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ELECTRICAL DIAGRAMS
G-3
POWER FEED® 25M
SCHEMATIC - COMPLETE MACHINE - CODE 11313 (G5638)
EN-170
S
O
L
ID
E
D
G
E
G5638
E
NGI
N
EE
RI
NG
CO
NT
RO
LLE
D
MA
NU
FA
CT
URE
R:
No
R
EL
EASE
D
A.02 F
R
OM "
X".
A
T
HE I
NF
ORMA
T
IO
N
ON
T
HIS
PRIN
T
IS
F
OR
RE
F
ER
ENC
E
ON
LY.
C
O
MPON
EN
T
S
AND
CIRCUI
T
RY
MA
Y
BE
DIFFER
ENT
F
RO
M
AN
AC
T
UAL
M
ACHIN
E.
G5638
POWER FEED 25M
MACHINESCHEMATIC
NO
NE
G4440
JIMJ/KJ
ENYEDY
D
RAWN
BY:
DESIG
N
I
NFO
RMATI
ON
ENG
I
NEER:
AP
PRO
VED
:
REFERENCE:
EQ
UIP
M
ENT
TYPE:
SUBJECT:
SCA
L
E:
MATERIAL
DISPOS
IT
ION:
APPROVAL
DATE:
PROJECT
NUMBER:
NA
C
RM38268
1
PAGE ___ OF
___
1
DO
C
UM
E
NT
N
UM
BE
R:
DOCUMENT
REVISION:
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBA
L, INC.
AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
TO O
THER PARTIES OR US
ED FOR
AN
Y
PURPOS
E WITHOU
T
THE EXPRES
S WRIT
TEN PERMISSION
OF LINCOLN GLOBAL, INC.
PRO
PRIETARY & C
ONFIDENTIAL:
9/13/200
6
J8
6
C
AVI
TY
NU
MBE
RIN
G SEQ
UENCE
(
COMPONENT
S
IDE OF
P
.C.
BO
ARD
)
J8
1,J
82
6
5
10
1
3
4
1
2
J8
5,J
87
9
8
16
1
4
6
1
3
J8
4,J
810
5
4
8
1
J1,J
8
3,J
88
J2,J
811
1
2
LE
A
D
C
OL
O
R
COD
E:
B-
BL
ACK
R-
RED
U-
BL
UE
W-
W
HIT
E
C
OM
PONE
NT
V
AL
U
E
U
NIT
S:
CAPA
CIT
O
R: MF
D/
V
OLT
S
RE
SI
ST
O
R:
O
HM
S/
W
ATT
S
CONNE
CT
O
R
PI
N
N
UM
BER
S:
VIEW
OF
CONNEC
TO
RON PC BOARD
1
6
7
12
LA
TCH
EX.
12
PINCONNEC
TO
R
LABELS:
C
OMM
ON
FR
AM
E
GROUND
FEE
D
HEA
D
P.C. B
OA
RD
4J88
3
21
CUR
RE
NT
W
FS
VOLTS
TRIM
PANEL EN
CO
DERS
2 S
TEP
/4 S
TEP
SWIT
CH
-
+
DI
O
DE B
RI
D
GE
5-32 V
DC
3.1 O
H
MS
13 S
EC. AVE
RA
GE
CUR
RE
NT
LIMIT
=
3.5
A
(LIMIT IS SO
FT
WA
RE SET)
PUS
H
-P
ULL
GUN
DA
UG
HTE
R
P.C. B
OA
RD
5K
7 PIN
PUS
H
-P
ULL
GUN
C
ON
NE
CTI
ON
PRO
VI
DE
S
BRA
KI
NG
O
F
TH
E
PUSH-PULL
GUN
MO
TOR
A
ND
COND
ITIO
N
S
THE
SIG
NA
L
FRO
M T
HE
POTEN
TI
OMETER.
2J811
TO P
US
H
-P
ULL
GU
N
MOT
O
R
D
RIVE
+40V
D
C S
UPPLY
FO
R
PUS
H
-P
ULL
GU
N
MOT
OR
(NON-
ISOLATED
)
DISPLAY P. C. B
OA
RD
(S
C
HE
MATIC: L11
897)
FLE
X
E
3J81 4J81
{
TRI
G
GE
R
0V
TO
C
OMMO
N
W
HE
N
SWIT
C
H
CL
OSE
D
5J84
6J85
9J85
C
OL
D I
NC
H/
GAS P
UR
GE S
WIT
CH
GAS P
UR
GE
C
OL
D I
NCH
579
586
535
GAS
PERFORM
S
AL
L
USER
INTERFAC
E, WI
R
E
DR
IVE,
AND
GA
S
SOLEN
OI
D
CONTRO
L
FUNC
TI
ON
S.
(S
C
HE
MATIC: G4456)
LEDS
LED
DISPLAY
LED
DISPLAY
A-
GUN
-B
PUS
HB
UTTO
N
LEDS
O
N
SIN
GLE
HEA
D
D
UAL
HEA
D
FEE
DE
R
F
UT
U
RE
SEE I
M MANU
AL FO
R E
RRO
R
COD
ES
O
R
WWW
.PO
WERW
AVESO
FT
WAR
E.C
OM
O
R SE
R
VICE
N
AVIGATO
R
DIA
GN
OSTI
C
UTILITIES
SET
SWIT
C
H 1 "
ON
"
(SI
N
GLE
HEA
D)
AN
D S
WIT
C
H 2 "
ON
"
(
FEE
DE
R)
AS SH
OW
N
O
N
DIP S
WIT
C
H S9.
MOT
O
RS
WILL
N
OT
RU
N I
F
DI
O
DE IS
OPE
N,
REVE
RSE
D,
O
R
DIS
CON
NE
CTE
D
MOTOR +
CAPA
CIT
O
R
CON
NE
CTS
FR
OM PI
N 10
O
F S
HIEL
DE
D
CABLE TO
F
RA
ME G
ROUN
D.
2J81
1J81
4J82
3J82
2J82
1J82
14J85
13J85
+15V
OV WHEN "ON"
INP
UT ELECT
RO
DE
CABLE
CON
NE
CTI
ON
67B
FEED PLATE
GENERAL
GMA
W STD.
CV
5
CV
GMA
W P
O
WE
R
MO
DE 40
F
CA
W STD.
CV
6
STICK SO
FT
(7018
)
1
S
TICK C
RISP
(6010
)
2
CC
TIG
TO
UC
H STA
RT 3
GOU
GE -
--
9
AL
UMI
N
UM
0.035 3/64 1/16
GMAW
Ar 148
71 7
3
4043
PULSE
Ar 149
72 74
PULSE O
N P
ULSE A
r
98 99 10
0
+15V
DC
+5V
DC
SIG
NAL
STEEL
0.030 0.035 0.045 0.052
GMA
W
C
O2
-
--
10 20 2
4
GMA
W
Ar
(
MI
X)
94 11 21 25
PULSE
(C
RISP
)
Ar
(
MI
X)
95 12 22 26
PULSE
(S
O
FT
)
Ar
(
MI
X)
-
--
14 19 28
ST
T (
N
O TAIL O
UT
)
C
O2 A
r
/C
O2
109 109 125 125
ST
Tll
C
O2 A
r
/C
O2
110 110 126 12
6
0.035 3/64 1/16
GMA
W
Ar 151
75 7
7
5356
PULSE
Ar 152
76 7
8
PULSE O
N P
ULSE Ar 101
102 10
3
S
TA
INLESS
0.030 0.035 0.04
5
GMA
W A
r (
MI
X)
61 31 41
GMA
W A
r
/He/
C
O2 63
33 43
PULSE Ar/
C
O2 6
6 36 4
6
PULSE Ar/
O2
62 32 42
PULSE Ar/
He/
C
O2
---
34 44
ST
T
Ar/
He/
C
O2 109
109 125
ST
Tll
Ar/
He/
C
O2 110
110 126
ME
TA
L CORE
0.045 0.052 1/1
6
GMA
W A
r
/C
O2 8
1 83 85
PULSE Ar/
C
O2 8
2 84 86
W
FS
AMPS
VOLTS
TRIM
3
21
580
585B
585A
587
585
582
581
FLE
X
SET UP
LED
WEL
D
MO
DE,
WI
RE SI
ZE,
ER
RO
R
CO
DES, SEVEN
SEGME
NTA
N
D ALP
HA
NU
ME
RIC
DISPLAY
IN
F
RARE
D T
RANS
CEIVE
R
(
WI
RELESS C
OM
MU
NI
CATI
ON)
WEL
D
MO
DE LE
D
AR
C
CO
NT
R
OL LE
D
SELECT
PUS
HB
UTTO
N
SELECT PUS
HB
UTTO
N
EN
D
OPTIO
NS LE
D
START OPTIO
NS LE
D
16 DETENT
EN
CO
DE
R
541A
542A
500D
540C
CAN
CAN
COM
+40VDC
8
7
6
5
4
3
2
1
SHIEL
DE
D
CABLE
6J810
4J810
3J810
2J810
8J810
1J810
5J810
526
548
6J84
6J85
8J84
1J88
518
PUS
H
-P
ULL
GUN
BRAKE SIG
NAL
(0 V
OLT
=
MOT
O
R B
RAKE
0-5V P
US
H
-P
ULL
GUN
POTENTI
OMETE
R SI
G
NAL
RE
Q
UI
RE
D
FOR
4 S
TEP
MO
DE
SEE
ER
RO
R TABLE
IN IM MA
N
UAL
NOR
MAL
SPE
ED
ON D
E
F
.
LO
W SPEE
D
EX
TRA TO
RQ
UE
OF
F
D
E
F
.
FE
ED
SPE
ED
G
E
AR
8
F
U
N
C
T
I
ON
7
6
5
4
3
2
DI
P SWIT
CH
S
1
SETT
ING CH
AR
T
T
OG
GL
E
N
O
.
1
POL
AR
ITY
NE
G
SP
AR
E
POS
10J86
9J86
8J86
7J86
6J86
5J86
4J86
3J86
2J86
1J86
10P86
9P86
8P86
7P86
6P86
5P86
4P86
3P86
2P86
1P86
(S
C
HE
MATIC L120
08)
ON
O
FF
S1
SEE DIPSWIT
C
H S1
SET
TIN
G
C
HA
RT
(S
C
HE
MATIC
G3883)
1J811
5J83
5J83
554
640
A
5J88
595
640
SE
T
UP
M
ENU
To
acce
s
s, p
re
s
s the
r
ight and lef
t push but
tons
on t
he MSP
4 pa
nel simult
ane
ousl
y
S
et
u
p feat
ur
e
numbe
rs m
ay v
a
ry b
et
wee
n s
oft
ware
ve
rsi
o
ns.
Must
re
a
d s
mal
l d
is
pl
ay to
fin
d y
our
spec
ific
feat
ur
e y
o
u
wa
nt.
T
h
es
e
P
numbe
rs liste
d
ar
e fo
r r
ef
ere
nc
e.
SE
T
UP
M
ENU FE
AT
URES
P.0 =
On/
Off enter e
x
it set up
m
ode
P1 =
W
FS Engli
sh/metri
c
P2 = Left display a
m
ps/
w
fs
P4 = T
r
igger me
m
or
y
re
call
P5 = T
r
igger p
ro
cedu
re
change
P6 = Stall facto
r
P7 = Push pull gun
offset
P8 =
Ne
w
TIG solenoid fe
ature
P80-89 = Sense
s f
rom stud
s on S256
29-09
P99 = Sho
w
test m
ode 200.201
P10
0 = Vie
w
diag
nosti
cs
P10
2 =
Fatal log
P10
3 = Vie
w
soft
w
are
P10
4 =
Ha
rd
w
are ver
s
ion
P10
5 =
Welding soft
w
are
P20
0 =
C
C te
st 25
-600
P20
1 =
CV te
st 10
-35
P20
2 =
C
C te
st 10A
P20
3 =
C
C te
st 355A
P20
4 =
C
C te
st 455A
P205
=
C
C test 550A
P206
=
C
V test 10V
to
30 V
P207
= 1/0 test 25-600
P208
=
ST
T
test
170A
P209
= 1
cu
rv
e 0-600A
P210
=
Step resp background
P211
=
V cur
v
e 0-70V 10-70V
P212
=
OC
V test
P215
= Touc
h sen
se
P255
=
Sho
w w
eld file
10J85
7J85
5J85
12J85
11J85
580
A
587
A
585C
582
A
581
A
S3
S2
1J83
2J83
3J83
4J83
D
UAL
PR
O
CE
DU
RE
A
C
PR
O
CE
DU
RE
A =
OPE
N
B =
CL
OSE
D
1J84
7J84
4J84
2J85
1J85
3J85
532
E
570F
543
A
MOT
O
R
GEA
RB
OX
TAC
H
3
4
5
6
R
U
B
R
U
B
5VD
C TA
C
H S
UPPLY
TAC
H SI
G
NAL
TACH
C
OM
W
B
(ACCES
S
TH
IS
CONNECTOR
BY
REMO
VI
NG
TH
E WI
R
E
DR
IVE
ASSEMBLY)
550
551
553
554
PWM
CO
NT
R
OLLE
D
6.5
VD
C
W
HE
N
GAS IS
FL
O
WI
N
G.
C
OIL
MEASU
RES 21 O
H
MS.
12 VD
C
C
OIL
L
5
TO
R
OI
D
MOT
O
R
+
MOT
O
R
-
GAS SOLE
N
OI
D
+
GAS SOLE
N
OI
D
-
531
537
534
TRI
G
GE
R
SUPPLY
FO
R T
RI
G
GE
R A
N
D
D
UAL
D
UAL P
RO
CE
DU
RE
0VD
C
@
50 IN/MI
N
24VD
C
@
700
IN/MI
N
6 PIN
RE
MOTE
FO
OT
AMPTR
OL
CON
NE
CTI
ON
(LOWER CAS
E
FRONT)
570
B
532
B
77B
76B
75B
DA
C
B
F
B
A
M
E
F
C
DG
75A
76A
77A
MOTOR -
532
A
570
A
P5
P3
321
8A
321
4A
321
8
321
4
76
75
77
(LOCATED
A
T
REAR
O
F
FEEDER)
(CAS
E
FRONT)
PUS
H
-P
ULL
GU
N
WI
RE
FEE
D SPEE
D
CO
NT
R
OL
PUS
H
-P
ULL
GU
N T
RI
G
GE
R
AMPHE
N
OL
(LOWER CAS
E
FRONT)
+40
AC
(WI
R
E
DR
IVE
ARE
A
FRON
T
TOP)
(WI
R
E
DR
IVE
FRON
T
TOP)
PCT A
N
D
RESISTO
RS
PR
OTE
CTED
ON
DA
UG
HTE
R B
OA
RD
J87
N
OT
USE
D
CLEA
N
RO
OM
USE
P1
P2
(D
IVI
DER
P
ANE
L
REAR
ACCES
S
DOOR
SI
DE)
532
570D
543
D
E
B
{
SP
AR
E
SP
AR
E
SP
AR
E
SP
AR
E
SP
AR
E
(BEHIND COVER
A
ND
MOTOR
A
REA)
PUS
H
-P
ULL M
OT
OR
FL
OW
ME
TER
(OUT
SI
D
E
BAC
K O
F
CASE)
GOO
D
FO
R A
r
, C
O2,
C
O2/A
r
BLEN
DS
AD
J
UST VALVE
BALL
FL
OAT
USE MI
D
DLE
O
F
BALL
TO SET
25
TO 35
NOR
MAL
FL
O
W
RATE
L
6
TO
R
OI
D
AR
C V
OLTAGE
FEE
DBA
CK
6J1
VOLTAGE SENSE
SELECT P.C. BOA
RD
2J2
513
400
2J1
1J1
3J1
4J1
J2
67B
514
N
OTE: WILL W
O
RK
WIT
H LI
NK
NET
POWE
R S
OUR
CE B
UT
WILL
O
NL
Y S
HO
W A
N
D
HAVE
L
INK
NET
FEAT
U
RES
A
B
C
D
E
541
542
67
67A
540
500
500
B
500C
(S
C
HE
MATIC S247
79)
67A
(LOCATED
A
T
REAR
O
F
FEEDER)
(LOCATED
B
EHIND
W
IRE
REE
L
COVER)
1
2
3
4
5
6
7
8
P11
541
A
542
A
540
A
500
A
500C
520
530
7P7
P8
8
7
P10
500D
1
2
R3 R2
530
A
8P7
540
E
S5 HEATER
540
B
540D
DIP S
WIT
C
H S9
4
3
5
7
6
W
B
RE
D/
G
REE
N
STA
TUS LED
1
2
15J85
16J85
1B
1W
8
1
4
3
579
A
586
A
535
A
2
578
578
A
579C
579
B
R1
590
B
W
B
W
1J88
518C
518D
6
518
B
8J84
518
MOT
O
R
F
RA
ME
IS H
OT TO
ELECTR
O
DE
TYP: I
PM
50 - 800/IPM NO
R
MAL SP
EED
30-400/IPM E
X
TRA TO
RQ
UE
570G
P4
P6
1
2
3
532
570D
543
532C
L2
TO
R
OI
D
5
4
10
6
7
321
4A
321
8A
L1
TO
R
OI
D
9
8
532
A
570
A
532D
570C
570
E
543
A
321
4
321
8
77A
75A
76A
76
75
77
P6
L1
TO
R
OI
D
J1
(S
C
HE
MATIC: L11
756)
MEMO
R
Y P.C. B
OA
RD
MSP4 P
.C. B
OA
RD
LIG
HT LE
D S
WIT
CH
(
USE
D I
N
DA
RK A
REAS
)
S4
P89
L4
TO
R
OI
D
540
B
S1 POWE
R
(LEF
T
LOWER CAS
E
FRONT)
40 VD
C
C
OM
MU
NI
CATI
ON
{
{
5 PIN A
R
CLI
NK
CON
NE
CT
O
R T
O
PO
WE
R S
OUR
CE
HELPS KEEP MOISTU
RE
OF
F
O
F
WI
RE
(ABOV
E WI
R
E
FEED
MO
TOR)
(BEHIND
W
IR
E
REE
L
COVER)
P9
40 O
H
MS
10 WAT
TS
AR
CLI
NK
OPTIO
N
USE
J86 SPI USE
WI
RE
MOT
OR
USE
SERIAL N
U
MBER A
ND
CO
DE
NU
MBER L
O
CATE
D
BELO
W WI
RE
FEE
D
D
RIVE
R
OLL A
REA
SEE IM MAN
UAL
FO
R
MO
RE
DETAILS
1
2
475 OH
MS
(BAC
K O
F
WI
R
E
DR
IV
E
PANE
L - S
OLDER
ON
B
RACKET)
P7
OPE
N
=
4 S
TEP
: CL
OSE
D
=
2 S
TEP
(ABOV
E WI
R
E
FEED
MO
TOR
T
OP)
(LOCATED
O
N
B
ACK
SI
D
E O
F
BOARD)
(ON
P
UL
L
DOWN DOOR
F
RONT)
(BEHIND
P
UL
L
DOWN DOOR
F
RONT)
(BEHIND
F
RON
T
PUL
L
DOWN DOOR)
(TO
P
FRONT)
(BEHIND D
IS
PLA
Y
BOARD)
(TO
P
FRONT)
(BAS
E
CONTROL
BD.
A
REA)
(BEHIND
W
IR
E
FEED
MO
TOR)
400H
ADAPTER
L
7
TO
R
OI
D
L3
TO
R
OI
D
400
E
CON
NE
CTS TO S4
(LEF
T
LOWER CAS
E
FRONT)
(BEHIND CASE
FRONT)
CAPA
CIT
OR
400F
400G
400D
400C
400
B
(CONTRO
L
BO
X
TOP)
(CONTROL
BO
X
TOP)
(BEHIND CAS
E
FRONT)
(CONTROL
BO
X
BOTTO
M)
G-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.