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Lincoln Electric POWER FEED 25M Service Manual

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All manuals and user guides at all-guides.com
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
DO NOT INSTALL,
your part.
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 MANUAL
opyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric POWER FEED 25M

  • Page 1 All manuals and user guides at all-guides.com SVM185-A July, 2008 POWER FEED ® 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 .
  • Page 2 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.
  • Page 3 All manuals and user guides at all-guides.com i i i i SAFETY i i i i 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”...
  • Page 4 All manuals and user guides at all-guides.com i i i i i i S S A A F F E E T T Y Y i i i i i i WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion.
  • Page 5 All manuals and user guides at all-guides.com i i v v S S A A F F E E T T Y Y i i v v 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû...
  • Page 6 (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 Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 All manuals and user guides at all-guides.com 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-...
  • Page 8 All manuals and user guides at all-guides.com - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX Page Safety ................i-iv Installation .

  • Page 9: Table Of Contents

    All manuals and user guides at all-guides.com TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 All manuals and user guides at all-guides.com INSTALLATION TECHNICAL SPECIFICATIONS – POWER FEED® 25M K2536-1 INPUT VOLTAGE and CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 40 VDC RATED OUTPUT @ 104°F (40°C) INPUT AMPERES DUTY CYCLE 60% rating 100% rating GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW...

  • Page 11: Installation

    All manuals and user guides at all-guides.com INSTALLATION SAFETY PRECAUTIONS HIGH FREQUENCY PROTECTION CAUTION WARNING Locate the POWER FEED® 25M away from radio con- ELECTRIC SHOCK CAN KILL. trolled machinery. The normal operation of the • Turn the input power OFF at the POWER FEED®...

  • Page 12: Digital Control Cable

    All manuals and user guides at all-guides.com 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 Power Source W ire Feeder cables for digital communication. The cables are cop- per 5 conductor cable in a SO-type rubber jacket.

  • Page 13: Weld Cable Sizes

    All manuals and user guides at all-guides.com 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.

  • Page 14: Electrode Polarity

    All manuals and user guides at all-guides.com 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.
  • Page 15 All manuals and user guides at all-guides.com 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.

  • Page 16: Wire Drive Configuration

    All manuals and user guides at all-guides.com 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.

  • Page 17: Remote Sense Lead Specification

    All manuals and user guides at all-guides.com INSTALLATION REMOTE SENSE LEAD SPECIFICATIONS LOADING SPOOLS OF WIRE WARNING Welding with Multiple Arcs: ( 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.
  • Page 18 All manuals and user guides at all-guides.com A-10 INSTALLATION A-10 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. •...
  • Page 19 All manuals and user guides at all-guides.com TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 20: Operation

    All manuals and user guides at all-guides.com OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. INPUT POWER WARNING • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri-...

  • Page 21: Definition Of Welding Terms

    All manuals and user guides at all-guides.com OPERATION GENERAL DESCRIPTION DEFINITION OF WELDING TERMS 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 wire • A Non-synergic welding mode requires all welding feeder features a 2 roll MAXtrac™...
  • Page 22 All manuals and user guides at all-guides.com 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" •...

  • Page 23: Case Front Controls

    All manuals and user guides at all-guides.com OPERATION CASE FRONT CONTROLS Connector for a remote control. (See Figure B.1) 14. 7- pin connector 1. Left DISPLAY window Connector for a push-pull gun. Shows WIRE FEED SPEED or AMPERAGE. 15. Cover Covers location for optional water cooling line.
  • Page 24 All manuals and user guides at all-guides.com OPERATION 11. ON-OFF SWITCH The On-Off Switch turns the wire feeder power on and off. It does not control the power to the welding power source. WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

  • Page 25: Making A Weld With Waveform Technology Power Sources

    Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding pro-...
  • Page 26 All manuals and user guides at all-guides.com OPERATION SMAW (Stick) Welding Display FIGURE B.3 AMPS VOLTS TRIM LESS MORE OUTPUT OUTPUT AMPS AMPS MSP4 OPERATION START OPTIONS FUNCTION START TIME: If no remote control is installed, 0 to 10 seconds this control sets the time for the weld output to ramp up or down from a preset Start cur-...
  • Page 27 Power Wave 455M K2203-1 Power Wave 455M/STT K2230-1 Power Feed 10M, Bench Model K2234-1 Power Feed 10M Dual, Bench Model K2536-1 Power Feed 25M KP1696-xx, Drive Roll Kit, 2 Roll Feeder KP1697-xx KP1505-xx, Drive Roll Kit, 4 Roll Feeder KP1507-xx K1543-xx...
  • Page 28 All manuals and user guides at all-guides.com B-10 OPERATION B-10 Non-Synergic GMAW and FCAW Welding Display Mode 40: Modes 5 and 6: 25.3 AMPS VOLTS TRIM AMPS VOLTS TRIM Less More Shorter Longer Less More Less More Volts Volts START OPTIONS MSP4 OPERATION EFFECT / RANGE DESCRIPTION...
  • Page 29 All manuals and user guides at all-guides.com B-11 OPERATION B-11 GMAW (MIG) 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 WFS (left) knob is rotated, the voltage is adjusted accordingly to maintain a similar arc length.
  • Page 30 All manuals and user guides at all-guides.com B-12 OPERATION B-12 GMAW (MIG) Synergic Welding Display SYNERGIC CV VOLTAGE DISPLAY When the voltage knob is rotated, the display will show Synergic CV programs feature an ideal voltage best an upper or lower bar indicating if the voltage is above suited for most procedures.
  • Page 31 All manuals and user guides at all-guides.com B-13 OPERATION B-13 STEEL AND STAINLESS SYNERGIC GMAW-P (PULSED MIG) 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.
  • Page 32 All manuals and user guides at all-guides.com B-14 OPERATION B-14 STAINLESS STEEL GMAW (MIG)WELDING FIGURE B.8 K2368-1 Power Wave® 355M 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 K2536-1 POWER FEED®...
  • Page 33 All manuals and user guides at all-guides.com B-15 OPERATION B-15 Steel and Stainless GMAW-P (Pulsed MIg)Display 1.06 AMPS VOLTS TRIM Less More Shorter Longer Deposition Deposition MSP4 OPERATION WELD MODE START OPTIONS WIRE SIZE ELECTRODE AND PREFLOW TIME DESCRIPTION 0.030 0.035 0.045 0.052 Steel(Crisp) Ar(Mix) 0 - 10 seconds...
  • Page 34 All manuals and user guides at all-guides.com B-16 OPERATION B-16 ALUMINUM SYNERGIC GMAW-P (PULSED FIGURE B.11 MIG)AND GMAW-PP (PULSE ON PULSE) WELDING The POWER 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.
  • Page 35 All manuals and user guides at all-guides.com B-17 OPERATION B-17 ALUMINUM GMAW-P AND 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.
  • Page 36 All manuals and user guides at all-guides.com B-18 OPERATION B-18 ALUMINUM GMAW-P AND GMAW-PP WELDING FIGURE B.14 K2368-1 Power Wave® 355M K2202-1 Power Wave® 455M K2203-1 Power Wave® 455M/STT K2230-1 POWER FEED® 10M, Bench Model Requires K1634-1 Spool cover K2234-1 POWER FEED®...
  • Page 37 All manuals and user guides at all-guides.com B-19 OPERATION B-19 Aluminum Pulse and Pulse-On-Pulse (Synergic) Weld Display 1.06 AMPS VOLTS TRIM Less More Shorter Longer Deposition Deposition MSP4 OPERATION WELD MODES START OPTIONS WIRE SIZE ELECTRODE AND GAS PREFLOW TIME DESCRIPTION 0.035 3/64 1/16 ALUMINUM 4043...
  • Page 38 FIGURE B.15 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 welding on parts with poor fit-up.
  • Page 39 All manuals and user guides at all-guides.com B-21 OPERATION B-21 GMAW-STT™ ---- Waveform Control Technology™ maximizes the ability to modify the arc for the perfect weld. When AMPS VOLTS TRIM STT™ welding, the parameters to control are: • Wire Feed Speed - sets the deposition rate. •...
  • Page 40 All manuals and user guides at all-guides.com B-22 OPERATION B-22 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.
  • Page 41 All manuals and user guides at all-guides.com B-23 OPERATION B-23 GTAW (TIG) WELDING The POWER FEED® / Power Wave system is excellent for Touch Start TIG welding. The system supports TIG torches with or without gas control valves. TIG torches with gas control valves con- nect directly to the gas flow regulator.
  • Page 42 All manuals and user guides at all-guides.com B-24 OPERATION B-24 GTAW (TIG) WELDING Maximum Amperage AMPS VOLTS TRIM Output Output WELD MODE MODE TOUCH START START OPTIONS START PROCEDURE The Start Procedure controls the Amperage at a fixed level for the set amount of time. WAVEFORM CONTROL TECHNOLOGY IR PORT SETUP...
  • Page 43 All manuals and user guides at all-guides.com B-25 OPERATION B-25 Change the value of the blinking parameter by rotating SET-UP FEATURES MENU the SET knob. The Setup Menu gives access to the set-up configura- After changing a parameter it is necessary to press the tion.
  • Page 44 All manuals and user guides at all-guides.com B-26 OPERATION B-26 Press the left button to exit the set-up menu. Push Pull Gun, Stall Factor Adjustment. The stall factor controls the stall torque of the push WFS units motor when using a push-pull gun. The wire Metric = m/min wire feed speed units feeder is factory set to not stall unless there is English = in/min wire feed speed units...
  • Page 45 All manuals and user guides at all-guides.com B-27 OPERATION B-27 TIG Gas Control (Two Settings) P.13 Adjust Arc Force 1. "Valve (manual)", the internal solenoid will not Use this menu to adjust Arc Force values for actuate while TIG welding, gas flow is manually Start, Weld and Crater.
  • Page 46 All manuals and user guides at all-guides.com B-28 OPERATION B-28 P.99 Show Test Modes P.106 Ethernet IP Address Many weld tables include special modes for Press the right MSP4 button to view the IP testing and servicing the welding system. Set address of the Ethernet board.
  • Page 47 All manuals and user guides at all-guides.com B-29 OPERATION B-29 PROCEDURE/MEMORY PANEL OPERA- USER MEMORIES TION Recall a memory with memory buttons The Dual Procedure/Memory Panel performs three To recall a user a memory, press one of the six user functions: memory buttons.
  • Page 48 All manuals and user guides at all-guides.com B-30 OPERATION B-30 LIMITS To set limits, press the desired memory button 1-6 and hold for 5 seconds. Release the memory button when the LED begins to blink rapidly and the MSP4 Limits allow the welder to adjust the welding procedure displays "Memory X Set Limits"...
  • Page 49 All manuals and user guides at all-guides.com B-31 OPERATION B-31 The memory value must always be less than or equal Four items show on the MSP4 panel. • Memory Value to the high limit, and greater than or equal to the low •...
  • Page 50 All manuals and user guides at all-guides.com B-32 OPERATION B-32 INTERNAL CONTROLS ITEM 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 to the Electrode Connection...
  • Page 51 All manuals and user guides at all-guides.com B-33 OPERATION B-33 NOTE: All switches described on this page will func- tion only when power source is ON. 2 STEP - 4 STEP - TRIGGER OPERATION COLD FEED/GAS PURGE SWITCH 4 STEP COLD FEED The 2 Step - 4 Step switch changes the Cold Feed and Gas Purge are combined...
  • Page 52 All manuals and user guides at all-guides.com B-34 OPERATION B-34 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...
  • Page 53 All manuals and user guides at all-guides.com B-35 OPERATION B-35 EXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start UPSLOPE: and Arc End. Tailoring the arc start and arc end is a Once the wire touches the work and an arc is estab- common method for reducing spatter and improving lished, both the machine output and the wire feed weld quality.
  • Page 54 All manuals and user guides at all-guides.com B-36 OPERATION B-36 EXAMPLE 3 - 2 STEP TRIGGER: Customized Arc WELD: Start, Crater and Arc End. Sometimes it is advanta- After upslope, the power source output and the wire geous to set specific arc start, crater and arc ending feed speed continue at the weld settings.
  • Page 55 All manuals and user guides at all-guides.com B-37 OPERATION B-37 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.
  • Page 56 All manuals and user guides at all-guides.com B-38 OPERATION B-38 UPSLOPE: EXAMPLE 5 - 4 STEP TRIGGER: Manual control of During upslope, the power source output and the wire Start and Crater times with Burnback ON. The 4 step feed speed ramp to the weld settings throughout the trigger sequence gives the most flexibility when the start time.
  • Page 57 All manuals and user guides at all-guides.com B-39 OPERATION B-39 REAR CONTROLS: ITEM DESCRIPTION Flow Meter Shielding Gas Inlet 5-Pin Arclink Cable Connector Electrode Cable Cover for Optional Water Line Connector POWER FEED® 25M...
  • Page 58 All manuals and user guides at all-guides.com B-40 OPERATION B-40 FLOW METER The flowmeter shows the flow rate of shielding gas and has a valve to adjust the flow. The flow meter is scaled for CO , Ar, and CO /Ar blends.
  • Page 59 All manuals and user guides at all-guides.com TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Factory Installed Equipment .
  • Page 60 All manuals and user guides at all-guides.com ACCESSORIES FACTORY INSTALLED EQUIPMENT • 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...
  • Page 61 All manuals and user guides at all-guides.com ACCESSORIES Includes: 1 "T" adapter for K2429-1 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. K857 Used most often with SMAW welding.
  • Page 62 All manuals and user guides at all-guides.com ACCESSORIES Includes: 5 pin to 5 pin 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. K910-1 Ground Clamp Includes: One 300 Amp Ground Clamp.
  • Page 63 All manuals and user guides at all-guides.com ACCESSORIES 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.
  • Page 64 All manuals and user guides at all-guides.com ACCESSORIES 4. Use a 5/16" nut driver to remove the screws holding INSTALLATION OF THE K590-6 WATER the water cooling cover on the case front of the inner COOLING KIT module and on the rear of the case. WARNING ELECTRIC SHOCK can kill.
  • Page 65 All manuals and user guides at all-guides.com ACCESSORIES WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the disconnect switch before working on this equipment. • Do not touch electrically hot parts. • Only qualified personnel should install, use or service this equipment.
  • Page 66 All manuals and user guides at all-guides.com NOTES POWER FEED® 25M...
  • Page 67 All manuals and user guides at all-guides.com TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
  • Page 68 All manuals and user guides at all-guides.com MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off at the fuse box before working in the terminal strip.
  • Page 69 All manuals and user guides at all-guides.com TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Physical Description .
  • Page 70 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.2 - GENERAL PHYSICAL DESCRIPTION VOLTAGE SENSE LEAD #67A LEAD #67 PUSH PULL DAUGHTER DRIVE GEAR BOX MOTOR CONDUCTOR CONTROL BOARD BLOCK FEEDHEAD TO POWER FEEDBACK TACH SOURCE STATUS LED GUN TIGGER AND DIP SWITCHES DUAL PROCEDURE...
  • Page 71 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.3 - GAS SOLENOID CONTROLS VOLTAGE SENSE LEAD #67A LEAD #67 PUSH PULL DAUGHTER DRIVE GEAR BOX MOTOR CONDUCTOR CONTROL BOARD BLOCK FEEDHEAD TO POWER FEEDBACK TACH SOURCE STATUS LED GUN TIGGER AND DIP SWITCHES DUAL PROCEDURE...
  • Page 72 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.4 - CONTROL BOX DISPLAY AND ENCODER PANEL (STANDARD) STATUS SMALL PANEL MEMORY LARGE PANEL MSP4 CONTROL BOX (USER INTERFACE) The POWER FEED® 25M wire feeders do not have User Interface Boards in the control box.
  • Page 73 All manuals and user guides at all-guides.com TROUBLESHOOTING COMPONENT STATUS LIGHTS component is causing the problem. By using the status lights the operator can quickly pinpoint the system problem to a particular component. See the following Each network component has a single status light. The table for a complete listing and description of all status light is a bicolor, Green/Red, LED.
  • Page 74 All manuals and user guides at all-guides.com TROUBLESHOOTING STATUS LIGHT STATES (CON’T) LED State Power Source LED LED on any other nodes (components); Wire Feeder, Control Box Etc. Red LED blinking Power source needs to be reprogrammed. System component (node) needs to be at a fast rate Contact your Local Authorized Lincoln Field reprogrammed.
  • Page 75 All manuals and user guides at all-guides.com TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 76: Troubleshooting And Repair

    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.

  • Page 77: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 78 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER FEED® 25M...
  • Page 79 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER FEED® 25M...
  • Page 80 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER FEED® 25M...
  • Page 81 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER FEED® 25M...
  • Page 82 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER FEED® 25M...
  • Page 83 POWERWAVE® and the work- place. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER FEED® 25M...
  • Page 84 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER FEED® 25M...
  • Page 85 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER FEED® 25M...
  • Page 86 All manuals and user guides at all-guides.com F-12 NOTES F-12 POWER FEED 25M...

  • Page 87: Voltage Sense Pc Board Test

    VOLTAGE SENSE PC BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 88 All manuals and user guides at all-guides.com F-14 TROUBLESHOOTING AND REPAIR F-14 VOLTAGE SENSE PC BOARD TEST (continued) FIGURE F.1 – PLUG J1 AND J2 LOCATIONS NOTE: Inspect the molex plug con- nector pins on the Voltage Sense Board. If any of them are gold plat- ed the P.C.

  • Page 89: Tach Feedback Test

    TACH FEEDBACK TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 90 All manuals and user guides at all-guides.com F-16 TROUBLESHOOTING AND REPAIR F-16 TACH FEEDBACK TEST (continued) FIGURE F.2 – PLUG J84 LOCATION BLUE Black PROCEDURE 5. With the gun trigger activated and the motor 1. Remove input power from the wire feeder unit. running, check the feedback voltage at plug J84 (blue wire) positive to (black wire) negative.

  • Page 91: Drive Motor Test

    DRIVE MOTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 92 All manuals and user guides at all-guides.com F-18 TROUBLESHOOTING AND REPAIR F-18 DRIVE MOTOR TEST (continued) FIGURE F.3 – QUICK CONNECTOR #550 AND #551 LOCATIONS #550 #551 PROCEDURE 5. If the correct voltages are NOT present at the motor leads, check the associated 1.

  • Page 93: Gear Box And Drive Motor Removal And Replacement

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 94 All manuals and user guides at all-guides.com F-20 TROUBLESHOOTING AND REPAIR F-20 GEAR BOX REMOVAL AND DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.4 – GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT THUMB THUMB Control Box Cover SCREW SCREW CONDUIT CONDUIT...
  • Page 95 All manuals and user guides at all-guides.com F-21 TROUBLESHOOTING AND REPAIR F-21 GEAR BOX REMOVAL AND DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) TO REMOVE THE DRIVE MOTOR “top” of the drive motor to the gear box. FROM THE GEAR BOX: 6.
  • Page 96 All manuals and user guides at all-guides.com F-22 NOTES F-22 RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. •...
  • Page 97 All manuals and user guides at all-guides.com TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram Entire Machine Code 11313 (G5585) .

  • Page 98: Electrical Diagrams

    All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - COMPLETE MACHINE - CODE 11313 (G5585) N. D. BRI DGE 640A DI SPLAY RECTI FI ER P. C.BOARD 530A LI GHT HEATER 579C 534 526 551 553 640A 542A 540C 540E 535 537...
  • Page 99 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE - CODE 11313 (G5638) ENGINEERING CONTROLLED RELEASED A.02 F ROM " X". LEAD COLOR CODE: COM PONENT VALUE UNIT S: MANUFACTURER: VOLTAGE SENSE B- BLACK SELECT P.C. BOARD CAPACIT OR: MF D/ VOLTS CAVITY NUMBERING SEQUENCE R- RED...
  • Page 100 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - 42 VAC & ARCLINK FEEDER PC BOARD #1 (G3883-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER FEED® 25M...
  • Page 101 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - 42 VAC & ARCLINK FEEDER PC BOARD #2 (G3883-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER FEED® 25M...

  • Page 102: Schematic - Msp4 Optional Display Pc Board (G4456

    All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - MSP4 OPTIONAL DISPLAY PC BOARD (G4456) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER FEED® 25M...

  • Page 103: Schematic - Spi Display Pc Board - (L11756

    All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - SPI DISPLAY PC BOARD - (L11756) R i i STANDARD This print is Current NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER FEED®...

  • Page 104: Pc Board Assembly - Spi Display - (L11757-1

    Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 105: Schematic - Voltage Sense Select Pc Board - (S24779

    All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - VOLTAGE SENSE SELECT PC BOARD - (S24779) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER FEED® 25M...

  • Page 106: Pc Board Assembly - Voltage Sense Select (M19540)

    Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 107: Schematic - Spool Gun Pc Board (L12008

    All manuals and user guides at all-guides.com G-11 G-11 ELECTRICAL DIAGRAMS SCHEMATIC - SPOOL GUN PC BOARD (L12008) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER FEED® 25M...

  • Page 108: Pc Board Assembly - Spool Gun (M20159

    Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

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