RETURN TO MAIN MENU MAGNUM SG ™ IM408 February, 2005 SPOOL GUN 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii 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.
iii iii SAFETY 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. 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. 6.b.
iv SAFETY 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You 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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page SAFETY PRECAUTIONS ..............................................................................................i thru iv INTRODUCTORY INFORMATION ..........................................................................................v TABLE OF CONTENTS ..........................................................................................................vi PART A ..........................................................................................................
PART A PRODUCT DESCRIPTION RECOMMENDED PROCESSES AND EQUIPMENT The K487 Magnum™ SG spool gun is a lightweight, handheld combined semiautomatic wire feeder and welding gun, designed primarily for aluminum welding using argon shielding gas. The feeding distance of the self-contained wire supply to the arc is only several inches, eliminating the wire feeding problems normally associated with feeding soft aluminum electrode through a conventional gun and cable assembly.
PART B INSTALLATION — Power source must be turned “OFF” and power leads disconnected when installing this unit. Safety Precautions — 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. Unpacking the Spool Gun Carefully unpack the Magnum K487 Spool Gun, and make sure you have all of the parts shown below.
a. Wire drive release lever up position moves pressure roller away from drive roll to stop wire feed. Down position moves pressure roller to wire. Operate wire drive release lever and see pressure roller move. Spool Gun Installation The spool gun attaches easily to CV type welders through the Magnum SG Control Module. The spool gun also attaches easily to Lincoln models SP-150, SP-200 and SP-250 power sources and may be adapted to other similar welders. b. Drive roll with two wire grooves.
Installation to Lincoln SP-250 3. Route end of spool gun control through hole in front panel and attach to mating connector of K516 Spool Gun Adapter assembly. The K487 Spool Gun connects directly to the SP-250 with either a K531-1 or K531-2 Spool Gun Module Kit. The K531-1 kit is for SP-250’s with a S19636-1 (or earlier) ROM and the K531-2 kit is for S19636-2 ROM (or later). To see which kit you need, turn the SP-250 on and watch the display.
6. Connect spool gun power cable to (+) stud terminal on SP-150. Disconnect any lead already attached there. 7. Connect work lead to (–) stud terminal on SP-150 if not already connected there. Close left side door. 8. On front control panel of SP-150: 8A. Connect spool gun gas line to gas outlet fitting. 9. Connect regulated argon gas supply to gas inlet fitting on rear panel of SP-150. 8B. Set welding voltage.(1) 8C. Set wire feed speed.(1) (1) See Part B, “Test Weld Settings".
Installation to Lincoln SP-200 4. Disconnect any cables attached to (+) stud terminal on front panel and connect spool gun power cable to same. NOTE: Remote wire speed control will not be functional when K487 Spool Gun is connected to SP-200. Installation of K487 to SP-200 requires K517 Adapter Assembly. 5. Connect work cable to (–) stud terminal, disconnecting any leads already attached there. 6. On front control panel of SP-200: 6A. Connect spool gun gas line to gas outlet fitting.
Installation to Similar Welders with Wire Feed 9. Set wire feed speed and welding voltage controls.(1) Control (1) See Part B, “Test Weld Settings”. NOTE: Remote wire speed control will not be functional when K487 Spool Gun is connected to welders with internal wire feed control circuitry. K516 Adapter assembly required. NOTE: Connector pinouts show view of mating side of connectors. Installation to other welders is possible as long as the welder meets the following requirements: 1.
matching. In addition, several wire sizes are available, and the choice here will depend upon several factors, including base metal thickness and the arc transfer process used. Consult your local dealer or appropriate AWS publication for help in selecting an appropriate alloy type and wire size. Also refer to Part B, “Procedure Settings”, for wire sizes used with typical base metal thicknesses and procedure settings. OPERATING INSTRUCTIONS Safety Precautions Loading Electrode Wire 1.
9. Screw on spool brake tension nut and adjust for slight wire spool braking action. 5. Select wire of size and type needed. Wire must be straight, with no kinks or bends. Check drive roller for the correct groove positioning for the size wire selected. See Part B, “Drive Roll Groove Selection”, for details. FITTING THE ELECTRODE WIRE • Replace the spool brake assembly. 6. Put wire spool on shaft and route wire into plastic tube.
10. Obtain contact tip sized to match wire selected. Slip contact tip over wire and screw into diffuser. Tighten securely. SPOOL COVER SPOOL BRAKE ASSEMBLY SPOOL HUB NUT SPOOL WASHER SHIM WASHERS 11. Push on gas cone and cut off wire close to end of contact tip. FLAT WASHER LOCK WASHER SPOOL HUB BOLT CAUTION: BE CAREFUL WHEN PUSHING ON GAS CONE. WIRE END COULD PUNCTURE YOUR HAND. INCREASING BRAKE TENSION ON THE SPOOL FITTING THE ELECTRODE WIRE (Cont.
4. Slide drive roll off motor shaft. Turn roller over, end for end. Drive Roll Groove Selection The drive roll has two grooves, a wider and a narrower one, to accommodate changes in wire size used. Changing between the grooves simply requires reversing the drive roll. The following information is to be used to determine proper groove positioning and to change it, if necessary, for the wire size selected. 5. Slide drive roll back on motor shaft and tighten set screw.
The procedure settings below can be used to make a test weld when the spool gun is used with a Lincoln model SP-150, SP-200 or SP-250 power source: SP-150 SP-200 SP-250 Wire Wire Speed Arc Speed Arc Wire Arc Dial Voltage Dial Voltage Speed Voltage Setting(1) Setting Setting(1) Coarse Fine Percentage Setting Wire Size in. (mm) .030 (.8 mm) .035 (.9mm) 3/64 (1.2 mm) 325 300 225 6.5 7.0 7.5 375 350 250 18-23 2.5 18-23 2.5 18-23 2.5 42% 39% 32% 15 16 21 (1) Dial not calibrated when used with spool gun.
Procedure Settings The following procedure settings for aluminum wire and argon gas can be used as starting points for developing specific welding procedures: Wire Size in. (mm) Metal Thickness ga. in. (mm) .030 (0.8) 22 20 18 16 14 12 10 3/16 1/4 3/8 .030 (0.8) .036 (1.0) .048 (1.2) .060 (1.6) .075 (2.0) .105 (2.5) .135 (3.5) (5.0) (6.0) (10.0) 13-14(1) 13-14(1) 14-15(1) 15-16(1) 16-17(1) 16-18(1) 24-26 24-26 28-29 28-30 200 (5.1) 240 (6.1) 290 (7.4) 340 (8.6) 370 (9.4) 430 (10.9) 460 (11.7) 500 (12.
Troubleshooting Guide PROBLEM SYMPTOMS No arc, wire feed, or gas flow. 1. 2. 3. 4. 5. 6. No arc, weak arc. 1. Poor ground connection to work. 2. Power cable connection loose. Cable connections loose. Trigger switch loose or defective. Welder not turned on. Welder not plugged in. Cable or adapter cable damaged. Adapter (if used) not connected. 3. Voltage set too low. 4. Tip too large for wire size. No wire feed. 1. Feeding small diameter wire with large groove on drive roller. 2.
DISASSEMBLY AND ASSEMBLY HINTS Numbers in parentheses refer to Parts List page number and Item Number. When applying torque on nozzle parts (P198-D,#1 through #8), hold gun by molded base (P198-D,#27) or body block (P198-D#43), not by handle (P198D,#13) or motor(P198-D,#42). When assembling handle to molded base, make sure switch wires (P198-D,#19) are not pinched between handle and motor. Pinched wires could cause welding voltage to short to control circuit.
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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