Lincoln Electric Wire Feed Module 12207 Operator's Manual
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Lincoln Electric Wire Feed Module 12207 Operator's Manual

Lincoln Electric Wire Feed Module 12207 Operator's Manual

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Operator's Manual
WIRE FEED MODULE
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10171
| Issue D ate Oct- 13
© Lincoln Global, Inc. All Rights Reserved.
™
For use with machines having Code Numbers:
12207
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 Operator’s Manual ™ WIRE FEED MODULE For use with machines having Code Numbers: 12207 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...

  • Page 2: Safety Depends On You

    THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 4: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
  • Page 7 TABLE OF CONTENTS...

  • Page 8: General Description

    WIRE FEED MODULE™ PRODUCT DESCRIPTION GENERAL DESCRIPTION The Wire Feed Module (WFM) is an additional output control device designed to be easily installed into the Classic 300HE and SAE 300HE. The WFM modifies ® the dynamic output characteristics of the welder to provide excellent voltage control for semiautomatic wire electrode welding and other open arc processes.

  • Page 9: Technical Specifications

    WIRE FEED MODULE™ INSTALLATION TECHNICAL SPECIFICATIONS RATED OUTPUT Model K3964-1 Wire Feed Module Factory-Installed Wire Rating @ 60% Max. Output @ Auxiliary Power to be Field Installed Feed Module & Welder Per: Duty Cycle 35% Duty Cycle K3198-1 Not Available Classic ®...
  • Page 10 WIRE FEED MODULE™ INSTALLATION ASSEMBLE INTO ENGINE DRIVEN WELDERS: CLASSIC 300HE K3198-1 ® SAE-300 K3201-1, K3202-1 ® Pre Installation Unpack WFM and check the contents against the listed items. ITEM DESCRIPTION QTY. Control Module Assembly Panel Components and Harness Assembly Mounting Hardware Packet Instruction Manual and Literature Classic...
  • Page 11 WIRE FEED MODULE™ INSTALLATION ASSEMBLE WFM INTO THE CLASSIC 300HE AND SAE- INSTALLATION SEQUENCE: ® ® HE WELDERS: SAE-300 HE (See Exploded View the following Page) ® 1. Remove the bottom 3 mounting screws from the upper control INSTALLATION SEQUENCE: nameplate.
  • Page 12 WIRE FEED MODULE™ INSTALLATION EXPLODED VIEW FOR: CLASSIC ® 300HE AND SAE-300 ®...
  • Page 13 WIRE FEED MODULE™ INSTALLATION 4. Remove 2 screws from brush wraparound cover. 7. Feed power cable assembly through the rectangu- Loosen and rotate the wraparound cover until neg- lar window on the bottom of the generator. ative brushholder is exposed. (Large flat head screwdriver and pliers).
  • Page 14 WIRE FEED MODULE™ INSTALLATION 10. Locate and remove 12-pin jumper plug and install 12-pin 13. Mount the control box using .62 spacers, flat washers, lock connector from control box to 12-pin connector. Connect washers and hex nuts provided in the mounting hardware control box 6-pin connector to control panel 6-pin connector.
  • Page 15 WIRE FEED MODULE™ INSTALLATION 16.a. Using the bolt from step 15, connect WFM control box's 17. Remove the guard from the left side of the welder. Using two positive power cable and machine's positive output cable screws from the mounting hardware package, fasten the out- to machine's positive output terminal.

  • Page 16: Connection Of Lincoln Electric Wire Feeders

    WIRE FEED MODULE™ INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS CONNECTION OF THE LN-7, LN-7 GMA TO THE WIRE FEED MODULE WARNING Requires K584-(L) input cable, K864 adapter and optionally the K857 for remote control. See the connection diagram in the Diagrams section.

  • Page 17: Recommended Processes

    WIRE FEED MODULE™ OPERATION DESIGN FEATURES When the WFM is in the “CV” mode, the maximum auxiliary power will be reduced by 25%. To obtain maximum auxiliary output, • Easy access to the controls located on the welder place the CC/CV switch in the CC position. control panel.

  • Page 18: Engine Speed Adjustments

    WIRE FEED MODULE™ MAINTENANCE ENGINE SPEED ADJUSTMENTS CAUTION Any increase in the engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the A.C. auxiliary voltage. If this voltage goes above 140 volts, the control circuits of the WFM and wire feeders will be damaged.

  • Page 19: Troubleshooting Chart

    WIRE FEED MODULE™ TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 20 WIRE FEED MODULE™ TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Machine has no output with machine Electrode or work lead loose or broken. Repair Connection. switch in CV mode. No generator output. Refer to quick check procedure for generator only.
  • Page 21 WIRE FEED MODULE™ TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Machine does not have maximum output. Voltage adjust potentiometer leads Check and repair broken leads. open. Voltage adjust potentiometer defective. Refer to procedure for checking Voltage Control Potentiometer on Machine.
  • Page 22 WIRE FEED MODULE™ TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE - a) Frayed or pinched lead insulation. CONTROL P.C. BOARD b) Poor lead termination, such as a poor contact or a short to adjacent connection or surface. 1.
  • Page 23 WIRE FEED MODULE™ TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 3. Check to see that leads 2 and 4 are connected. Put a 4. With an ohmmeter on X1K, connect it to lead 76A voltmeter across these leads and the meter should read and 77A on S2.
  • Page 24 WIRE FEED MODULE™ TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 8. Quick Check Procedure for Generator Only 1. Try running the machine with the mode switch on STICK (CC mode), and check output at CC+ and CC- studs. If a voltage of 45 to 100 volts DC is measured, the generator is working properly.
  • Page 25 WIRE FEED MODULE™ DIAGRAMS...
  • Page 26 WIRE FEED MODULE™ DIAGRAMS...
  • Page 27 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 28 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 29 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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