent in min and gear box ratio dependent WAVEFORM CONTROL TECHNOLOGY Memory 1 SETUP Voltage Trim e Arc Control Limits may be set for WELD MODE 7 START OPTIONS e Wire Feed Speed Amperage ARC CONTROL 7 C END OPTIONS SET Weld modes cannot be selected through the Limits Setup memu and must be chosen and saved to mem ory before entering the Limits Setup Menu POWER FEED 25M LINCOLN P 35 If the passcode does not equal zero 0000 enter the passcode now lf the passcode has been forgotten a p c computer application or Palm O S application is required to change the passcode Memory Value High Limit Low Limit CONTROL TECHNOLOGY 200 2 200 IR PORT ni 1 80 4 SETUP Weld WFS WELD MODE 7 START OPTIONS ARC CONTROL 7 END options SET Parameter Name If
56. amp Literature 6 K586 1 Shielding Gases Shielding Gas Hose POWER FEED 25M LINCOLN 10 5 5 6 OPERATION Non Synergic GMAW and FCAW Welding Display Mode 40 300 25 3 ob WFS OAMPS VOLTS OTRIM gt 250 WFS OAMPS Less More WFS WFS Arc 54 VOLTS OTRIM Longer Arc Less More Less More WFS WFS Volts Volts MSP4 OPERATION WELD MODE GMAW STANDARD CV GMAW POWER MODE FCAW STANDARD CV 6 START OPTIONS EFFECT RANGE DESCRIPTION Preflow Time Adjuststhe time that shielding gas 0 25 0 seconds flows after the trigger is pulled and prior to feeding wire Run In sets the wire feed speed from the time the trigger is pulled until an arc is estab Run In WFS Off 30 to150 in min lished 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 Start Procedure 0 10 seconds WAVEFORM CONTROL TECHNOLOGY STD CV MIG IR PORT SETUP WELD MODE 7 ARC CONTROL _ 7 START OPTIONS END oPrioNs ARC CONTROL EFFECT RANGE DESCRIPTION PINCH Pinch controls the arc characte ristics when short ar
57. are made on the user interface Because of the different configuration options your system may not have all of the following adjustments Regardless of availability all controls are described below SMAW STICK WELDING SMAW is most often used for outdoor construction pipe welding and general repairs The wire feeder controls Amperage Output Control and Arc Force dur ing SMAW welding 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 or OFF See Figure 3 SMAW Welding See Figure B 2 OPERATION FIGURE B 2 Power Wave 355M Power Wave 455M Power Wave 455M STT POWER FEED 10M Bench Model POWER FEED 10M Dual Model K2536 1 2 3 POWER FEED 25M 3 K1543 xx Digital Control Cable 2683 4 1842 Weld Power Cable Lug to Lug K910 xx Ground Clamp K909 xx Electrode Holder K21 76 1 Twist Mate to Lug Cable Adapter POWER FEED 25M LINCOLN P Ba SMAW Stick Welding Display FIGURE B 3 WFS OAMPS VOLTS OTRIM LESS MORE OUTPUT OUTPUT AMPS AMPS OFF ON MSP4 OPERATION START OPTIONS START TIME FUNCTION Oto 10 seconds 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 kn
58. art set tings to the weld settings is called UPSLOPE WELD After upslope the power source output and the wire feed speed continue at the weld settings BURNBACK As soon as the trigger is released the wire feed speed is turned OFF and the machine output contin ues for the burnback time POSTFLOW Next the machine output is turned OFF and shielding gas continues until the post flow timer expires Trigger Released Burnback Postflow Idle Weld FIGURE B 20 2 Step Trigger Start ON Crater OFF g 9 Burnback ON E 2 a a E o e 5 Idle Preflow Strike Upslope Shielding Dien Gas Off Start time Weld Power 1 5 sec Source Output art Off Weld WFS Run in Off POWER FEED 25M LINCOLN P 45 3 2 STEP TRIGGER Customized Arc Start Crater and Arc End Sometimes is advanta geous to set specific arc start crater and arc ending parameters for the ideal weld Many times when welding aluminum crater control is necessary to make a good weld This is done by setting Start Crater and Burnback functions to desired values See Figure B 21 For this sequence PREFLOW Shielding gas begins to flow immediately when the gun trigger is pulled RUN IN After preflow time expires the power source regulates to the start output and wire is advanced towards the work piece at the Run In WFS If an arc is not estab lished within 1 5 seconds the power sourc
59. ature dis abled Use the SETUP menu and change P 4 to enable memory recall with the gun trigger Save a memory with memory buttons 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 button for more than 5 seconds when saving a user memory Note that memories may be locked in the set up menu to prevent accidental overwrite of the memories If an attempt is made to save a memory when memory sav ing is locked the message Memory save is Disabled will appear briefly in the MSP4 display RECALL PRESS 1 SECOND SAVE PRESS 2 SECONDS POWER FEED 25M LINCOLN P 37 LIMITS Limits allow the welder to adjust the welding dure 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 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 The system machine limits are
60. c welding Soft 10 0 to Crisp 10 0 END OPTIONS EFFECT RANGE DESCRIPTION Spot Timer Adjust the time welding will Oto 120 0 Seconds continue even if the trigger is still pulled This option has no effect in 4 Step Trigger Mode Postflow Time Adjusts the time that shielding 0 to 25 0 seconds gas flows after the welding out put turns off Crater Procedure Crater Procedure controls the 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 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 Burnback 0 to 25 Seconds POWER FEED 25M LINCOLN P 11 GMA 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 WES left knob is rotated the voltage is adjusted accordingly to maintain a similar arc length FIGURE B 5 9 2368 1 Power Wave 355M K2202 1 Power Wave 455M K2203 1 Power Wave 455M STT POWER FEED 10M Bench Model POWER FEED 10M Dual Bench Model KP1697 xx KP1507 xx K2683 xx D 1842 Weld Power C
61. d current adjusts the overall heat input into the weld Changing the background current changes the shape of the back bead 10096 CO requires less background current than when welding with blended shielding gases FIGURE B 17 Background Background Current Current Optimum Too High TAILOUT Tailout provides additional heat into the weld without increasing the arc length or the droplet size Higher tailout values improve wetting and may give faster travel speeds POWER FEED 25M LINCOLN B 23 OPERATION B 23 GTAW TIG WELDING The POWER FEED Power Wave system is excel lent for Touch Start TIG welding The system supports TIG torches with or without gas control valves TIG torches with gas control valves connect directly to the gas flow regulator For TIG torches without gas control valves connect the output gas hose on the wire feeder to the TIG torch gas hose The wire feeder gas solenoid may be enabled or dis abled by parameter P 8 in the set up menu found in this operations section Touch Start TIG No Foot Hand Amptrol With Foot Hand Amptrol Weld Sequence 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 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 amptrol
62. d equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 SAFETY PR CAUTIONS DE SURETE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes Sdret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits a l lectrode et la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pinc
63. d wire feed speed skips to the weld settings START The power source welds at the start WFS and voltage until the trigger is released OPERATION B 47 UPSLOPE During upslope the power source output and the wire feed speed ramp to the weld settings throughout the start time The time period of ramping from the start settings to the weld settings is called UPSLOPE 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 CRATER During CRATER the power source continues to sup ply output at the crater WFS and voltage BURNBACK When the trigger is released the wire feed speed is turned OFF and the machine output continues for the burnback time POSTFLOW Next the machine output is turned OFF and shielding gas continues until the post flow timer expires FIGURE B 23 4 Step Trigger 5 3 Start ON 5 2 ON 5 8 2 5 Burnback ON 2 5 5 D 5 5 ul 5 5 D DS 5 2 E lt E Idle Preflow Strike Start Ups ope Weld Downslope Crater Burnback Postfow Idle LI LI Shielding Gas i i i 1 1 1 i i 1 1 1 Weld 1 5
64. de set this option to Yes When the power source is turned off and back on again the test modes will no longer appear in the mode list Test weld modes typically require the machine output to be connected to a grid load and cannot be used for welding View Diagnostics Diagnostics are only used for servicing or troubleshooting the Power Wave system Select Yes to access the diagnostic options in the menu Additional parameters will now appear in the setup menu 101 102 etc View Event Logs Used for viewing all the system event logs Press the right MSP Button to enter the option Rotate Set knob to select the desired system log to read Press the right button again to enter the selected log Rotating the Set knob will scroll through the event log displaying the log index number event code and some other data Press the left button to back out to select another log Press the left button again to exit this option View Fatal Logs Used for viewing all the system fatal logs Press the right MSP Button to enter the option Rotate Set knob to select the desired log to read Press the right button again to enter that log Rotating the Set knob will scroll through the log displaying the log index number and fatal code Press the left button to back out to select another log Press the left button again to exit this option POWER FEED 25M LINCOLN P 30 30 USER DEFINED PARAMETERS View Software
65. do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 25M LINCOLN 8 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Linc Net System Error Codes Fault Code Description Possible Adjustments 1 The wire feeder has not received 1 Verify the power source is operat a recognition command from the ing properly Status light steady power source green Check control cable for loose or broken leads See power source Instruction Manual Verify the power source is operat shutdown command ing properly Status light steady green Check control cable for loose or broken leads See power source Instruction Manual ArcLink System Error Codes Err 81 Motor overload long term 1 The wire drive motor has over 1 Check that the electrode slides heated easily through the gun and cable Remove tight bends from the gun and cable Check that the spindle brake is not too tight Verify a high quality electrode is being used Wait for the error to reset and the
66. e upper bar displayed voltage no bar displayed Preset voltage below ideal voltage lower bar displayed Off 30 10150 in min SYNERGIC CV VOLTAGE DISPLAY knob is rotated the display will show an upper or lower bar indicating if the voltage is above or below the ideal voltage ideal START OPTIONS EFFECT RANGE DESCRIPTION Preflow Time 0 25 0 seconds Adjusts thetime thatshielding gas flows after the trigger is pulled and prior to feeding Run In sets the wire feed speed from the time the trigger is pulled until an arc is estab lished The Start Procedure controls the WFS Voltsat 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 END OPTIONS EFFECT RANGE DESCRIPTION Adjust the time welding will continue even if the trigger is still pulled This option has no effect in 4 Step Trigger Mode 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 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 Procedu
67. e WFS voltage arc control etc immediately change the contents inside the selected procedure memory USER MEMO RIES ARE COPIED TO PROCEDURE MEMORIES PROCEDURE MEMORY OPERATION Demi User memories work by copying the weld procedure from one of the eight memories into either the A or B procedure Weld procedures are saved into the memo ries only when the operator chooses Using Procedure Memories Procedure memories can be selected by choosing either A or procedure directly with the memory panel by selecting GUN and using dual dure to select between procedure A When selecting procedures with the gun switch A or will flash to show which procedure is active PRESS SELECT PROCEDURE B 36 USER MEMORIES Recall a memory with memory buttons To recall a user a memory press one of the six user memory buttons The memory is recalled when the button is released Do not hold the button for more than two seconds when recalling a user memory Recall a memory with the gun trigger If desired memories 2 through 8 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 Note the wire feeder is factory set with this fe
68. e and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be
69. e de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age
70. e knurled thumbscrews counter clockwise to unscrew them from the feed plate 4 Rotate the triangular lock and remove the drive rolls oN LOCKED POSITION UNLOCKED POSITION 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 7 Install a drive roll on each hub assembly secure with the triangular lock 8 Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews 9 Close the idle arm and engage the idle roll pressure arm Adjust the pressure appropriately POWER FEED 25M LINCOLN 8 8 INSTALLATION A 8 REMOTE SENSE LEAD SPECIFICATIONS Welding with Multiple Arcs See Figure A 7 Special care must be taken when more than one arc is welding simultaneously on a single part Arc blow and arc interference may occur or be magnified Each power source requires a work lead from the work stud to the welding fixture Do not combine all of the work leads into one lead Performing welding in the direc tion away from the work leads Connect all of the work sense leads from each power source to the work piece at the end of the weld such that they are out of the path of the weld current See Figure A 7 For the best results when pulse welding set the wire size and wire feed speed the same for all the arcs When these parameters are identical the pulsing fre quency will be the same helping to stabilize
71. e output and wire feed speed skips to the weld settings START amp UPSLOPE 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 OPERATION B 45 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 CRATER amp 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 BURNBACK After the crater time expires the wire feed speed is turned OFF and the machine output continues for the burnback time POSTFLOW Next the machine output is turned OFF and shielding gas continues until the post flow timer expires FIGURE B 21 2 Step Trigger Start ON Crater ON gt Burnback 2 2 2 5 a 5 o 5 5 E Idle Preflow Strike Upslo pe Weld Downslope Burnback Idle i Shielding Gas i of Starttime Wald EE dmt 1 T Power 1 1
72. ersonnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning
73. es 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 STT modes keep the arc characteristics the same when the wire feed speed is changed Note STT is available only with specially equipped Power Wave power sources like the Power Wave 455M STT For best results Attach the work sense lead as close as possible to the welding arc Use only solid steel stainless steel or silicon bronze electrodes FIGURE B 15 K2203 1 Power Wave 455M STT 3 K1543 xx Digital Control Cable 2683 K1796 xx 2593 Coaxial Weld Power Cable Lug to Lug 910 Ground 16 K940 xx Sense Lead Kit Literature Deluxe Regulator for Mixed EM Shielding Gas Hose POWER FEED 25M LINCOLN 21 OPERATION B 21 GMAW STT Waveform Control Technology maximizes the 220 xim ability to modify the arc for the perfect weld When STT welding the parameters to control are Wire Feed Speed sets the deposition rate Peak Current controls the arc length Background Current regulates the bead contour Tail out provides additional power in the arc Mores Deposition Deposition ol WFS OAMPS VOLTS OTRIM There
74. found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment
75. ft arc and higher with a stiff arc Spot Timer 0 to 120 0 Seconds START OPTIONS PREFLOW TIME DESCRIPTION 0 25 0 seconds Off 30 to150 in min END OPTIONS EFFECT RANGE FUNCTION Adjust the time welding will continue even if the trigger is still pulled This option has no effect in 4 Step Trigger Mode Adjusts the time that shielding gas flows after the trigger is pulled and prior to feeding wire Run in sets the wire feed speed from the time the trigger is pulled until an arc is estab lished 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 Postflow Time 0 to 25 0 seconds POWER FEED 25M LINCOLN 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 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 B 15 16 ALUMINUM GMAW P PULSED MIG AND GMAW PP PULSE ON PULSE WELDING The P
76. fumes have been eliminated ELECTRIC AND MAGNETIC FIELDS 359 may be dangerous 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your bogy 1 f Do not put your hands near the engine fan Do not attempt to override the idler by pushing on the throttle control rods
77. g the start time the machine will ramp up or down from the Start Procedure to the preset Welding Procedure END OPTIONS EFFECT RANGE FUNCTION Spot Timer Adjust the time welding will 0 to 120 0 Seconds even if the trigger is still pulled This option has no effect in 4 Step Trigger Mode Postflow Time 0 to 25 0 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 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 POWER FEED 25M LINCOLN B 19 B 20 OPERATION B 20 GMAW STT WELDING 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 weld ing on parts with poor fit up Low spatter even when using 100 shielding gas results in cost sav ings in gas and part clean up Several sets of STT weld mod
78. ge Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 2 ARC RAYS burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 0 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 p
79. igger Save a memory with memory buttons 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 button for more than 5 seconds when saving a user memory Note that memories may be locked using Weld Manager from a P C or Palm application to prevent accidental overwrite of the memories If an attempt is made to save a memory when memory saving is locked the message Memory save is Disabled will appear briefly in the MSP4 display RECALL PRESS 1 SECOND SAVE PRESS 2 SECONDS PROCEDURE 0 Gees HOLD 2 SECONDS TO SAVE PRESS SELECT PROCEDURE OR QUICK TRIGGER WHILE WELDING POWER FEED 25M LINCOLN P B 34 OPERATION B 34 LIMITS Set Limits Press 5 Limits allow the welder to adjust the welding seconds dure only within a defined range MEMORY 4 BR Each user memory 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 WEG to 275 through 310 in min while memo 3 may not have limits Parameters are
80. ight buttom button SET Knob Left Right buttom button SET Knob POWER FEED 25M LINCOLN 26 26 USER DEFINED PARAMETERS Exit Setup Menu This setup menu parameter can be used to exit the setup menu When P 0 is displayed press the left Mode Select button to exit the setup menu Wire Feed Speed Units P 1 selects which units wire feed speed will be displayed in English in minute wire feed speed units default Metric m minute wire feed speed units Arc Display Mode P 2 selects what value will be shown on the upper left display while welding Amps The left display shows Amperage while welding default WEG The left display shows Wire Feed Speed while welding Display Energy P 3 selects whether or not energy is displayed on the MSP4 while welding The total energy from the previous weld will persist the display until another weld is started or a user interface control is changed P 3 will only show up in the list if the power source is capable of calculating energy a power source software update may be necessary When P 3 No ener gy will not be displayed default When P 3 Yes energy is displayed Recall Memory with Trigger Allows the operator to recall a memory by quickly pulling and releasing the gun trigger To recall a memory quickly pull and release the trigger the number of times that correspond to the mem ory number For example to reca
81. ill jump to the welding wire feed speed WELD The power source output and the wire feed speed continue at the weld settings for as long as the trigger is pulled POSTFLOW As soon as the trigger is released the power source output and the wire feed speed are turned OFF Shielding gas continues until the post flow timer expires FIGURE B 19 2 Step Trigger Start OFF e o Crater OFF 9 b Burnback OFF E e 3 m 8 Preflow Run In Weld POWER FEED 25M LINCOLN flow 43 44 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 For this sequence PREFLOW Shielding gas begins to flow immediately when the gun trigger is pulled RUN IN After preflow time expires the power source regulates to the start output and wire is advanced towards the work piece at the Run In 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 OPERATION B 44 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 st
82. in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas O IJI CRRBTES ARE Ro ao Sel dos AREY cus 13 Ja y e Aale Cut dl WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR LEIA COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USO SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR 2 HA 3890 CL TRHORERMEL HDT FEU PE RU BA DIR 8 FR EE 7S O A Bd oot SXISHAIR HA 50917 44 EFSA Jall gl d AA oig ql giall agil L LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 216 486 1751 WEB SITE www lincolnelectric com
83. ium Frequency Width High Frequency Focused POWER FEED 25M LINCOLN P 14 OPERATION STEEL AND STAINLESS GMAW P PULSED WELDING FIGURE B 8 90 6 Power Wave 355 Power Wave 455M Power Wave 455M STT K2230 1 2234 1 2536 1 2 3 POWER FEED 25M 2 KP1696 xx Drive Roll Kit 2 Roll Feeder KP1697 xx KP1505 xx Drive Roll Kit 4 Roll Feeder KP1507 xx ER K1543 xx K2683 xx Digital Control Cable K1796 xx K2593 xx Coaxial Weld Power Cable Lug to Lug K910 xx Ground Clamp 5 See Magnum MIG gun Literature Deluxe Regulator for Mixed K586 1 Shielding Gases Shielding Gas Hose POWER FEED 25M LINCOLN P B 14 15 MSP4 OPERATION OPERATION STEEL AND STAINLESS SYNERGIC GMAW P PULSED WELDING 220 ob WFS OAMPS Less More Deposition Deposition 1 06 VOLTS OTRIM Shorter Longer Arc Arc WELD MODE WIRE SIZE 1419 RUN IN WFS WAVEFORM CONTROL TECHNOLOGY STEEL 035 12 Pulse Crisp ArMix START OPTIONS END OPTIONS Start Procedure 10 0 SOFT to 10 0 STIFF ARC CONTROL FOCUS 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 so
84. justment key Includes Gas Regulator for 3000290 Adjustable Gas Regulator Mixed Gases and 10 3 0m Hose Includes Deluxe Gas Regulator Deluxe Adjustable Gas Regulator for Mixed Gases Adapter for 2 and 10 3 0m Hose POWER FEED 25M LINCOLN 8 5 ACCESSORIES 5 INSTALLATION THE 590 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 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 3 Remove the module from the case by lifting the front of the module approximately 25 6 mm and then sliding forward 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 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
85. ll memory 3 quickly pull and release the trigger 3 times To recall memory 1 quickly pull and release the trigger the number of user memories plus 1 Memories cannot be recalled while the system is welding A memory panel must be installed in order to use this feature Disabled The gun trigger cannot be used to recall user memories default Enabled The gun trigger can be used to recall user memories POWER FEED 25M LINCOLN P 27 OPERATION B 27 USER DEFINED PARAMETERS Procedure Change Method Selects how remote procedure selection A B will be made The selected procedure can be changed locally at the user interface by pressing the A Gun B button The following methods can be used to remotely change the selected procedure Use an external switch wired to the procedure select input Quickly releasing and re pulling the gun trigger Using a dual schedule gun which incorporates a procedure select switch in the trigger mecha nism pulling the trigger more than half way changes the procedure from A to B The possible values for this parameter are External Switch Procedure selection may only be performed the memory panel or an external switch e g K683 Quick Trigger The selected procedure can be changed remotely by releasing and re pulling the trigger quickly while welding This feature is disabled in 4 Step trigger mode The external procedure switch is disabled To operate 1 Select GU
86. ll torch will behave Gun Pot Enabled The welding wire feed speed is always controlled by the potentiometer on the push pull gun default The left front panel knob is only used to adjust Start and Crater wire feed speed Gun Pot Disabled The wire feed speed is always controlled by the left front panel knob This setting is useful when the operator wishes to have wire feed speed settings recalled from memories and not have the potentiometer overwrite the setting Gun Pot Procedure A When in procedure the welding wire feed speed is controlled by the potentiometer on the push pull gun When in procedure B the welding wire feed speed is con trolled by the left front panel knob This setting allows a fixed wire feed speed to be selected in procedure B and not have the potentiometer overwrite the setting when procedure changes Sense From Studs Use this option for diagnostic purposes only When power is cycled this option is automatically reset to False False Voltage sensing is determined by the DIP switch configuration and the selected weld mode default True Voltage sensing is forced to studs regardless of the DIP switch configuration and selected weld mode Show Test Modes Most power sources contain weld modes used for calibration and test purposes By default the machine does not include test weld modes in the list of weld modes that are available to the operator To manually select a test weld mo
87. ls the arc length with Trim instead of voltage When trim arc length is adjusted the Power Wave 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 Increasing the trim value increases the arc length while decreasing the trim value decreases the arc length FIGURE B 12 Trim 50 Trim 1 00 Trim 1 50 Arc Length Short Arc Length Medium Arc Length Long POWER FEED 25M LINCOLN P 18 OPERATION B 18 ALUMINUM GMAW P AND GMAW PP WELDING FIGURE B 14 Power Wave 355M 1 Power Wave 455M Power Wave 455M STT 2230 1 POWER FEED 10M Bench Model Requires K1634 1 Spool cover K2234 1 POWER FEED 10M Dual Bench Model 2 Requires K1634 1 Spool cover 1507 Drive Roll Kit 4 Roll Feeder 1796 K2593 xx Coaxial Weld Power Cable Lug to Lug 910 Ground Clamp 6 K2447 xx Python Plus Air cooled Deluxe Regulator for Mixed 7 K586 1 Shielding Gases Shielding Gas Hose POWER FEED 25M LINCOLN P 19 OPERATION Aluminum Pulse and Pulse On Pulse Synergic Weld Display 220 1 06 Less Deposition 90 WFS OAMPS Deposition VOLTS OTRIM Shorter Arc kA Longer MSP4 OPERATION WELD MODES WIRE SIZE ELECTRODE AND GAS 0 035 3 64 1 16 ALUMINUM 4043 Ar 149 72 74 ALUMIN
88. m es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria etai AP5AmtRE 207 OR ames 1c OF OR fE HEEL SR ER TR S e 42274 ESAE Belle e MASP Ash 75 4274714 27 amp oe fyn duly sui gal bic ja 3 Ar ggill Jiul J oi Mall ce oaa SI e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e X7LTTLZA V U AULURSUPD 4 gt e HEMMER e SHA AHS chez Gh ail AN uit gS Jl alil e Do not operate with panel open guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung
89. me spent in the arc start and arc crater steps Press the push button on the case front to toggle between 2 Step and 4 Step operation The 2 Step 4 Step trigger has no effect when weld ing with SMAW or CAG procedures Lu 0 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 start ing 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 4 Step Trigger 4 Step trigger operation gives the welder additional control in the welding sequence 4 Step trigger allows the welder to choose the arc start weld and arc end time It may also be set up to work as a trigger inter lock POWER FEED 25M LINCOLN P 43 Shielding 9 Gas 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 RUN IN After preflow time expires the power source regulates to the welding output and wire is advanced towards the work piece at the Run In WFS If an arc is not established within 1 5 seconds the wire feed speed w
90. motor to cool approximately 1 minute Err 82 Motor overload short term 1 The wire drive motor current draw 1 Check that motor can turn freely has exceeded limits usually when idle arm is open because the motor is in a locked 2 Verify that the gears are free of rotor state debris and dirt Err 95 Spool gun or pull gun motor 1 The drive motor in the spool gun 1 Check that the wire moves freely or push pull gun is drawing too through the gun when the gun is much current straight Verify the correct size contact tip is installed in the gun Err 263 No usable weld modes 1 The power source does not have 1 See the power source Instruction any welding programs loaded Manual for load welding pro grams CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 25M LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Output Problems The feeder does power up dis 1 The POWER FEED 15M power 1 Turn the POWER FEED 15M play no cold feed switch is OFF power switch ON The Power Wave power source 1512 Turn ON the Power Wave power OFF Source The circuit breaker for the wirel3 Reset
91. nd Accidental contact can cause overheating and create a fire hazard 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutti
92. ndle to the power source work connection and the other end to the work piece Minimize the length of any work lead extension for best results 4 Insulate all connections FIGURE 5 Work Power Source Work Electrode Coaxial Weld Cable Electrode Wire Feeder Work TABLE A2 RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 75 C COAXIAL CABLE LENGTH AMPERES DUTY 0 to 25Ft 25 to 50Ft 50 to 75 Ft 75 to 100 Ft CYCLE 0 107 6 7 6 to 15 2M 15 2 to 22 9M 250 100 300 60 350 60 1 1 1 1 1 1 1 1 0 1 0 1 0 1 RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 167 F 75 C CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES 0 to 50Ft 50 to 100Ft 10010 150Ft 15010 200 Ft 200 to 250 Ft 0 to15M 15 to 30M 30 to 46M 46 to 61M 61 to 76M AMPERES PERCENT D a D dl D gt j Tabled values for operation at ambient temperatures of 104 F 40 C below Applications above 1042 40 may require cables larger than recommended or cables rated higher than 167 F 75 C POWER FEED 25M LINCOLN 8 5 ELECTRODE POLARITY The wire feeder is factory set for Electrode Positive welding Most GMAW welding procedures use Electrode Positive welding Most GTAW and some Innershield procedures use Electrode Negative weld ing
93. ng and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powere
94. ng in the wire drive 18 Reassemble the busbar and tighten the mounting hard ware with a 3 4 open end wrench 19 Place the new gear on the motor shaft Secure the gear to the motor shaft with the collar washer and screw 20 Reassemble the lower drive roll hub and lower drive roll hub retainer 21 Reassemble the gear cover 22 Reassemble the inner wire guide drive rolls and outer wire guide 23 Place the welding gun into the gun bushing and secure with the thumb screw POWER FEED 25M LINCOLN 8 7 WIRE DRIVE CONFIGURATION See Figure 6 Changing the Gun Receiver Bushing A WARNING 9 ELECTRIC SHOCK can kill the input power OFF the welding power source before instal lation or changing drive rolls and or guides Do not touch electrically live parts e When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released e Only qualified personnel should perform mainte nance work Tools required 1 4 hex key wrench Note Some gun bushings do not require the use of the thumb screw Turn power off at the welding power source Remove the welding wire from the wire drive Remove the thumb screw from the wire drive Remove the welding gun from the wire drive Loosen the socket head cap screw that holds the connector bar against the gun bushing Importan
95. nicating to the power source properly MSP4 display window Shows detailed welding and diagnostic information Left Button Changes the display to show the Weld Mode or Arc Control Procedure Button Selects A or B procedure or gun control 2 Step 4 Step Button Toggles between 2 step and 4 step trigger opera tion 5 pin connector Trigger connector for a push only gun ON OFF switch Controls power to the POWER FEEDTM 25M 6 pin connector Connector for a remote control Cover Covers location for optional water cooling line 7 pin connector Connector for a push pull gun Right Display window Shows VOLTAGE or TRIM Right Knob Adjusts values in the right display Thermal Lights when the drive overheats Set Up Lights when feeder is set up IR port Used to transfer information to palm computers etc B 5 OPERATION B 5 18 Right Button Changes the display to show Start Options or End Options 19 Set Knob Changes the value on the display 20 Memory Buttons For selection of common procedures FIGURE B 1a POWER FEED 25M LINCOL
96. ob to adjust Start current while the Start Options LED is displayed CC STICK MODES RL Stick _Soft 7018 Stick Crisp 6010 WAVEFORM CONTROL TECHNOLOGY Stick IR PORT SETUP CC Stick Soft WELD MODE 7 START OPTIONS ARC CONTROL END OPTIONS SET ARC CONTROL ARC FORCE DESCRIPTION END OPTIONS Soft 10 0 to Lower values will provide less short No arc ending options are active for Crisp 10 0 circuit current and a softer arc SMAW Stick welding modes Higher settings will provide a higher short circuit current a more forceful arc and possibly more spatter POWER FEED 25M LINCOLN P 9 OPERATION B 9 NON SYNERGIC GMAW AND FCAW nomsynergic welding modes are available Specialized GMAW mode Mode WELDING GMAW Standard Best for traditional See Figure B 4 MIG welding 5 0 6 Non synergic GMAW FCAW welding mimics the GMAW Power welding controls of traditional welding power sources Voltage and WFS are set as independent variables FIGURE B 4 Best for self shield ed electrodes like Innershield K2368 1 Power Wave 355M 1 K2202 1 Power Wave 455M K2203 1 Power Wave 455M STT K2230 1 POWER FEED 10M Bench Model K2234 1 POWER FEED 10M Dual Bench Model 2536 1 2 3 POWER FEED 25M 1697 1507 K2683 xx 4 K1842 xx Weld Power Cable Lug to Lug K910 xx Ground Cl
97. op per 5 conductor cable in a SO type rubber jacket POWER SOURCE WIRE FEEDER 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 electrode sense lead in Function ArcLink ArcLink ArcLink ArcLink CABLE CONNECTIONS 67 voltage sense 67 voltage sense 40 VDC 40 VDC There are three circular connectors on the front of the Common Common POWER FEED 25M See 5 pin 6 pin and 7 pin Figure A 1 FIGURE A 1 Function Trigger Not used Common Dual Procedure Selection Common 5 pin trigger con nector for push only guns moou 27 77 Remote potentiometer 5K 75 Remote potentiometer common 76 Remote potentiometer wiper Switch On Off Switch common Not used 6 pin connector for remote control or foot hand amptrol nmuoou Motor Motor 77 Remote potentiometer 5K 76 Remote potentiometer wiper Switch On Off Switch common 75 Remote potentiometer common 7 pin connector for push pull guns There is circular connector the of the POWER FEED 25M Maximum control cable length is 200 ft 61 FIGURE A 2 ArcLink ArcLink 67 Electrode Voltage Sense 40VDC Common POWER FEED 25M LIN
98. ously for 6 minutes and then must sit idle for 4 minutes POWER FEED 25M LINCOLN P 3 OPERATION RECOMMENDED PROCESSES GMAW Synergic CV Pulse STT Power Pulse Pulse Push Pull FCAW SMAW GTAW Lift Start only Solid wires 025 to 1 16 Cored wires 035 to 5 64 Cored wires 035 to 3 32 when configured for extra torque EQUIPMENT LIMITATIONS Works only on ArcLink or LincNet Power Wave power sources When operating on LincNet power sources not all features are available Maximum gun length is 25ft 7 6m for push only systems Maximum gun length is 50ft 15 2m for push pull Systems Spool guns do not work with the POWER FEED 25M A remote control foot amptrol and a push pull gun may not be connected to the POWER FEEDTM 25M simultaneously Maximum spool size is 12 in 305 mm diameter Maximum spool weight is 44 Ib 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 LINCOLN B 3 4 4 CASE FRONT CONTROLS CODE 11313 SEE FIGURE B 1 1 Left DISPLAY window
99. p trigger operation switches the welding output ON OFF direct response to the trigger 4 Step trigger operation provides trigger interlock capability and gives the ability to control the amount of time spent in the arc start and arc crater steps Place the toggle switch in the UP posi tion for 4 Step operation and in the DOWN position for 2 Step operation 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 start ing 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 4 Step Trigger 4 Step trigger operation gives the welder additional control in the welding sequence 4 step trigger allows the welder to choose the arc start weld and arc end time It may also be set up to work as a trigger inter lock OPERATION B 42 2 STEP 4 STEP TRIGGER OPERATION Code 11456 and higher The 2 Step 4 Step switch changes the function of the gun trigger 2 Step trigger operation switches the welding output ON OFF in direct response to the trig ger 4 Step trigger operation provides trigger interlock capability and gives the ability to control the amount of ti
100. r cover 6 Use 9 16 socket and ratchet wrench to remove the lower drive roll hub retainer Remove the lower drive roll hub 7 With a Phillips screwdriver remove the screw washer and collar holding the pinion gear Remove the pinion gear 8 Remove the busbar by unscrewing the bolt using a 3 4 open end wrench 9 With a 1 4 hex key wrench loosen the socket head cap screw securing the gun bushing Remove the gun bush ing from the wire drive 10 With a 5 16 nut driver remove the five screws securing the wire drive panel Lift out the wire drive panel and disconnect the molex connections Using a 5 16 nut driver remove the four screws secur ing the cover 12 With a Phillips screwdriver remove the three screws and lock washers securing the motor Remove the motor 13 Place the motor in the new position 14 Assemble the three screws and lock washer holding the wire drive motor 15 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 16 Move DIP switch 8 on the Feed head board to the appropriate position Gear Select DIP Switch 8 Setting Normal Speed 50 800 ipm Extra Torque 30 400 ipm 17 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 bushi
101. ransfer 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 LINCOLN 8 D 1 1 TROUBLESHOOTING 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you
102. rating GEARING WIRE FEED SPEED RANGE WIRE SIZE 50 800 023 1 16 50 800 ipm 030 5 64 factory setting 2 5 20 3m min 0 6 1 6mm 2 5 20 3m min 0 8 2 0mm Extra torque 30 400 ipm 023 1 16 30 400 030 3 32 1 3 10 4m min 0 6 1 6 1 3 10 4 0 8 2 4mm PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 14 5 Inches 8 5 Inches 23 5 Inches 35 lbs 368 mm 216 mm 597 mm 15 9 kg Handle folded down Memory Panel Closed TEMPERATURE RANGE 40 F to 122 40 C to 50 E 40 F to 185 F 40 C to 85 POWER FEED 25M LINCOLN B 2 INSTALLATION 2 SAFETY PRECAUTIONS WARNING ELECTRIC 5 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 e 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 e Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes e Only qualified personnel should perform mainte nance work 69 For best wire feeding performance place the POWER FEED 25M a stable and dry surface Keep the
103. re to the Crater Procedure B 13 OPERATION B 13 STEEL AND STAINLESS SYNERGIC GMAW P PULSED 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 Wave 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 Increasing the trim value increases the arc length while decreasing the trim value decreases the arc length FIGURE 6 50 Trim 1 00 1 50 Arc Length Short Arc Length Medium Arc Length Long ARC CONTROL For steel and stainless pulse modes Arc Control regulates the focus or shape of the arc Arc Control values greater than 0 0 increase the pulse frequency while decreasing the background current resulting in a tight stiff arc best for high speed sheet metal welding Arc Control values less than 0 0 decrease the pulse frequency while increasing the background current for a soft arc good for out of position welding FIGURE B 7 Arc Control 10 0 Arc Control OFF Control 10 0 Low Wide Med
104. s EA e 248 YZ AIX NL Am JA ALI Aal Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo HRUSBICRBRELTE SU e ARR HRAEBSHRRAR ez 119 Sol HSE AIS diii die de Lily ellen cil sai Sg A 2 3 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fu
105. 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 NI POWER FEED 25M LINCOLN 8 6 INSTALLATION A 6 CHANGING THE DRIVE MOTOR GEAR RATIO WARNING Turn off input power at the weld ing power source before installa tion or changing drive roll and or wire guides Do not touch electrically live parts such as the wire drive or internal wiring When feeding with the gun trigger the electrode and wire drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released Only qualified personnel should perform this operation 0 Extra Torque Gearing Feed Force Normal Speed Gearing gt WFS 400 800 Extra Torque Gearing Normal Speed Gearing Tools required 1 4 hex key wrench 3 4 open end wrench 9 16 socket and ratchet wrench 7 16 nut driver 5 16 nut driver Phillips screw driver 1 Turn power off at the welding power source 2 Remove the spool of electrode from the wire feeder 3 Loosen the thumb screw at the wire drive and remove the welding gun 4 Remove the outer wire guide drive rolls and inner wire guide 5 Use a 7 16 nut driver to remove the gea
106. t Do not attempt to completely remove the socket head cap screw 6 Remove the outer wire guide and push the gun bushing out of the wire drive Because of the pre cision 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 OUTER WIRE GUIDE CONNECTOR BLOCK SOCKET HEAD x CAP SCREW LOOSEN TIGHTEN INSTALLATION A 7 8 Connect the shielding gas hose to the new gun bushing if required 9 Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned 10 Tighten the socket head cap screw 11 Insert the welding gun into the gun bushing and tighten the thumb screw PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES A WARNING __ ELECTRIC 5 can kill Turn the input power OFF at the welding power source before instal lation or changing drive rolls and or guides Do not touch electrically live parts e 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 Turn power off at the welding power source Release the idle roll pressure arm Remove the outer wire guide by turning th
107. ten beyond the contact tip or the wire the stickout to 3 8 to 1 2 inches stickout is too long Poor gas shielding on processes 5 Check gas flow and mixture requiring gas Remove or block sources of drafts Poor arc starts with sticking 1 procedures or Iech See Gas Metal Arc Welding blast offs weld porosity narrow Guide GS 100 and ropy looking bead The wire feed speed amperage and 1 The software in the POWER Contact the local authorized voltage trim display work during FEED 25M must be upgraded Lincoln Field Service Shop set but show nothing during welding CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 25M LINCOLN 8 1 Enhanced Diagram DIAGRAMS epoo jueuudinbe 10 94 e qiDej si ou j sjeued y euo UO ou episul pejsed si epoo 10 jenueu siy 104 eq jou over ar 2 2 205 LN3NOdWOO 39N3nO3S SNIH3SNWDN ALAY
108. ual Procedure Memory Operation B 36 thru B 38 Internal Controls senssa riai iae irra B 39 B 40 Cold Feed Gas Purge Switch Light Switch Heater Switch Pressure Arm Adjustment B 41 2 Step 4 Step Trigger Operation and Graphics B 42 thru B 47 RES Lee e EE 48 leUlE tin DELE 49 Operation On Lincnet Power Sources nennen nennen B 49 ACCOSSOMNCS m M Section C Factory Installed Equiprient oiii REESEN C 1 Driv Roll EE C 1 Common Packages with Accessories Used C 2 thru C 4 Installation of Water Cooling Kit C 5 Water Cooled Guns sise C 6 Maintenance Section D Safety le TER D 1 Routine Maintenance EE D 1 P riodie EE D 1 E lee Meed Er D 1 LIeOrndgripin Section E How to Use Troubleshooting Guide sse E 1 Error Codes EEN 2 Troubleshooting Guide A E 3 thru E 4 Wiring Diagrams amp Dimension Prints nnne nnne Section F Parts CDI a H E P 534 Series vi 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS POWER FEED 25 2536 1 2 3 INPUT VOLTAGE and CURRENT INPUT VOLTAGE 10 INPUT AMPERES RATED OUTPUT 104 F 40 C DUTY CYCLE INPUT 5 60 rating 100
109. uminate the inside of the POWER FEED 25M HEATER SWITCH Turn the heater switch ON to warm the inside of the POWER FEED 25M The heater is useful for reduc ing condensation build up on the spool of wire The heater is thermo statically protected OPERATION B 41 PRESSURE ARM ADJUSTMENT ELECTRIC SHOCK can kill 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 e When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released Do not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work The pressure arm controls the amount of force the drive rolls exert on the wire Proper adjustment of pressure arm gives the best welding performance Set the pressure arm as follows See Figure B 18 Aluminum wires between 1 and 3 Cored wires between 3 and 4 Steel Stainless wires between 4 and FIGURE B 18 FLUXGORE 32 ALUMINUM Aluminum wires Cored wires ARC wELDING 4 56 ARC WELDING Steel Stainless wires POWER FEED 25M LINCOLN 42 2 STEP 4 STEP TRIGGER OPERATION 11313 2 Step 4 Step switch changes the function of the gun trigger 2 Ste
110. uring normal welding conditions which results in the wire burning back to the tip or rapid tack welds you are experiencing bird nests check for other feeding problems before adjusting the stall factor The default value for the stall factor is 75 with a range of 5 to 100 POWER FEED 25M LINCOLN 28 OPERATION 28 USER DEFINED PARAMETERS Gun Offset Adjustment Range 30 to 30 default 0 Adjusts the wire feed speed calibration of the pull motor of a push pull gun This should only be performed when other possible corrections do not solve any push pull feeding problems An rpm meter is required to perform the pull gun motor offset calibration To perform the calibration procedure do the following 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 an rpm meter to the drive roll in the pull gun Pull the trigger on the push pull gun Measure the rpm of the pull motor The rpm should be between 115 and 125 rpm If neces sary decrease the calibration setting to slow the pull motor or increase the calibration setting to speed up the motor Postflow time expires When machine output on off is controlled via an arc start switch or foot Amptrol gas will begin flowing when the output is turned on and will continue flowing until the output is turned off and the Postflow time expires Crater Delay Range Off
111. ut and exit this option View Lockout Parameters Originally used to prevent inadvertent changes of secure setup parameters P 500 was previ ously used as a gateway to these parameters Presently this option does not exist in any setup menu Encoder Lockout Locks one or both of the upper knobs encoders preventing the operator from changing wire feed speed amps volts or trim The function of each upper knob depends on the selected weld mode When a constant current weld mode is selected e g Stick TIG Gouge the upper right knob will always function as an on off switch This parameter can only be accessed using Weld Manager or Power Wave Manager software Memory Change Lockout Determines if the memories can be overwritten with new contents No Memories be saved and limits can be configured default Yes Memories cannot be changed saving is prohibited and limits cannot be re configured This parameter can only be accessed using Power Wave Manager POWER FEED 25M LINCOLN P B 31 OPERATION B 31 USER DEFINED PARAMETERS Memory Button Disable Disables the specified memory button s When a memory is disabled welding procedures can not be restored from or saved to that memory If an attempt is made to save or restore a dis abled memory a message will be displayed on the Mode Select Panel indicating the memory number is disabled In multi head systems this parameter disables the same memory buttons
112. with K613 7 Lincoln gun and hex key tors Magnum 550 guns patible with Tweco 5 Includes Gun receiver bush Gun Receiver Bushing for gun ing with hose nipple set screw with K466 3 Lincoln gun connec and hex key wrench tors compatible with guns POWER FEED 25M LINCOLN 8 C 4 ACCESSORIES C4 Includes Gun receiver bushing K1500 5 Gun Receiver Bushing compatible with hose nipple 4 guide tubes with Oxo guns set screw and hex key wrench K489 7 Gun Receiver Bushing for Lincoln Includes Gun receiver bushing Fast Mate guns with trigger connector Used with 2211 and K2212 xx Python Guns Includes Push K2339 1 Push Pull Gun Connection Kit Pull gun bushing fittings valve removal tool modified gas bypass valve and control cable extension Includes 2 hoses with female quick connectors at each end 2 K590 6 Water Connection Kit male connectors for 3 16 ID hose 2 male connectors for 1 4 ID hose and mounting hardware Spindle Adapter for mounting 14 Includes Spindle Adapter made K435 Ib 6 4 kg Innershield Coils on 2 from 2 coil retainers Electrode in 51 mm spindles not included Spindle Adapter for mounting 8in Includes 2 Spindle Adapters K468 203mm diameter spools 2 in for 2 wide spools and the 51 mm spindles other for 3 wide spools Includes Gas Guard Regulator K659 1 Gas Guard Regulator and ad
113. xpires FIGURE B 22 4 Step Trigger 5 Start OFF g 2 Crater OFF 2 Burnback OFF 5 c ki c n 5 ul 5 2 T Weld LF LI 1 5secm x 4 ee _ POWER FEED 25M LINCOLN P m o Idle 1 1 1 1 1 1 1 1 1 1 1 F 1 1 46 47 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 In this sequence PREFLOW Shielding gas begins to flow immediately when the gun trigger is pulled RUN IN After preflow time expires the power source regulates to the start output and wire is advanced towards the work piece at the run inWFS If an arc is not estab lished within 1 5 seconds the power source output an

Lincoln Electric IM892-C User's Manual

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