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IM892-C
March, 2010
™
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
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i i 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 ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product T Th ha an nk k Y Yo ou u ••• 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, purchas
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vi vi TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ..................................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – POWER FEED™ 25M K2536-1, -2, -3 INPUT VOLTAGE and CURRENT INPUT AMPERES INPUT VOLTAGE ± 10% 4A 40 VDC RATED OUTPUT @ 104°F (40°C) INPUT AMPERES DUTY CYCLE 60% rating 500 400 100% rating GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING WFS RANGE WIRE SIZES WFS RANGE WIRE SIZES Normal Speed 50 – 800 ipm .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 tor
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS HIGH FREQUENCY PROTECTION CAUTION WARNING ELECTRIC SHOCK CAN KILL. Locate the POWER FEED™ 25M away from radio • Turn the input power OFF at the controlled machinery. The normal operation of the welding power source before POWER FEED™ 25M may adversely affect the oper- installation or changing drive rolls ation of RF controlled equipment, which may result and/or guides. in bodily injury or damage to the equipment. • Do not touch electrically live parts.
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A-3 A-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 A.3) 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 frequ
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A-4 A-4 INSTALLATION To install: WELD CABLE SIZE 1. Turn the input power off at the welding power source. 2. Connect one end of the center lead to the power source Table A.1 located below are copper cable sizes recommended for electrode connection, and the other end to the wire feed- different currents and duty cycles. Lengths stipulated are the dis- er electrode connection. tance from the welder to work and back to the welder again. Cable 3. Connect the outer lead bundle to the power source
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A-5 A-5 INSTALLATION SHIELDING GAS CONNECTION ELECTRODE POLARITY WARNING The wire feeder is factory set for Electrode Positive welding. Most GMAW welding procedures use CYLINDER may explode if Electrode Positive welding. Most GTAW and some damaged. Innershield procedures use Electrode Negative weld- ing. • Keep cylinder upright and chained to support. CAUTION • Keep cylinder away from areas where it may be damaged. When changing the electrode polarity, the weld • Never lift welder with
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A-6 A-6 INSTALLATION 8. Remove the busbar by unscrewing the bolt using a 3/4" CHANGING THE DRIVE MOTOR GEAR RATIO open end wrench. WARNING 9. With a 1/4" hex key wrench, loosen the socket head cap screw securing the gun bushing. Remove the gun bush- • Turn off input power at the weld- ing from the wire drive. ing power source before installa- tion or changing drive roll and/or 10. With a 5/16" nut driver remove the five screws securing wire guides. the wire drive panel. Lift out the wire d
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A-7 A-7 INSTALLATION WIRE DRIVE CONFIGURATION 8. Connect the shielding gas hose to the new gun (See Figure A-6) bushing, if required. Changing the Gun Receiver Bushing 9. Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate. WARNING Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned. ELECTRIC SHOCK can kill. 10. Tighten the socket head cap screw. • Turn the input power OFF at the 11. Insert the weldin
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A-8 A-8 INSTALLATION REMOTE SENSE LEAD SPECIFICATIONS LOADING SPOOLS OF WIRE Welding with Multiple Arcs: WARNING ( See Figure A.7) • Keep hands, hair, clothing and tools Special care must be taken when more than one arc away from rotating equipment. is welding simultaneously on a single part. Arc blow • Do not wear gloves when threading and arc interference may occur or be magnified. Each wire or changing wire spool. power source requires a work lead from the work stud • Only qualified person
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A-9 A-9 INSTALLATION TYPICAL SYSTEM CONFIGURATIONS • Brass-to-brass connections between the electrode Standard Features connection and the gun minimize voltage drop varia- tions, resulting in consistent arc performance all Arc Performance day, every day. • Push-Pull ready for welding aluminum with Pulse and Pulse-on-Pulse™ waveforms. • Powerful, quiet motor with integrated tachometer for accurate WFS regulation. • STT™ capable when used with STT™ equipped Power Waves. Extras: • Flowmeter with
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B-1 B-1 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION THIS MACHINE OR IN THIS MANUAL BEFORE OPERATING MACHINE. INPUT POWER WARNING • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ON ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri- OFF cally energized and could remain energized several sec- onds after the welding ceases.. • Do not touch electrically live part or electrode WIRE FEEDER with skin or w
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B-2 B-2 OPERATION DEFINITION OF WELDING TERMS GENERAL DESCRIPTION General Physical Description NON-SYNERGIC WELDING MODES The POWER FEED™ 25M is a premium portable wire feeder for use with the Power Wave products. The • A Non-synergic welding mode requires all welding wire feeder features a 2 roll MAXtrac™ drive coupled process variables to be set by the operator. to a powerful motor for driving wire through difficult sit- uations. The easy-to-use, MSP4 interface provides SYNERGIC WELDING MODE
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B-3 B-3 OPERATION RECOMMENDED PROCESSES • GMAW (CV, Synergic CV, Pulse, STT™, Power, Pulse on Pulse™, Push-Pull) • FCAW • SMAW • GTAW (Lift Start only) • Solid wires .025" to 1/16" • Cored wires .035" to 5/64" • Cored wires .035" to 3/32" when configured for "extra torque" EQUIPMENT LIMITATIONS ® • Works only on ArcLink or LincNet Power Wave power sources. • When operating on LincNet power sources, not all features are available. • Maximum gun length is 25ft.(7.6m) for push-only systems. • Max
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B-4 B-4 OPERATION 15. Cover CASE FRONT CONTROLS (CODE 11313) Covers location for optional water cooling line. (SEE FIGURE B.1) 16. Set-Up 1. Left DISPLAY window Lights when feeder is set-up. Shows WIRE FEED SPEED or AMPERAGE. 17. Memory Panel Door 2. Left KNOB (See Memory Panel Operations in this Section) Adjusts values in left display. 3. Right Display window FIGURE B.1 Shows VOLTAGE or TRIM. 1 4. Right Knob Adjusts values in the right display. 2 3 5. Status LED 5 Illuminates a steady green whe
