RETURN TO MAIN MENU IM632-B ® MAGNUM 450WC & 650WC March, 2008 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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
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 ARC RAYS can burn. 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 and CUTTING 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 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode 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! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi TABLE OF CONTENTS vi Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A General DescriptIon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-1 A-1 INSTALLATION 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 100% duty cycle with mixed argon shielding gases. There are several 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.
A-2 A-2 INSTALLATION The WATER OUT “RED HOSE” must be connected to the receptacle marked water in. The water cooler provided with the Powerwave will provide adequate flow to cool the gun and has a safety switch that will produce 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. INSTALLATION WARNING ELECTRICAL SHOCK can kill. • Have an electrician install and service this equipment.
B-1 OPERATION 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 electrode is slightly wavy after a wire feed stop. a) Check that the welding power source is on and that the shielding gas supply is set for the proper flow rate. ELECTRODES AND EQUIPMENT b) Position electrode over joint.
C-1 EXPENDABLE REPLACEMENT PARTS EXPENDABLE REPLACEMENT PARTS FOR MAGNUM® 450WC GUN & CABLE ASSEMBLIES Part Number (Color Code) English Size (In.) Metric Size (mm) KP44-3545-15 KP44-116-15 KP44-564-15 .035-.045" .052-1/16" 1/16-5/64 0.9-1.2 mm 1.3-1.6 mm 1.6-2.0 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 0.9-1.2 mm 1.6 mm 0.9-1.2 mm For Cables 10' (3.
D-1 D-1 MAINTENANCE Periodically remove and clean the nozzle, contact tip and gas diffuser. Replace the nozzle insulator if damaged. 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.
D-2 D-2 MAINTENANCE REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR LINERS FITTING A HARD WIRE LINER FOR FEEDING SOLID AND CORED STEEL ELECTRODE INSTALLATION INSTRUCTIONS FOR LINERS DESIGNED FOR FEEDING SOLID AND CORED STEEL WIRE STENCIL ON LINER BUSHING WIRE SIZE LINER COLOR GUN KP44-3545-15 .035-.045 (0.9-1.2mm) KP44-3545-15 .045 (1.2MM) 450WC KP-44-116-15 .052-1/16 (1.3-1.6mm) KP-44-116-15 1/16 (1.6mm) 450WC KP44-564-15 1/16-5/64 (1.6-2.0mm) KP1933-3 5/64 (2.
D-3 D-3 MAINTENANCE REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR LINERS FITTING A SOFT LINER FOR FEEDING ALUMINUM ELECTRODE INSTALLATION INSTRUCTIONS FOR KP1958-ALL LINERS DESIGNED FOR FEEDING ALUMINUM WIRE LINER WIRE SIZE GUN LENGTH LINER COLOR KP1958-1 10 FT. (3.0M) .030-.035 (0.8-0.9mm) BLACK KP1958-2 15 FT. (4.5M) .030-.035 (0.8-0.9mm) BLACK KP1958-3 10 FT. (3.0M) 1/16 (1.6mm) RED KP1958-4 15 FT. (4.5M) 1/16 (1.6mm) RED KP1958-5 10 FT. (3.0M) .035-3/64 (.09-1.
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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS 1. Drive rolls turn, but wire will not feed or wire feeding is rough. A. Gun cable kinked and/or twisted. 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. G.Worn or improper size cable liner.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED 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 electrode stubbing into plate while B. Improper gas shielding. welding.
NOTES MAGNUM® 450WC & 650WC
G Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO G Keep flammable materials away. G Wear eye, ear and body protection. G Mantenga el material combustible G Protéjase los ojos, los oídos y el electrode with skin or wet clothing. G Insulate yourself from work and ground. G No toque las partes o los electrodos bajo carga con la piel o ropa mojada. G Aislese del trabajo y de la tierra.
G Keep your head out of fumes. G Use ventilation or exhaust to G Turn power off before servicing. G Do not operate with panel open or guards off. remove fumes from breathing zone. G Los humos fuera de la zona de res- piración. G Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. G Gardez la tête à l’écart des fumées. G Utilisez un ventilateur ou un aspira- G Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
• 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.
