Lincoln Electric IM398 User's Manual
Contents
1. 8 10 INSTALLATION 11 Sale PICCAUNIONS L urus ls uska tia ia a a ent 11 Unpacking the Control Module 2 00030 ci a ede RR n t CR OR a 11 Control Module Familiarization 11 Connection to Power Source 12 Installation of K492 10 Input Cable to Power Sources with a Terminal Strip 12 Installation of K493 10 Input Cable to Power Sources with a 14 pin Connector 12 Installation of K691 10 Input Cable with14 Pin Connector to 115V Plug 13 Setting the Mode Switch on Rear Panel 13 Connection to Spool Gun 14 Work Lead Connection 13 OPERATING INSTRUCTIONS 15 Safety ee Em 15 Initial Checkout of Magnum SG System Installation 15 Setting Gas Flow Rate on Gas Cylinder Regulator 16 Setting Gas Preflow Time on Control Module 16 Setting the Wire Speed 6 usura iaia uqa ena a s awa ac ee ede Ped ua iso e saa 16 Setting Wire Speed When Using a K469 Spool Gun 16 Setting Wire Speed When Using a K487 Spool Gun Having Remote Spe2. SJeued eunsoJoue ay JO euo uo aulyoeu y episui pejsed si epoo Je nomed e Jo wWelBeip ojioeds eu penueu siy Ag peJeAoo seuluoeui IS JO e1e4n9oe JOU SI y AJUO e2u849JeJ 104 SI LURIBEIP SIU 31ON EF NOTES Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages
3. Z lt ZIZ Z lt Z lt Z Z lt Z lt Z lt lt Z lt Z lt lt Z lt Z For non Lincoln equipment having a terminal strip and either switch closure or 115VAC activated output contactor if present use K492 10 0 INSTALLATION Safety Precautions Unpacking The SG Control Module Carefully unpack the Control Module and make sure you have A WARNING the following contents e Have an electrician install and Control Module service this equipment e Turn the input power off at the fuse box before working on equipment ELECTRIC SHOCK Do not touch electrically hot parts can kill Read Arc Welding Safety Precautions in the Operating Manual before proceeding Only personnel that have read and understood the Operating Manual should install and operate this equipment Operating Manual Power source must be connected to system ground per the U S National Electrical Code and any applicable local codes Control Module Familiarization Become familiar with the various controls and connectors on the Control Module before connecting to power source Refer to illustrations and numbered items below for brief description 1 Wire speed control potentiometer for varying wire feed speed 8 Connector for input cable assembly control cable to power source 2 Preflow timer 0 1 second adjusts wire feeder start up delay time from when gas flow starts 9 Input connector for input cable assembly electrode cable 3 2
4. amp Wire Matic 250 K518 Adapter K607 1 Spool Gun Adapter Kit SP 255 SP 255 l amp Wire Matic 255 K518 Adapter K672 1 Spool Gun Adapter Kit CV Output Machine with Contactor K518 Adapter K488 Control Module K492 10 Input Cable for machines with terminal strip OR K493 10 Input Cable for Lincoln macines with 14 pin connector K469 25 with K473 Extension Cable K518 Adapter K517 Adapter K518 Adapter K607 1 Spool Gun Adapter Kit K473 requires minor modification K518 Adapter K672 1 Spool Gun Adapter Kit same as above K487 25 K516 Adapter No remote WFS control K517 Adapter No remote WFS control K607 1 Spool Gun Adapter Kit K672 1 Spool Gun Adapter Kit K488 Control Module K492 10 Input Cable for machines with terminal strip OR K493 10 Input Cable for Lincoln machines with 14 pin connector K487 25 with K473 Extension Cable K516 Adapter No remote WFS control K517 Adapter No remote WFS control K607 1 Spool Gun Adapter Kit K473 requires minor modification K672 1 Spool Gun Adapter Kit same as above ACCESSORIES For Rotating Engine Driven Type Power Sources Machine Classic II 14 pin Amphenol connector Terminal Strip 2 4 31 32 Z Internal Contactor Outlet Z 115V AC lt Recommended Input Cable Assembly K691 10 Cold Electrode Classic Il w Wire Feeder Modu
5. avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas O0ONAIPAIN EMVALIZE TRBHERPFELEVCE FL e SS IR E ES NS Eo ezo Y OM AIS Z by cils UI yal UA add y e Aale Get Al dl Ayan WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO SA FIA Chinese LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR fESMMCRBHOA A OIRBEEKMA EFBRLTF SEW TLTAHOR EME NES TRE HAMM BUE 38 88 ROS R E ERU BLUR LL ER US o iso ZIQREAME SASHA FAL At LATAS EPA Gigi S El aad cala Al gil Catia Al lila J gg all dg SS eall clala ad y a L LINCOLN E ELECTRIC e World s Leader in Welding and Cutting Products e e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
6. engine parts and current creates EMF fields around welding cables and igniting Do not spill fuel when filling tank If welding machines fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving i U m Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known 1 e In some cases it may be necessary to remove safety All welders should use the following procedures in order to guards to perform required maintenance Remove minimize exposure to EMF fields from the welding circuit guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible arts P 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right
7. passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life 44 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment 6 TABLE OF CONTENTS SAFETY PRECAUTIONS a od ead o 2 5 PRODUCT DESCRIPTION 8 SPECIFICATIONS sie ci rd ua ace ses OTe E dati a daa cdit ide rd 8 REQUIRED EQUIPMENT 8 OPTIONAL ACCESSORIES
8. to remove fumes from breathing zone e Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca e Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5mtRES L 2 U TC Fat ORAV HELCTIHELTFEL EEE E e 1 IP UR E s FB X8 I sk RSR UE Secr SHINS Belle Syor 23745 HASI Bal 7HAXI717iu EDS AHgSHIAIg i gis ye lua dl su e cat gal bias Shem si Aasch ail e qub di Qui AMA ge ll sag ue e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig off nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e Ate HE ZLCRU PD PSR STEEL U TE g tJ ES Us e MEARE E Alan Ada pill d ily gst Juill lo Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou
9. un S ret Pour Soudage A L Arc chauffement et un risque d incendie 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines 9i on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n i
10. while the engine is running side the work cable should also be on your right side qe Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment e Semiautomatic DC Constant Voltage Wire Welder e DC Manual Stick Welder e AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electro
11. with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment at or one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals _ a 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only Prices include shipment by 4th Class Book Rate for U S A Mainland Only Plea
12. 8 25 x 9 0 inches 254 x 210 x 229mm Weight 13 Lbs 5 9kg Dimensions H x W x D dimension includes handle Optional Accessories Several accessories are optionally available for use with the K488 control module and they are as follows 1 Three 10 ft 8 0m input cable assemblies are available and consist of control and electrode cables and gas line The proper input cable assembly must be ordered in addi tion to the control module as none are included with the control module A K492 10 for use with Lincoln CV power sources having terminal strip control connections Lincoln R3S CV 400 and DC family machines Can also be used with non Lincoln CV power sources B K493 10 for use with Lincoln CV power sources having 14 pin control cable connection Lincoln CV and CV I series Invertec V 200 C K691 10 for use with Lincoln engine driven power sources having 14 pin control cable connection and or 115VAC outlet 2 K473 Spool Gun Extension Cable 25 extension cable extends distance between spool gun and K488 control module 3 K518 Adapter for K469 Spool Gun Adapts K469 spool gun to K488 Control Module or to K473 Extension Cable For convenience here is a summary of needed equipment to use the various combinations of available Magnum spool guns and accessories ACCESSORIES For Static Transformer Type Power Sources Power Source SP 150 None required None required SP 250 SP 250 I
13. A circuit breaker manual reset protects control circuitry 10 Lockout bar for mode switch 4 Output connector for spool gun electrode cable 11 Mode switch for selecting type of contactor circuit in power 5 Connector for spool gun control cable source 6 Gas fitting for spool gun gas line 12 Gas fitting for input cable assembly gas line 7 Carrying handle 13 Control Module code and serial numbers INSTALLATION to Power Source Connection Connect the gas line to the gas cylinder regulator Connect the control module to the power source using either a K492 10 K493 10 or K691 10 Input Cable Assembly ordered separately and follow the simple steps below Installation of K492 10 Input Cable to Power Sources with a Terminal Strip 1 Identify the cable end which has the Amphenol connector associated with it This end attaches to the Control Module 2 Attach the control cable Amphenol connector gas line connector and elec trode cable terminal to their respective connec tors on the rear panel of the Control Module 3 Atthe other end of the cable 4 Connect the elec trode cable to the positive output S ELECTRODE CABLE POWER stud on the power source CONTROL CABLE 5 Locate and open the access panel for the terminal strip on the power source and connect the control cable a Connect the terminal on the green lead marked GND to the ground screw E on the chassis panel or
14. A constant voltage CV type welding output 2 Capability to supply 115 volt AC power to the control module 3 Optional for cold electrode switched welding output An output contactor It can be either of two types A Switch closure Internally energized type actuated by an external switch B 115 VAC Externally energized type actuated by 115 volts AC supplied from the control module to the power source A selector switch on the back of the control module is used to select which of these two types of control circuit is being used It is imperative that this switch be set correctly before attaching to the power source See Setting the Mode Switch on Rear Panel for more details The control module is not required when connecting Magnum spool guns to Lincoln models SP 150 or SP 200 which have built in wire feed control circuits In addition the Lincoln models SP 250 SP 255 Wire Matic 250 Wire Matic 255 do not require the control module when the optional K607 1 or K672 1 Spool Gun Adapter kit is installed since these kits also provide wire feed control circuits Specifications Model Magnum SG Control Module Type K488 Power Requirements Voltage 115 VAC 50 60 Hz Current 0 5 amps maximum Welding Current Rating Motor Output Preflow Time 250 amps at 60 duty cycle 5 28 VDC 0 1 second Contactor Circuit Output Normally open relay contacts Closure or 115 VAC selectable 10 0 x
15. ND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel y Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Du De Shielding gases used for arc welding can displace ar and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from yo
16. OM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 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 AN FOR ENGINE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment ae ieee j 1 a Turn the engine off before troubleshooting and maintenance 3 work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors y o QN ap ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame S may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz localized Electric and Magnetic Fields EMF Welding ing on contact with hot
17. RETURN TO MAIN MENU IM398 MAGNUM SG CONTROL MODULE 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 thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT GAS PRE FLOW TIME WIRE SPEED WITHOUT READING THIS Geh 3 4 S 3 MANUAL AND THE SAFETY alo 3 B PRECAUTIONS CONTAINED b cd A THROUGHOUT And most d 1 10 AS importantly think before you act and be careful CONTROL Cap E CH SG Control Module ipon Gun Date of Purchase Serial Number Code Number Model Where Purchased PER OPERATOR S MANUAL LINCOLN e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY AA WARNING 1 CALIFORNIAPROPOSITIONGS WARNINGS 1 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 FR
18. arts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PR CAUTIONS DE S RET zones ou Pon pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes Quand on ne soude pas poser la pince a une endroit isol de la masse Un court circuit accidental peut provoquer
19. ce at the start of the bead A contaminated appearance at the start of the bead probably indicates a longer preflow time is needed Setting the Wire Speed Set the wire speed per the instructions in sections 1 and 2 below to obtain the wire speed specified in the procedure set tings given in the spool gun manual Measure the wire speed with a wire speed meter or drive roll tachometer if available Alternatively the wire speed can be set by adjusting until the welding current per desired welding procedure is achieved Setting Wire Speed When Using a K469 Spool Gun The wire speed control knob on the Control Module varies the wire speed from approximately 50 to 650 ipm 1 3 to 16 5 m min Use this control to set the desired wire feed speed Setting Wire Speed When Using a K487 Spool Gun Having Remote Speed Control Set the wire speed control knob on the Control Module to maximum The control in the handle of the spool gun now varies the wire speed across the entire range approximately 50 to 650 ipm 1 3 to 16 5m min In general the spool gun potentiometer varies the speed between 0 and 100 of the Control Module wire speed control setting A good practice is to set the Control Module speed potentiometer for the maximum anticipated wire speed needed so that the control in the handle of the spool gun gives good range control Alternatively the spool gun handle potentiometer can be set to maximum and the Control Module potentiometer us
20. ctrode cable gas line and control cable of the spool gun to their respective connectors on the front of the Control Module 14 Work Lead Connection Connect the work lead to the negative polarity output stud or connector on the power source Make sure the lead is of sufficient length and gauge for your setup per standard welding practice OPERATION Safety Precautions Initial Checkout of Magnum SG System Installation If all of the following steps check okay then your system is WARNING correctly installed and operational 1 Inspect all cables and connectors for missing or incorrect Do not touch electrically live parts connections or electrode with skin or wet clothing In particular ensure that ground lead is correctly attached to chassis ground inside welder with terminal strip control connections Insulate yourself from work and ground ELECTRIC SHOCK 2 Open gas cylinder valve and adjust regulator can kill Keep your head out of fumes 3 Setpower source to minimum tap or output setting 4 Setpower source mode switch for CV output if applicable Use ventilation or exhaust to remove fumes from breathing 5 Remove idle roll pressure in spool gun by pushing release zone lever up so that it will not feed wire Can aa 3 6 Apply power to power source dangerous 7 Pick up spool gun and squeeze spool gun trigger Solenoid Keep flammable material away valve in Control Module should energize Ga
21. de electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see ltems 6 c and 8 4 b 5 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES A
22. ed Control 16 VT tee a Weld TEE 16 MAINTENANCE 16 cicer P Des de E E AA EE 16 AQUINO Malte aea 9 da We SUM R wu ba Eod xe ea de 16 WIRING DIAGRAM 17 FARTS LIST ds dE dee eke ee a um eee rd P198 Series Product Description The Magnum SG Control Module is an interface between the welding power source and the Magnum Spool Gun The Control Module and Spool Gun combination provide a system for welding primarily with aluminum electrode wire using a con stant voltage welding power source The Control Module provides control of both wire speed and gas flow It also provides connections from the welding power cable control cable and gas hose from the power source and gas cylinder regulator to the spool gun The Control Module will operate with any power source that provides constant voltage welding output and has an output contactor Required Equipment To operate the Magnum SG Control Module the following equipment is required and ordered separately Magnum Spool Gun K487 25 or K469 25 with K518 Adapter A Power Source The Control Module will operate with any Lincoln CV or CV CC power sources with many Lincoln engine driven welders see the complete list at the end of this section and with many non Lincoln type power sources In general power sources must have the following 1
23. ed as a conventional speed control Making a Weld Refer to your spool gun operating manual for instructions for welding MAINTENANCE Safety Precautions WARNING TA e Do not operate with covers removed Disconnect input power from power source before servicing control module ELECTRIC SHOCK can kill Do nottouch electrically live parts 16 Routine Maintenance The Control Module is designed to give years of trouble free service with little maintenance Recommended maintenance is limited to keeping the case and cables clean Use a damp rag to wipe down the case parts and cables Mild detergent can also be used but do not use solvent based cleaners on nameplate plastic parts or cables Any questionable cleaner should be tried first on an inconspicuous place on the machine DIAGRAMS Wiring Diagram 68 cl S WVHOVIC ONIHIM 3 1nQOW 10H1NOO DS WIND VIN l ss AS a _ ee GA ma npo N O11u0O e oejdeoeu g nid ejoeide2eu Bn d aj9eidaoay 9 Bnid H L vr 3 1 7 xg 8 T MOJ 3 9 YOUMS SPON OYUAA AEIS Cep SIUAAISIE H elo 8 usalo V UMOIY oi 89d paads AIM 19 e91g PNO V G Bueino 3 1968111 7 3 U8810 A pay MC HOO Nz UMOIG MOJ 9A 3001 anig eTuAw nig MOJ 8A Jlequinu epoo Japjam ay SAID jueujeoejdai e Jo juawuedeag 201S eu 01 au ejqi amp ej si weep eu U
24. either internally energized or externally energized from 115 VAC The Control Module is shipped with the mode switch in the left switch position and is for power sources requiring only circuit clo sure i e continuity to energize the output contactor Lincoln ma chines are of this type Right switch position is for power sources re quiring that 115 VAC be supplied to the contactor INSTALLATION When connecting the Control Module to a non Lincoln power source determine which type of output contactor your power source has If the switch is not in the correct position remove the single screw securing the lockout bar and remove Slide the switch to the correct position and reinstall lockout bar on other side using screw already in place there Replace first screw in original location CAUTION Be sure that mode switch is in correct position before attempting to operate control module Incorrect switch position could result in damage to the control module and or power source Cunsult your power source instruction manual to see what type of output contactor circuit it has Be sure to reinstall lockout bar if switch position is altered Connection to 487 25 Spool Gun Connect the electrode cable gas line and control cable of the spool gun to their respective connectors on the front of the Control Module Connection to 469 25 Spool Gun 1 Connect K518 adapter to spool gun control cable 2 Connect the ele
25. g They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located e Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot p
26. h to Industrial Economics 5 00 NA ANA Welding Preheat Calculator 3 00 WC 8 Pipe Welding Charts 4 50 ED 89 SUB TOTAL Additional Shipping Costs ifany TOTALCOST Name 2222 LLLI AUTOS A e uit te l Telephone AAA Signature as it appears on Charge Card LLLLLLLLLLLLLLL Exp Date LL ITT 5 00 SU MELLE RE aso HAY rr RN e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground WARNING Spanish e No toque las partes o los electrodos AVISO D E bajo carga con la piel o ropa moja P R ECAU C O N T del trabajo y de la tierra French ATTENTION German WARNUNG Portuguese ATENCAO e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec da e Isole se da peca e terra Japanese SS N CEERHORANA MAEHE EM SS IS ET EEN d A o I T 19 7 Z gt 5 HR 5 EBS NTUI CLTFAL e X BA SCR UL 2 Ez BB aB cE GR ER SE SEO Pa HIHI Rl T fries Korean Jet ge ill sl ja oua Y Aral n ag il ds ell AI guapa aal DIS dus ule Y jo pue e Ber hren Sie keine stromf hrenden trodos com a pele ou roupa molha e Kee
27. le K691 10 lt Z Classic Ill K691 10 Classic Ill w Wire Feed Module K691 10 Classic HD K691 10 Classic D w Wire Feed Module K691 10 Commander 300 K691 10 Commander 400 Stick K691 10 Commander 400 Stick amp Wire K691 10 Ranger 10 K691 10 Ranger 10LX Incl CSA K691 10 Ranger 275 K691 10 Ranger 300D K691 10 Ranger 300DLX K691 10 Ranger 8 Incl CSA amp LPG K691 10 Ranger 9 Incl CSA K691 10 SA 250 K691 10 SA 250 w CV Adapter K691 10 SA 250 w Wire Feed Module K691 10 350 SA K691 10 350 SA w Wire Feed Module K691 10 SAE 350 w CV Adapter K691 10 SAE 400 w CV Adapter K691 10 SAE 400 WELD N AIR w CV Adapter K691 10 SAM 400 K492 10 450 SAE w CV Adapter K691 10 SAM 650 K492 10 Weldanpower 150 AC DC K691 10 Weldanpower 225 G7 K691 10 Weldanpower 250 D10 K691 10 Weldanpower 250 D10 PRO K492 10 Weldanpower 250 G9 PRO ZIZ Z Z Z Z Z Z Z Z Z lt S Z SS Z Z lt Z KIA A lt Z lt Z lt X lt Z lt Z K492 10 Weldanpower G8000 Z Z lt lt Z Z Z lt Z lt Z Z ZZ ZZ ZZ Z ZZ Z ZZ Z Z Z ZZ ZZ Z Z Z lt lt Z Z Z lt Z lt Z Z Z lt Z lt Z Z lt Z lt Z lt lt Z lt Z lt lt Z lt Z lt lt lt lt x xxx K691 10 Z xx Z Z Z lt
28. mportant pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title
29. mporte quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les o assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement i
30. ol connector to the mating con nector on the power source Set the Mode Switch on back of the Control Module for the type of contactor circuit in the power source being used See Setting the Mode Switch on Rear Panel WARNING Improper switch position may result in equipment damage 6 66 Installation of K691 10 Input Cable to Power Sources with a 14 pin Connector 1 Identify the cable end which has a 115V cordset with plug attached to the Amphenol connector This end attaches to the engine driven power source ES Connect the gas line to the gas cylinder regulator connect the electrode cable to the positive output stud on the power source connect the control cable to the 14 pin Amphenol connector on the power source if present and plug the 115V plug into the outlet for 115V auxilliary power Make appropriate power source and connections At the other end of the cable attach the control cable Amphenol connector gas line connector and electrode cable terminal to their respective connectors on the rear panel of the control module Set the Mode Switch on back of the Control Module for the type of contactor circuit in the power source being used See Setting the Mode Switch on Rear Panel WARNING Improper switch position may result in equip ment damage Setting the Mode Switch on Rear Panel The slide switch on the rear panel selects between power sources whose output contactors are
31. p flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e 952030 6008 CORTE TEX HENE UC EGA e i tJ z PA d BET 1F1 FPF o Se Aal nig Ax gn Jasa ALAN ll mu e e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo e H HRUSHICRBARELTE GAME ef mH HRSESUREME ez 79 Sol Tears AS HAL dal due le Ally uy ci gai eo deua 9 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN e Keep your head out of fumes e Use ventilation or exhaust
32. s should be heard flowing from cone of spool gun Drive roll in spool gun should rotate clockwise 8 Hotate wire speed control knob on Module from minimum to maximum with trigger pressed and verify that drive roll WELDING SPARKS speed increases significantly can cause fire or explosion 9 For K847 spool gun only rotate speed control in handle and verify that speed varies between 0 and 10096 of setting on Wear eye ear andbody Control Module protection 10 Release trigger Gas flow should be heard to stop 11 Setpreflow time on Control Module to minimum and press trigger Drive roll should start rotating after approximately ARC RAYS 1 second can burn 12 Turn preflow control on Control Module to minimum and squeeze trigger Drive roll should start rotating immediately Release trigger 13 Verify that the output contactor in power source is opera tional with the spool gun by pressing the trigger On some machines the contactor will be audible on others it may be silent Observe that voltage is present observed with power sources equipped with a voltmeter 15 OPERATION Setting Gas Flow Rate on Gas Cylinder Regulator Gas handling systems having adjustable flow valves should be set per the information in the spool gun operating manual A typical value is 30 cubic feet per hour cfh or 14 liters per minute Setting Gas Preflow Time on Control Module Set the preflow to achieve good bead appearan
33. se allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add l 5 00 For order value up to 49 99 l 10 00 l 15 00 I IFor North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry No C O D Orders CHECKONE Please Invoice only if order is over 50 00 _ Check or Money Order Enclosed U S Tu s only I Credit Card FP a VISA lyse THIS FORM TO ORDER looks OR FREE INFORMATIVE CATALOGS I lLincoln Bo Mg School Titles I ED 80 New Lessons in Arc Welding Seminar Information Procedure Handbook Twelfth Edition l ED 45 How to Read Shop Drawings Educational Video Information ED 93 NES Dames F Lincoln Arc Welding The American Century of onn C Lincoln 5 00 AC Foundation Book Information i JFLF 515 I l For order value between 50 00 amp 99 99 For order value between 100 00 149 00 Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Incentive Management 5 00 IM A New Approac
34. terminal strip b Connect the white and black lead terminals marked 31 and 32 to the corresponding 115 VAC terminals on the terminal strip c Connect the remaining two leads marked 2 and 4 to the corresponding terminals which activate the output contactor whether it be by switch closure or 115 VAC supplied to the power source from the Control Module 6 Set mode switch on back of the Control Module for the type of contactor circuit in the power source being used See Setting the Mode Switch on Rear Panel WARNING Improper switch position may result in equipment damage GAS LINE CONNECTOR ELECTRODE CABLE POWER Installation of K493 10 Input Cable to Power Sources with a 14 pin Connector 1 Identify the cable end which has a lug on the end of the electrode cable This end attaches to the Control Module GAS LINE CONNECTOR ELECTAODE CABLE POWER CONTROL CABLE 19 INSTALLATION Attach the control cable Amphenol gas line con nector and electrode cable terminal to their respective connectors on the rear panel of the Control Module At the other end of the cable TWIST MATE ELECTRODE CABLE GAS LINE CONNECTOR CONTROL CABLE Connect the gas line to the gas cylinder regulator Connect the Twist Mate plug on the electrode cable to the positive polarity mating plug on the power source Connect the 14 pin Amphen
35. ur welding distributor or from the manufacturer Also see item 1 b Mar 95 SAFETY 2 72 WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Hemember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or weldin
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