Lincoln Electric MAGNUM IM632-B User's Manual
Contents
1. A 2 Operation e Bea dy al Se ee dlke chews actes eae EU Oh kk n EGRE EE Section B Electrodes and Equipment ask sk ka ea Q ked eee B 1 M knga Weld ers ime vraies uera RERO ae BINE QUE aes eee Gr nea eu eats B 1 Avoiding Wire Feeding Problems B 1 Expendable Replacement Parts Section C Maintenance An pre eske sine Section D Cable Cleaning eie Rp RR x za d a naki skare nakke dey i n RG aaa D 1 Gun Tube Replaceable lt D 1 Removal Installation and Trimming Instruction for Liners D 2 D 3 Troubleshooting Section E Parts Li S S gt u ke eeu Tre kara al S karda ane h n eios feos aka a bak w l een dak Appendix MAGNUM 450 Water Cooled P202 V MAGNUM 650 Water Cooled P202 W MAGNUM 450WC amp 650WC LINCOLN A 1 INSTALLATION A 1 GENERAL DESCRIPTION The MAGNUM 450WC Water Cooled Gun is rated at 450 amperes 100 duty cycle using carbon dioxide shielding gas and cooled with water at a flow rate of 58 gallons per minute 2 2 liters per minute It is also rated 400 amperes 10096 duty cycle with mixed argon shielding gases There are sev2. amp 650WC INCOLN NOTES MAGNUM 450WC amp 650WC LINCOLN 8 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese SIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground e No toque las partes o los electrodos bajo carga con la piel o ropa moja d a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra o EPORA MARHE Zitt ch E J T 4p 7 Z p EE 4649 2 NTUSRIELTFAU e Ik BA zk A zik 4 5J mega J amp SHER Xe sa ass Su HAR nile e 27 Su H R OAS Ae Gall l AN oua VO J pal slay 2 ON d ib s elo alal Jarl JUS dus ule Yo pue Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e RAPTUEDORTCO BEER MHC U Cii VETA e BM BARNA o
3. de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 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 V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or
4. ess Sais Hc AIX ola Am OS JED ALIM 3l sU e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e B ERU SHSICOBREUCE amp uv ORMER E J J 4 5 SIRI ez 119 Fo sare y ue Lily alay cl sai aa J 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 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone 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
5. melted or improper size contact tip Incorrect diffuser 2 Variable or hunting arc A Contact tip worn or incorrect size B Worn or undersize ground cables or poor ground connections C Loose electrode connections CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 450WC amp 650WC INCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS FORSERE COURSE OF ACTION FUNCTION PROBLEMS 3 Poor arc striking with sticking or A Improper procedures or tech blast offs weld porosity narrow niques and ropy looking bead or elec trode stubbing into plate while B Improper gas shielding welding If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 4 Tip seizes in diffuser A Tip overheating due to prolonged or excessive high current and or duty cycle welding CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 450WC
6. KP1958 3 The MAGNUM 650 WC Water Cooled Gun is rated at 650 amperes 100 duty cycle using carbon dioxide shielding gas and cooled with water at a flow rate of 58 gallons per minute 2 2 liters per minute It is also rated 500 amperes 100 duty cycle with mixed argon shielding gases The gun is designed for gas metal arc welding GMAW with 5 64 and 3 32 gas shielded flux cored arc welding FCAW The gun tube angle is 60 degrees and the gun has a Fast Mate wire feeder end connector Optional gas nozzles are available See ACCESSORIES section for details TABLE A 2 MAGNUM 650WC AT 100 DUTY CYCLE WITH CO GAS Cable Gun Tube Liner Angle Description Gun Cable Length m Gas Diffuser Wire Size in mm Contact Tips K1637 1 5 64 2 0 KP2067 10B1 KP1959 2 M19127 2 M19365 1 4 5 MAGNUM 450WC amp 650WC LINCOLN 8 A 2 INSTALLATION A WARNING S ELECTRICAL SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts The 450WC gun can only be connected to a wire feeder with a Lincoln Fast Mate connector a European style gun connector or a wire feeder equipped with an adapter See Table B 1 for the vari ous adapters that are available Install the adapter per the Instructions sent with the adapter Check that the feeder outgoing guide as we
7. 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 Away from areas where they may be struck or subjected to physical damage 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 parts 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 I 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 manuf
8. is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 450WC amp 650WC LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS FORSERE COURSE OF ACTION FUNCTION PROBLEMS 1 Drive rolls turn but wire will not A Gun cable kinked and or twisted feed or wire feeding is rough B Wire jammed in gun and cable C Incorrect drive rolls and guide tubes D Gun cable liner dirty E Worn drive rolls F Electrode rusty and or dirty If all recommended possible areas of misadjustment have been checked and the problem persists G Worn or improper size cable Contact your local Lincoln liner Authorized Field Service Facility H Partially flashed
9. or to hot spatter or metal FUMES AND 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 3 The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 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 prod
10. 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 fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria e c 2A 5H RE32 KUC T ORIG HHEKCTDHEU TT e FLER e EF OR ES MH RL SR ER IS e zzv 871 8 goals SAXNACEFE g87I amp Ash Liz 58718 AScHAlg oe lua dul sui EAU gaal bic ja Jl Lil aria el oi all oe call lt e Turn power off before servicing 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 entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e Nao toque as partes el tricas nuas e xX77TTL7A 9 UACBRUD EFRR IFE FEMITFEV e HETT EE AHS HHS SL ald J it 4S juil sde Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes Nao opere com os paineis abertos ou guardas remo
11. the electrode 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 Items 6 c and 8 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 4 b Use suitable clothing made from durable flame resistant 5 f AUG 06 LINCOLN 8 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
12. ucts Shielding gases used for arc welding can displace air 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 your welding distributor or from the manufacturer Also see item 1 b SAFETY WELDING and CUTTING lt gt 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 Remember 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
13. F THE LINER CAN BE SEEN THROUGH THE HOLES IN THE GAS DIFFUSER 3 MARK THE LINER 3 16 5mm FROM THE END OF THE LINER GUIDE PULL THE LINER PARTIALLY OUT AND CUT OFF THE LINER AT THE MARK USING A SHARP KNIFE 4 SCREW THE BRASS LINER NIPPLE ONTO THE LINER AND INSERT THE NIPPLE INTO THE LINER GUIDE REPLACE THE LINER NUT AND THE GAS NOZZLE 3 16 5mm LINER GUIDE LINER GUIDE LINER NUT MAGNUM 450WC amp 650WC LINCOLN 8 E 1 TROUBLESHOOTING E 1 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine
14. GUN O THE BACK OF THE GUN SECURE LINER BY TIGHTENING THE LINER NUT DO NOT INSTALL THE GAS DIFFUSER AT THIS TIME LAY THE CABL CUT OFF DIME E OUT STRAIGHT AND TRIM THE LINER TO THE NSION SHOWN AND REMOVE ANY BURRS SECURE GAS DIFFUSER ONTO GUN TUBE AND REPLACE GAS NOZZLE IN OTHER GUNS THE VARIATION IN CABLE LENGTHS MAY PREVENT USE OF THE LINER LINER NUT MAGNUM 450WC amp 650WC LINCOLN D 3 MAINTENANCE D 3 REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR LINERS FITTING A SOFT LINER FOR FEEDING ALUMINUM ELECTRODE MAGNUM INSTALLATION INSTRUCTIONS FOR KP1958 ALL LINERS DESIGNED FOR FEEDING ALUMINUM WIRE P1958 1 10 FT 3 0M 030 035 0 8 0 9mm BLACK 1958 2 15 FT 4 5M 030 035 0 8 0 9mm BLACK P1958 3 10 FT 3 0M 1 16 1 6mm RED P1958 4 1958 5 10 FT 035 3 64 09 1 2mm BLUE 1958 6 15 FT 4 035 3 64 09 1 2mm THE VARIATION IN CABLE LENGTHS MAY PREVENT USE OF THE LINER IN OTHER GUNS LAY GUN AND CABLE OUT STRAIGHT ON A FLAT SURFACE REMOVE THE LINER NUT FROM HE CONNECTOR END OF THE CABLE AND PULL THE OLD LINER OUT OF THE CABLE EMOVE THE GAS NOZZLE 2 CHECK THE LINER FOR CORRECT WIRE SIZE AND LENGTH INSERT THE STEEL END OF THE LINER INTO THE BACK END OF THE GUN UNTIL THE STEEL END OF THE LINER IS FULLY INSERTED INTO THE DIFFUSER CHECK THAT THE COILS O
15. IM632 B MAGNUM 450WC amp 650WC Fast Mate Water Cooled Gun and Cable Assemblies 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 WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL C 150 9001 E Ne j Ge Quality Pro e Re CERTIFICATE NUMBER 30273 LINCOLN Copyright 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 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l SAFETY i AA WARNING AN CALIFORNIA PROPOSITION 65 WARNINGS N Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACE
16. LY REPLACEABLE PARTS Gun Tube Insulation Disk Nozzle Holder Set Screw Ceramic Insulator Insulation Ring Joint Compound Description CABLE LINER For Cables 15 4 5 m and less Steel Wire 22333 7A 524298 7B S24298 7C S22333 7D S24298 7G T12837 EXPENDABLE REPLACEMENT PARTS FOR MAGNU Part Number Color Code M19265 1 yellow English Size In 5 64 3 32 M 650WC GUN amp CABLE ASSEMBLIES Metric Size mm CONTACT TIP GAS DIFFUSER KP2067 10B1 KP2058 2 INSULATOR GAS NOZZLE 12 3 mm Recess 12 3 mm Recess 12 3 mm Recess 22031 2 M19127 1 M19127 2 M19127 3 GUN TUBE ASSEMBLY REPLACEABLE PARTS Gun Tube Insulation Disk Nozzle Holder Set Screw Ceramic Insulator Insulation Ring Joint Compound 524333 7 524333 7 S24298 7C S24333 7D S24333 7G T12837 Joint compound is required for assembly of these parts C 1 D 1 MAINTENANCE D 1 Periodically remove and clean the nozzle contact tip and gas diffuser Replace the nozzle insulator if dam aged Regular use of an anti spatter compound will reduce the adherence of spatter and ease its removal Clean cable liner after using approximately 300 pounds 136 kg of electrode Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using an air hose and only partial pressure gently blow out the cable liner from the
17. MAKER 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 powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes e outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated ELECTRIC AND SR MAGNETIC FIELDS 359 may be dangerous 2 a Electric current flowing through a
18. acturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations iv SAFETY iv PR CAUTIONS DE S RET 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 S ret Pour Soudage A L Arc 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
19. ale connection When connecting the hoses to the water cooler the WATER IN BLUE HOSE must be connected to the water out connector on the water cooler The WATER OUT RED HOSE must be connected to the water in connector on the water cooler Do not operate the gun without having water flowing through the gun IRREPARABLE DAMAGE to the gun will occur if incorrectly connected or if operated CAUTION even for a short time without an adequate supply of cooling water A flow sensor is recommended to pro tect the gun A K1536 1 flow sensor is available TABLE B 1 REQUIRED CABLE CONNECTOR KITS For K684 MAGNUM Guns Description Product Number Feeder Type Lincoln LN 7 Series LN 8 or LN 9 Lincoln LN 25 Miller wire feeders Tweco adapted wire feeders Hobart Series 2000 wire feeders L TEC wire feeders Lincoln 10 Series wire feeders ADAPTER FOR QUICK CONNECTION TO EXTERNAL CGA WATER FITTING A KP1529 1 adapter was designed to connect the quick connecting fitting on the water cooled gun water hoses to a Compressed Gas Association CGA 033 left hand male connection Two adapters are included in each kit MAGNUM 450WC amp 650WC INCOLN amp B 1 The wire feeder drive roll pressure should be set to a minimum to prevent wire from coming thru the cable when a wire feed stop occurs The ideal drive roll pressure is set so the drive rolls will slip when the ele
20. correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title 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 Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when id
21. ctrode is slightly wavy after a wire feed stop ELECTRODES AND EQUIPMENT The MAGNUM 450WC amp 650WC guns and cables have been designed for use with Lincoln L 50 and Super Arc L 56 solid steel wire electrodes for the GMAW process and Lincoln Outershield cored elec trodes for the gas shielded FCAW process Refer to the appropriate Lincoln Process and Procedure Guidelines for the electrode used for information on recommended electrical and visible stickouts MAKING A WELD Note Water cooled guns will have a higher voltage drop along the length of the cable than air cooled guns To compensate for the higher voltage drop the following table is a guide line to determine how much the welding voltage should be increased Welding Current Welding Voltage Increase Welding Voltage Increase For MAGNUM 450WC For MAGNUM 650WC Compared to MAGNUM 40 Compared to MAGNUM 550 200 amperes 0 5 volts 1 0 volts 1 5 volts 0 5 volts 0 7 volts 0 9 volts 1 2 volts 1 4 volts D Q 300 amperes 400 amperes 500 amperes 600 amperes 650 am The final voltage setting must be determined by the arc characteristics that are required for the welding AA WARNING e process ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing 5 Insulate yourself from work and ground 3 FUMES AND GASES can be dangerous CR Keep your head out of fumes Use ventilation or exhaus
22. entifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration 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 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS vi Page Installation EE EE Section A General Desctriptlon x lt nsadi RUE Santana pata Re ame SE Ee A 1 Connection to a Power Wave power source with a water cooler and Synergic 7 Feeder A 2 Connection to other water coolers A 2 Required Cable Connector Kits
23. eral models of guns designed for gas metal arc welding GMAW with 035 1 16 9mm 1 6mm solid electrodes and gas shielded flux cored arc welding FCAW with 045 5 64 1 2 mm 2 0mm cored electrodes The gun tube angle is as shown in the table below and the gun has a Fast Mate wire feeder end connector Two 10 ft 3 5 M guns with a 45 degree gun tube angle are available for feeding 035 1 16 9mm 1 6mm aluminum electrode Optional liners are available for feeding aluminum electrode with the 60 degree guns See ACCESSORIES section for details TABLE A 1 MAGNUM 450WC AT 100 DUTY CYCLE WITH CO GAS Description Gun Cable Length m Gas Diffuser Assembly Gun Tube Angle Wire Size in mm Contact Tips 035 0 9 045 1 2 KP2067 1B2 KP2067 5B1 KP2059 1 KP1957 4 KP44 3545 15 K684 12 035 0 9 045 1 2 KP2067 1B2 KP2067 5B1 KP2059 1 KP1957 4 KP44 3545 15 K684 13 052 1 3 1 16 1 6 KP2067 6B1 KP2067 7B1 KP2059 1 KP1957 4 KP44 116 15 K684 14 052 1 3 1 16 1 6 KP2067 6B1 KP2067 7B1 KP2059 1 KP1957 4 KP44 116 15 K684 15 1 16 1 6 5 64 2 0 KP2067 7B1 KP2067 10B1 KP2059 1 KP1957 4 KP44 564 15 K684 16 1 16 1 6 5 64 2 0 KP2067 7B1 KP2067 10B1 KP2059 1 KP1957 4 KP44 564 15 K684 17 035A 0 9A 045A 1 2A KP2067 1B2 KP2067 5B1 KP2059 1 KP1957 4 KP1958 5 K684 18 1 16A 1 6A KP2067 7B1 KP2059 1 KP1957 4
24. gas diffuser end A CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out GUN TUBE ASSEMBLY M4 X 0 7 THREAD INSULATION RING AT CERAMIC INSULATOR GUN TUBE INSULATION DISK DIFFUSER Figure E 1 Gun Tube Replaceable Parts a The gun tube insulation disk should be periodi cally examined for wear To replace the gun tube insulation disk remove the diffuser and pull off the gun tube insulation disk Although the gun tube insulation disk does not have a thread it can be unscrewed from the gun tube Refer to Figure E 1 b The nozzle holder can be replaced if the threads are damaged Remove the diffuser and gun tube insulation disk refer to a and Figure E 1 Remove the two 2 set screws that lock the nozzle holder in place Unscrew the nozzle holder Note The nozzle holder has a Left hand thread Pull the nozzle holder off the gun tube assembly Be careful to not drop the ceramic that may come off with the nozzle hold er Coat the inside diameter and the outside diameter of the ceramic with DOW CORNING 340 joint compound Lincoln part T12837 Check that the insulation ring is in place and place the ceramic on the gun tube Place the new nozzle holder over the ceramic and tighten in place Re
25. ht side the work cable should also be on your right side AW 2 d 4 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 turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN 8 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 Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding
26. ll as the drive rolls are appropriate for the electrode being used When using a Fast Mate Adapter Kit be certain that the adapter guide tube is also correct Align and fully engage the brass connector end of the gun into the mating connector on the outgoing side of the feeder wire drive Secure the cable connection by tightening the Fast Mate connector collar nut Connection to a Power Wave power source equipped with a water cooler and K685 Synergic 7 wire feeder Connect the water hose quick connects to the recep tacles on the front of the wire feeder When connect ing the hoses to the water supply the WATER IN BLUE HOSE must be connected to the water out connector on the wire feeder INSTALLATION A 2 The WATER OUT RED HOSE must be connected to the receptacle marked water in The water cooler pro vided with the Powerwave will provide adequate flow to cool the gun and has a safety switch that will pro duce a beeping noise to warn the welder that there is no water flow Do not weld until the flow problem is corrected and beeping stops Connection to other water coolers The water cooler should be rated for 58 gallons per minute 2 2 liters per minute at 60 psi 4 08 atm or greater The connectors on the gun water hoses have a male quick connect fitting that will mate to a Rectus Series 21 Coupler Note A KP1529 1 adapter is available to connect the male quick con nect to a CGA 033 left hand m
27. machines Si 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 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S 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 important 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
28. ny conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety ihe ad minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan e Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your rig
29. place the two 2 set screws Replace the gun tube insulation disk and the dif fuser THREAD SIZES FOR MAGNUM 450WC amp 650WC CONSUMABLES M4 X 0 7 THREAD M20 X 1 5 INTERNAL LEFT HAND THREAD 450WC amp M24 X 1 5 LEFT HAND THREAD FOR 650WC SPECIAL THREAD Mit X 1 FOR 450WC amp M12 X 1 FOR 650WC M8 X 1 25 Figure E 2 MAGNUM 450WC amp 650WC LINCOLN D 2 MAINTENANCE D 2 REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR LINERS FITTING A HARD WIRE LINER FOR FEEDING SOLID AND CORED STEEL ELECTRODE MAGNUM INSTALLATION INSTRUCTIONS FOR LINERS DESIGNED FOR FEEDING SOLID AND CORED STEEL WIRE LINER WIRE SIZE STENCIL ON LINER BUSHING COLOR KP44 3545 15 085 045 0 9 1 2mm KP44 3545 15 045 1 2MM KP 44 116 15 052 1 16 1 3 1 6mm KP 44 116 15 1 16 1 6mm KP44 564 15 1 16 5 64 1 6 2 0mm KP1933 3 5 64 2 0mm REMOVE THE GAS NOZZLE AND THE GAS DIFFUSER FRO THE GUN TUBE LAY GUN AND CABLE OUT REMOVE THE LINER NUT CABLE AND P STRAIGHT ON A FLAT SURFACE FROM THE CONNECTOR END OF THE ULL LINER OUT OF THE CABLE J 9 16 15M CHECK THE LINER FOR CORRECT WIRE SIZE AND INSERT AN UNTRIMMED L SEAT LINER BUSHING INT NER INTO THE BACK END OF THE
30. plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER u TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 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 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc 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 zones o l on pique le laitier LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif
31. 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 welding 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 Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 Ea CYLINDER may explode E
32. r cables f Keep cable clean by following maintenance instruc tions g Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication h Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed i When using aluminum electrodes 10 ft Maximum cable length is recommenced If longer cable lengths are used cable should be kept as straight as possible MAGNUM 450WC amp 650WC LINCOLN P C 1 Description CABLE LINER For Cables 15 4 5 m and less Steel Wire EXPENDABLE REPLACEMENT PARTS Part Number Color Code KP44 3545 15 KP44 116 15 KP44 564 15 English Size In 035 045 052 1 16 1 16 5 64 EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 450WC GUN amp CABLE ASSEMBLIES Metric Size mm For Cables 15 4 5 m and less Aluminum Wire KP1958 2 Black KP1958 4 Red KP1958 6 Blue 030 035 1 16 035 045 For Cables 10 3 0 m and less Aluminum Wire CONTACT TIPS KP1958 1 Black KP1958 3 Red KP1958 5 Blue KP2067 1B2 KP2067 1B2 KP2067 3B1 KP2067 3B1 KP2067 5B1 KP2067 9B1 KP2067 6B1 KP2067 7B1 KP2067 7B1 KP2067 10B1 035 3 64 1 16 035 3 64 GAS DIFFUSER KP2059 1 INSULATOR KP2060 1 GAS NOZZLE Flush Flush Flush 12 3 mm Recess 12 3 mm Recess Spot KP1957 1 KP1957 2 KP1957 3 KP1957 4 KP1957 5 KP1957 6 GUN TUBE ASSEMB
33. t to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion 24 RAYS burn Wear eye ear body protection OPERATION B 1 a Check that the welding power source is on and that the shielding gas supply is set for the proper flow rate b Position electrode over joint The end of the elec trode should be slightly off the work c Lower your welding helmet close the gun trigger and begin welding Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used d To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures a If a burn back or wire feed stop occurs release the trigger immediately Remove the contact tip free the wire and clean or replace the tip as necessary If the wire has been scored by the feed rolls dis card the damaged section of the wire This is nec essary because the damaged wire could jam in the contact tip and cause another burn back b Do not kink or pull cable around sharp corners c Keep the electrode cable as straight as possible when welding or loading electrode through cable d Avoid wrapping excess cable around handle or front of wire feeder e Do not allow dolly wheels or trucks to run ove
34. vidas NZWCADN ERVALEEE PI S LENS 40 Mel deje H Aga y cuts Vil jlgall la Ja ye Ale Ai d Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO SIR Chinese Korean LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR t 5 Ri X98450 EES AA VZM CT EV TL CTRHORSRMEL HTS HE B AR DB BR 3t XE A II KE BE 22 RU BI IJ JI JR HEBA fik JE PO E 75 f BI 55 RI EH 0 AZo SEE Seil SIAD HAY AK FERAIS eu re sHC Saal yakal QU dl aud s Llano AAA l n Gail gal Gales agil Oxa L LINCOLN B World s Leader in Welding and Cutting Products 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
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