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Lincoln Electric IM 513-B manual

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Table of contents for the manual

  • Page 1

    WIRE FEED MODULE  " $ "L#% For Wire Feed Module Code Number:   February, 2011 #+0/>C/:/8.=98)9? Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can [...]

  • Page 2

    " :9A/</./;?3:7/8> 1.a. Turn the engine off before troubleshooting and maintenance 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. _______________[...]

  • Page 3

    33 #$) 33 ARC R A Y S can b ur n. 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. I standards. 4. b . Use suitable clothing made from durable flame-resistant material to prote[...]

  • Page 4

    333 #$) 333 FOR ELECTRIC ALL Y pow er ed equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the[...]

  • Page 5

    3@ #$) 3@ "E%$##J"$E 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: #G</>F 9?<#9?.+1/L<- 1. Protegez-[...]

  • Page 6

    @ @ Thank Y ou for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pa[...]

  • Page 7

     SPECIFICATIONS .........................................................................................................................................8 GENERAL DESCRIPTION ............................................................................................................................8 DESIGN FEATURES ........................[...]

  • Page 8

    – 8– " #" $ The Wire Feed Module (WFM) is an additional output control device designed to be easily installed into the Classic ® and Pipeliner Series of Engine Welders or the SA-250 Perkins or 350SA Perkins engine driven welders (with code 10061 and above). The WFM modifies the dynamic output[...]

  • Page 9

    – 9– Where an engine driven welder is connected to premises wiring such as that in your home or shop, its frame must be connected for the system earth ground. See further connection instructions in the section entitled “Standby Power Connections” as well as the article on grounding in the latest U.S. National Electrical Code and the local c[...]

  • Page 10

    – 10 – ##$ ###"#  "  # +8. #  #$  $#!% 9<-9./= 1) Remove current range selector and fine current adjus[...]

  • Page 11

    – 11 – 8) Remove 2 screws from brush wraparound cover. Loosen and rotate the wraparound cover until neg- a t i v e b r u sh ho ld er i s e x p o s e d . ( L a r g e f l a t h e a d 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 – 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 t[...]

  • Page 13

    – 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

    – 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

    – 15 – 2 3) Drive three (3) self-tapping screws into output panel. (5/16” Nut driver or socket wrench). $ 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. The voltage should be[...]

  • Page 16

    – 16 – ## )$#'" #$  $#!% 9<9./ 1. Remove the bottom 3 mounting screws from the upper control nameplate. Keep the screws for later use to fasten the WFM nameplate. Once, the screws hav[...]

  • Page 17

    – 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 [...]

  • Page 18

    – 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. Using bolts from step 15, connect control box’s positive and negative power cables an[...]

  • Page 19

    – 19 – $   $" '""# #2?> 900 A/6./< ,/09</ 7+5381 +8C /6/-><3-+6 -988/->398= 988/->39890>9>2/'3<///.9.?6/ The LN-25 with [...]

  • Page 20

    – 20 –  " $#$"%$# ..3>398+6#+0/>C </-+?>398= $2/ 9?>:?> >/<738+6= +</ /8/<13D/. A2/8 >2/ /8138/ 3= <?88381  $2/ & 9?>:?> A366 ,/ .//8/< 13D/. 986C 30 ' 79./[...]

  • Page 21

    – 21 – $"%#$ $"% %## ' $KK$KK 1. Machine has no output with machine switch in CV mode. 2. Machine has minimum output and no control. a . Electrode or work lead loose or broken. b. No generator output. c. CR4 is not working, or no input to CR4. d. Protective circ[...]

  • Page 22

    – 22 – $"%#$ $"% %## ' $KK$KK 3. Machine does not have maximum output. 4 . Poor welding charac- teristics. Poor arc striking with sticking or “blast-offs”,weld poros- ity, narrow and ropey looking bead, or electrode stubbing into the plate. a. Voltage adjust[...]

  • Page 23

    – 23 – $"%#$ "%"#  9+<.$<9?,6/=299>381 <9-/.?</= Perform the following checks before replacing the P.C. Board. 1. Remove the cover to the Wire Feed Module box located on the right side of the machine. With the engine running the green and re[...]

  • Page 24

    – 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 bo x to the WF M c ontrol panel for loose or broken connections. Turn machine of[...]

  • Page 25

    – 25 –  !?3-52/-5 <9-/.?</09</8/<+>9<86C 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. If the gen- erator is working properly, the problem exists in the W[...]

  • Page 26

    – 26 – L9259 AMPHENOL 1 A D F 510 602 610A 503A 609 501 CONTACTOR CONTACTOR +++ 622 666 633 75A 76 77 75 R501 630 631 CV CONTROL 4 667 634 J2 J3 501 631 600 608 610A 509 503A 630 503 J4 2 1 GND 31 32 609 610A 510 501 503A 602 75 76 77 2 4 J1 E G J 32 31 4A GND 2A 77B 76B 75A 76B 76A 76 608 609 CV - CC + CC - 634 633 610 667 N.A. 76A 115 VAC GRO[...]

  • Page 27

    – – 27 – M17220 #2 HEAVY LEAD WIREFEED MODULE W.F.M. CONTROL PANEL NEG. POS. OUTPUT TERMINALS CONNECT TO POS. & NEG. CONNECT TO NEG. BRUSH HOLDER 608 609 #2 HEAVY LEAD #8 LEAD NEGATIVE CV OUTPUT TERMINAL PANEL MACHINE MUST NOT BE RUNNING WHEN MAKING THESE CONNECTIONS. * INLINE CONNECTORS ON ENGINE WELDER REMOVE JUMPER PLUG FROM CONNECTOR [...]

  • Page 28

    – 28 – M17323 LN-23P LN-23P APPLICATIONS. SEE LN-23P OPERATING N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND THE DUTY CYCLE OF IMMEDIATE AND FUTURE MANUAL FOR PROPER SIZES. N.B. IF ONLY ONE LN-23P IS USED, CONNECT TO FEEDER "A" TERMINAL STRIP IN ADAPTER. N.C. REMOTE VOLTAGE SENSING LEAD TO BE EXTENDED BY CUSTOMER [...]

  • Page 29

    – 29 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL S21036 CV- + N.C. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. SPARE 82 81 42 41 31 32 2 4 21 GND 75 76 77 31 3[...]

  • Page 30

    – 30 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. DIAGRAM SHOWS ELECTRODE POSITI[...]

  • Page 31

    – 31 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL S21038 CV- + N.C. ELECTRODE CABLE TO LN-7 14 PIN AMPHENOL N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.C. 76 [...]

  • Page 32

    – 32 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. DIAGRAM SHOWS ELECTRODE POSITI[...]

  • Page 33

    – 33 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. DIAGRAM SHOWS ELECTRODE POSITI[...]

  • Page 34

    – 34 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL S21268 CV- + N.C. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. SPARE 82 81 42 41 31 32 2 4 21 GND 75 76 77 31 3[...]

  • Page 35

    – 35 – CLASSIC I and PIPELINER 200D and 200G with WIRE FEED MODULE Reference Output Curves For Selected Open Circuit Volts (OCV) at Wire Feeder 0 0 2550 75100125150175200225250275300 5 10 15 20 25 30 35 40 45 50 55 60 LOAD AMPS (DC) LOAD VOLTS (DC) = WIRE FEEDER OCV CLASSIC I and PIPELINER 200D and 200G with WIRE FEED MODULE Reference Output Cu[...]

  • Page 36

    – 36 – CLASSIC II with WIRE FEED MODULE Reference Output Curves For Selected Open Circuit Volts (OCV) at Wire Feeder 0 0 2550 75100125150175200225250275300325350 375 400 5 10 15 20 25 30 35 40 45 50 55 60 LOAD AMPS (DC) LOAD VOLTS (DC) = WIRE FEEDER OCV CLASSIC II with WIRE FEED MODULE Reference Output Curves For Selected Open Circuit Volts (OC[...]

  • Page 37

    – 37 – CLASSIC III and 300G with WIRE FEED MODULE Reference Output Curves For Selected Open Circuit Volts (OCV) at Wire Feeder 0 0 2550 75100125150175200225250275300325 350 375 400 5 10 15 20 25 30 35 40 45 50 55 60 LOAD AMPS (DC) LOAD VOLTS (DC) = WIRE FEEDER OCV CLASSIC III and 300G with WIRE FEED MODULE Reference Output Curves For Selected O[...]

  • Page 38

    – 38 – CLASSIC IIID, CLASSIC 300D, SA250 and SAE-300 (CODES 10890 and above) with WIRE FEED MODULE Reference Output Curves For Selected Open Circuit Volts (OCV) at Wire Feeder 0 0 2550 75100125150175200225250275300325350 375 400 5 10 15 20 25 30 35 40 45 50 55 60 LOAD AMPS (DC) LOAD VOLTS (DC) = WIRE FEEDER OCV CLASSIC IIID, CLASSIC 300D, SA250[...]

  • Page 39

    – 39 – 350 SA and SA-250 (CODES 10889 AND BELOW) with WIRE FEED MODULE Reference Output Curves For Selected Open Circuit Volts (OCV) at Wire Feeder 0 0 2550 75100125150175200225250275300325 350 375 400 5 10 15 20 25 30 35 40 45 50 55 60 LOAD AMPS (DC) LOAD VOLTS (DC) = WIRE FEEDER OCV 350 SA and SA-250 (CODES 10889 AND BELOW) with WIRE FEED MOD[...]

  • Page 40

    – 40 – $# '"%[...]

  • Page 41

    – 41 – $# '"%[...]

  • Page 42

    – 42 – W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INS TRUCTION FOR THIS EQ UIPMENT AND THE CONSUMABLES T O BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LA S INS TRUCCIONES[...]

  • Page 43

    – 43 – W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A A S INS TRUÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E A S P AR TES DE USO , E SIGA A S PRÁTIC A S DE SEGUR ANÇA DO EMPRE GADOR. • Kee p yo ur h ead out of fum es. • Use ven tila t[...]

  • Page 44

    – 44 – • 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 • World's Leader in Welding and Cutting Products •[...]