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Lincoln Electric WIRE FEED MODULE IM 513-B Operator's Manual

Lincoln electric welder user manual.
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RETURN TO MAIN MENU
IM 513-B
WIRE FEED MODULE
February, 2011
For Wire Feed Module Code Number: 10066, 10914, 11806
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 thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR'S MANUAL
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

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Troubleshooting

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   Summary of Contents for Lincoln Electric WIRE FEED MODULE IM 513-B

  • Page 1

    RETURN TO MAIN MENU IM 513-B WIRE FEED MODULE ™ February, 2011 For Wire Feed Module Code Number: 10066, 10914, 11806 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 ...

  • Page 2

    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.

  • Page 3

    SAFETY...

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    SAFETY...

  • Page 5

    PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6

    Thank You...

  • Page 7

    Assemble into Classic Series Pipeliner, SA-250 and 350SA Installation Sequence (Codes 10066, 10914) ...10 thru 15 Assemble into SAE-300 Installation Sequence (Code11806) ...16 thru 18 Connection of Lincoln Electric Wire Feeders ...19 Connection of the LN-25 to the Wire Feed Module...19 Connection of the LN-7, LN-7 GMA to the Wire Feed Module...19...

  • Page 8: Specifications, General Description, Design Features

    “COLD TIP” con- tactor. This module easily attaches to the welders fuel tank support. Field installation takes approximately 60 minutes. DESIGN FEATURES • Easy access to the controls located on the welder control panel. Feed Factory-Installed Rating @ 60%...

  • Page 9: Installation Instructions

    To prevent dangerous electric shock, other equipment to which an engine driven welder supplies power must: a) Be grounded to the frame of the welder using a grounded type plug, b) Be double insulated. When a welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle.

  • Page 10

    ASSEMBLE INTO CLASSIC SERIES PIPELINER, SA-250 and 350SA INSTALLA- TION SEQUENCE: (For codes 10066, 10914) 1) Remove current range selector and fine current adjustment control knobs from front of machine. (small flat screwdriver and 3/32” Allen wrench.) 2) Remove 5 upper nameplate screws, or fastener buttons.

  • Page 11

    8) Remove 2 screws from brush wraparound cover. Loosen and rotate the wraparound cover until neg- ative brushholder is exposed. (Large flat head screwdriver and pliers). 9) The negative brushholder is in the 11:00 position looking at the control panel end of the generator. Remove negative brushholder 5/16”...

  • Page 12

    12) Feed power cable assembly through the rectan- gular window on the bottom of the generator. 13) Connect power cable/thermostat assembly and the existing cables to the negative brushholder using the .75” long 5/16” hex head cap screw, (provided in the mounting hardware packet). Make certain the thermostat assembly does not touch the brushholder spring and the cable is clear of any moving parts.

  • Page 13

    15) Locate and remove 12-pin jumper plug and install 12-pin connector from control box to 12-pin con- nector. Connect control box 6-pin connector to control panel 6-pin connector. Connect control box 9-pin connector to control panel 9-pin con- nector. For Classic 300D with Codes (11547, 11548, 11572, 11573) and Pipeliner 200D Code 11591.

  • Page 14

    18) Position control box into place. On some models, the control box must be maneuvered out, up and back to clear the door latch catch. On Classic II machines, make sure the battery cable is not caught between the wire feed module and generator. 19) Install flat washer, lockwasher, and hex nut to control box mounting studs and tighten.

  • Page 15

    23) Drive three (3) self-tapping screws into output panel. (5/16” Nut driver or socket wrench). NOTE: The CV outout terminal assembly mounts under the weld output terminals on all machines. 24) With the CC/CV switch set to CC, start the engine and check the open circuit voltage on the output terminals.

  • Page 16

    4. Insert the local / remote toggle switch (most wires connected to it) first into the upper control panel on the welder with the mounting tab down. Next mount the potentiometer and secure the knob. Next mount the cv / cc toggle switch with the mounting tab down.

  • Page 17

    8. Feed power cable assembly through the rectangu- lar window on the bottom of the generator. 9. Connect power cable/thermostat assembly and the existing cables to the negative brushholder using the .75” long 5/16” hex head cap screw, (provided in the mounting hardware packet). Make certain the thermostat assembly does not touch the brush- holder spring and the cable is clear of any moving parts.

  • Page 18

    14. Mount the WFM using .62 spacers, flat washer, lock washer and hex nuts provided in the mount- ing hardware packet. Tighten all fuel tank bolts to rail. 15. Remove both the positive and negative output ter- minal bolts. (3/4” Socket wrench). 16.

  • Page 19

    CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections. Connection of LN-25 to the Wire Feed Module The LN-25 with internal “COLD TIP” contactor requires the K444-2 Control Cable for voltage control at the feed- The LN-25 with internal “Cold Tip”...

  • Page 20: Operating Instructions, Troubleshooting Chart

    25%. To obtain maximum auxiliary output, place the CC/CV switch in the CC position. If the current rating of the welder is exceeded, a ther- mostat will reduce the output voltage to approximately 5 volts. The thermostat will reset automatically as the machine cools.

  • Page 21: Troubleshooting

    Turn engine off. Remove short circuit. e. Broken or loose connections from WFM to control panel and engine welder. Refer to wiring diagram to check. Refer to P.C. Board Troubleshooting Procedure. a. In CV mode, check for 10-60 VDC across pin 8 of J3 and pin 1 of J4 on WFM P.C.

  • Page 22

    TROUBLE 3. Machine does not have a. Voltage adjust potentiometer leads maximum output. open. b. Voltage adjust potentiometer defective. c. Faulty P.C. Board. 4. Poor welding charac- a. Poor work or electrode connection. teristics. Poor arc striking with sticking or b.

  • Page 23: Troubleshooting Procedures

    P.C. Board. If there is damage to the P.C. Board or if replacing P.C. Board corrects problem, return it to the local Lincoln Electric Field Service Shop. Output Voltage Voltage Constant Voltage Mode -- The open circuit voltage in CV mode is 7-55 volts DC.

  • Page 24

    3. Check to see that leads 2 and 4 are con- nected. Put a voltmeter across these leads and the meter should read close to zero volts. If voltage reads approximately 15 volts, then the trigger circuit (leads 2-4) is open. Check the wiring from the WFM control box to the WFM control panel for loose or broken connections.

  • Page 25

    If the generator is operating properly, disconnect P10 and recon- nect P5. Refer to Wire Feed Module Troubleshooting chart. 3. If the generator is not working with the jumper plug P10, then refer to the engine welder Troubleshooting chart. – 25 –...

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  • Page 35

    CLASSIC I and PIPELINER 200D and 200G with WIRE FEED MODULE For Selected Open Circuit Volts (OCV) at Wire Feeder = WIRE FEEDER OCV CLASSIC I and PIPELINER 200D and 200G with WIRE FEED MODULE For Selected Open Circuit Volts (OCV) at Wire Feeder = WIRE FEEDER OCV Reference Output Curves 200 225...

  • Page 36

    CLASSIC II with WIRE FEED MODULE For Selected Open Circuit Volts (OCV) at Wire Feeder = WIRE FEEDER OCV CLASSIC II with WIRE FEED MODULE For Selected Open Circuit Volts (OCV) at Wire Feeder = WIRE FEEDER OCV Reference Output Curves 100 125 150 175 200 225 250 275 300 325 350 375 400 LOAD AMPS (DC) 100 125 150 175 200 225 250 275 300 325 350 375 400...

  • Page 37

    CLASSIC III and 300G with WIRE FEED MODULE For Selected Open Circuit Volts (OCV) at Wire Feeder = WIRE FEEDER OCV = WIRE FEEDER OCV For Selected Open Circuit Volts (OCV) at Wire Feeder CLASSIC III and 300G with WIRE FEED MODULE Reference Output Curves 100 125 150 175 200 225 250 275 300 325 350 375 400 LOAD AMPS (DC)

  • Page 38

    CLASSIC IIID, CLASSIC 300D, SA250 and SAE-300 (CODES 10890 and above) with WIRE FEED MODULE For Selected Open Circuit Volts (OCV) at Wire Feeder = WIRE FEEDER OCV 100 125 150 175 200 225 250 275 300 325 350 375 400 LOAD AMPS (DC) Reference Output Curves –...

  • Page 39

    350 SA and SA-250 (CODES 10889 AND BELOW) with WIRE FEED MODULE L O A D A M P S ( D C ) 1 0 0 1 2 5 1 5 0 1 7 5 2 0 0 2 2 5 2 5 0 2 7 5 3 0 0 3 2 5 3 5 0 3 7 5 4 0 0 3 5 0 S A a n d S A - 2 5 0 ( C O D E S 1 0 8 8 9 A N D B E L O W ) w i t h W I R E F E E D M O D U L E F o r S e l e c t e d O p e n C i r c u i t V o l t s ( O C V ) a t W i r e F e e d e r R e f e r e n c e O u t p u t C u r v e s...

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    NOTES WIRE FEED MODULE – –...

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    NOTES WIRE FEED MODULE – –...

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    • 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 – 44 –...

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