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SVM185-A
July, 2008
®
POWER FEED 25M
For use with machine code numbers 11313
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANU
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ii ii 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 INJU
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iiii iiii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b
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iiiiii iiiiii S SA AF FE ET TY Y 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 b
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iiv v iiv v S SA AF FE ET TY Y 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement
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v v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln El
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vi vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions. If interference occurs, it may be necessary to take additional precautions such as filter
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I I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1 A-1 TABLE OF CONTENTS - INSTALLATION SECTION Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS – POWER FEED® 25M K2536-1 INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 40 VDC 4A RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 60% rating 500 100% rating 400 GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING 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 torque 30 – 4
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A-3 A-3 INSTALLATION SAFETY PRECAUTIONS HIGH FREQUENCY PROTECTION CAUTION WARNING ELECTRIC SHOCK CAN KILL. Locate the POWER FEED® 25M away from radio con- • Turn the input power OFF at the trolled machinery. The normal operation of the welding power source before POWER FEED® 25M may adversely affect the opera- installation or changing drive rolls tion of RF controlled equipment, which may result in and/or guides. bodily injury or damage to the equipment. • Do not touch electrically live parts. -
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A-4 A-4 INSTALLATION DIGITAL CONTROL CABLE, K1543-XX CONTROL CABLE CONNECTION: (See Figure A.3) ArcLink/LincNet control cables are special high quality Digital Control Cable: Figure A.3 cables for digital communication. The cables are cop- Power Source Wire Feeder per 5 conductor cable in a SO-type rubber jacket. There is one 20 gauge twisted pair for network com- E E E E D D A A A A D D munications. This pair has an impedance of approxi- mately 120 ohms and a propagation delay per foot of C C
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A-5 A-5 INSTALLATION COAXIAL WELD CABLE WELD CABLE SIZE Coaxial welding cables are specially designed welding Table A.1 located below are copper cable sizes recom- cables for pulse welding or STT™ welding. Coaxial weld mended for different currents and duty cycles. Lengths cables feature low inductance, allowing fast changes in stipulated are the distance from the welder to work and the weld current. Regular cables have a higher inductance back to the welder again. Cable sizes are increased for
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A-6 A-6 INSTALLATION SHIELDING GAS CONNECTION ELECTRODE POLARITY WARNING The wire feeder is factory set for Electrode Positive welding. Most GMAW welding procedures use CYLINDER may explode if 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 cyl
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A-7 A-7 INSTALLATION 7. Remove the busbar by unscrewing the bolt using a 3/4" CHANGING THE DRIVE MOTOR GEAR RATIO open end wrench. WARNING 8. With a 1/4" hex key wrench, loosen the socket head cap screw securing the gun bushing. Remove the gun bushing • Turn off input power at the welding from the wire drive. power source before installation or changing drive roll and/or wire 9. With a 5/16" nut driver remove the five screws securing the guides. wire drive panel. Lift out the wire drive panel
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A-8 A-8 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 welding g
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A-9 A-9 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 is away from rotating equipment. welding simultaneously on a single part. Arc blow and • Do not wear gloves when threading 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 personnel
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A-10 A-10 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 day, Arc Performance 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 TABLE OF CONTENTS - OPERATION SECTION Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Graphic Symbols that appear on this Machine or in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-
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B-2 B-2 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
