Lincoln Electric SVM185-A General Description, Definition of Welding Terms, Duty Cycle

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B-3

OPERATION

B-3

DEFINITION OF WELDING TERMS

GENERAL DESCRIPTION

 

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NON-SYNERGIC WELDING MODES

•A Non-synergicwelding mode requires all welding process variables to be set by the operator.

SYNERGIC WELDING MODES

•A Synergic welding mode offers the simplicity of sin- gle knob control. The machine will select the correct voltage and amperage based on the wire feed speed (WFS) set by the operator.

WFS

• Wire Feed Speed

CC

•Constant Current

CV

•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

•Flux Core Arc Welding

CAC

•Carbon Arc Cutting

CAG

•Carbon Arc Gouging

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 situa- tions. The easy-to-use, MSP4 interface provides ready access to all welding modes in the Power Wave. A six button memory panel is included with the POWER FEED® 25M and allows quick recall of favorite weld procedures. All the components are packaged in an engineered aluminum case protected by replaceable skids.

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 difficult 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 cycle. The duty cycle is based on a 10 minute cycle.

For example, when welding at 500 amps, the POWER FEED® 25M may run 6 minutes and must idle for 4 minutes.

POWER FEED® 25M

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Contents Power Feed 25M Power Feed 25M SafetyFumes and Gases Electric Shock can killIii For ElectricallySûreté Pour Soudage a L’Arc Précautions DE SûretéElectromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Power Feed 25M K2536-1 InstallationSafety Precautions High Frequency Protection LocationElectric Shock can Kill Wiring Power Source Wire FeederDigital Control CABLE, K1543-XX FunctionWeld Cable Size Coaxial Weld CableTable A.1 Gmaw Electrode Polarity Shielding GAS ConnectionGtaw Build UP of Shielding GAS MAYOFF Changing the Drive Motor Gear RatioProcedure to Install Drive Rolls and Wire Guides Wire Drive ConfigurationLoading Spools of Wire Remote Sense Lead Specifications Typical System Configurations Table of Contents Operation Section Operation Safety PrecautionsGeneral Description Definition of Welding TermsDuty Cycle Recommended Power Sources Recommended ProcessesEquipment Limitations 11. ON/OFF switch Connector for a remote controlPin connector Left Display windowStatus LED ON-OFF SwitchTable B.1 Definition7OPERATIONB-7 Technology Power SourcesMaking a Weld with Waveform Smaw Stick Welding8OPERATIONB-8 Process ModeSmaw Stick Welding Display MSP4 OperationNON-SYNERGIC Gmaw and Fcaw WeldingThree non-synergic welding modes are available Non-Synergic Gmaw and Fcaw Welding Display Modes 5 MSP4 OperationFigure B.5 Gmaw MIG Synergic Welding220 26.4 ARC Control Steel and Stainless Synergic GMAW-P Pulsed MIG WeldingStainless Steel Gmaw Migwelding 220 Aluminum Synergic GMAW-P Pulsed 16OPERATIONB-16Migand GMAW-PP Pulse on Pulse Pulse-on-Pulse WeldingAluminum Pulse Welding Aluminum GMAW-P and GMAW-PPFigure B.14 Aluminum GMAW-P and GMAW-PP WeldingAluminum Pulse and Pulse-On-Pulse Synergic Weld Display Figure B.15 GMAW-STT WeldingGMAW-STT 109Figure B.16 TailoutGtaw TIG Welding Touch StartTIG OFF Power Feed SET-UP Features Menu10M All Models Feed 10AQuick Preflow time will not be accessible from the MSP4 Operation PROCEDURE/MEMORY Panel Opera User Memories Tion Parameter Range Units LimitsMSP4 Display Limits may be set forHigh Limit Low LimitParameter Name Item D Escription Internal ControlsLight Switch Cold FEED/GAS Purge SwitchHeater Switch Step Trigger OperationPreflow 34OPERATIONStrike WeldFigure B.20 Figure B.21 UpslopePostflow 37OPERATIONB-37Figure B.23 StartRear Controls DescriptionFlow Meter Operation on Lincnet Power SourcesScfh Liter/MinTable of Contents Accessories Section Factory Installed Equipment AccessoriesWire Type Electrode Size KP KIT Drive Roll Kits UsedK2593-xx #1 Co-Axial Power Cable Accessories K1500-5 Gun Receiver Bushing compatible Cooling KIT InstallationUse a 5/16 nut driver to remove the screws holding Water cooling cover on the case front of the innerFigure C.1 Python Water Cooled GunsPower Feed 25M Table of Contents Maintenance Section Routine Maintenance MaintenancePeriodic Maintenance Calibration Specification1TABLE of CONTENTS-THEORY of Operation Section E-1 Figure E.2 General Physical Description Theory of OperationFigure E.3 GAS Solenoid Controls Power Feed 25MControl BOX User Interface Component is causing the problem. By using the status TroubleshootingComponent Status Lights Status Light StatesStatus Light States CON’T 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairSee Setting DIP Switches Wire Drive Troubleshooting and Repair Output Problems Power Power source is functioning Make certain the Power WaveSetting Dip Switches in the Wire Troubleshooting and Repair Fault Code Description Possible Adjustments ArcLink System Error CodesPower Feed 25M Voltage Sense PC Board Test Test DescriptionMaterials Needed Figure F.1 Plug J1 and J2 Locations ProcedureTach Feedback Test Blue RED Drive Motor Test #550 #551 Gear BOX and Drive Motor Removal and Replacement Procedure Gear BOX Removal and Drive Motor Figure F.4 Gear BOX and Drive Motor Removal and ReplacementTo Remove the Wire Drive Assembly from the Gear BOX Replacement ProceduresTo Remove the Drive Motor from the Gear BOX Retest After Repair SET UPTable of Contents Diagram Section Wiring Diagram Complete Machine Code 11313 G5585 Electrical DiagramsG5638 Schematic Complete Machine Code 11313 G5638Schematic 42 VAC & Arclink Feeder PC Board #1 G3883-2 Schematic 42 VAC & Arclink Feeder PC Board #2 G3883-2 Schematic MSP4 Optional Display PC Board G4456 Schematic SPI Display PC Board L11756 PC Board Assembly SPI Display L11757-1 Schematic Voltage Sense Select PC Board S24779 PC Board Assembly Voltage Sense Select M19540 Schematic Spool GUN PC Board L12008 PC Board Assembly Spool GUN M20159
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