Installation Guide

ManualsBrandsLincoln Electric ManualsTools & HardwareMagnum 100SG Welding Spool Gun

INSTALLATION

TECHNICAL SPECIFICATIONS - MAGNUM

100SG SPOOL GUN K2532-1

MODEL

WELDING PROCESS

WIRE ALLOYS

WIRE SIZES (DIAMETERS)

SPOOL SIZE

RATED WELDING CURRENT

AND DUTY CYCLE

OVERALL WEIGHT

CABLE LENGTH

OVERALL SIZE (BOUNDING BOX)

METHOD OF GUIDANCE

METHOD OF COOLING

K2532-1 Magnum

100SG Spool Gun

Aluminum GMAW (MIG), DC electrode positive

polarity with 100% argon welding shielding gas.

Aluminum only: alloys 4043 or 5356

Solid wire 0.030 or 0.035 inches (0.8 or 0.9 mm)

1 lb. weight, nominal 4 inch diameter spool

130 amps at 30% for 10-minute basis

3.5 lbs. with cable but without case or spool

10.0±0.2 feet

In inches: 15.75 long x 10.50 high x 4.25 thick max.,

without case or gun cable.

Semiautomatic (manually-guided)

Air-cooled

UNPACKING THE SPOOL GUN

The spool gun is factory-assembled and tested, and then packed in its own cush-

ioned carrying case. It is shipped fully-equipped to weld with 0.035 inch diameter alu-

minum wire. After opening the case, check that it contains the following items:

1. One fully assembled K2532-1 spool gun.

2. One T11862-65 Conical Compression Spring for use with alloy 5356 wire (spool

not included).

3. One spool of 0.035 aluminum alloy 4043 wire

4. Three S19726-3 contact tips

5. One instruction manual (IM913)

6. One M21182 electrical harness with toggle switch.

A-1

Plastic Bag

Summary of content (13 pages)

PAGE 1
INSTALLATION TECHNICAL SPECIFICATIONS - MAGNUM® 100SG SPOOL GUN K2532-1 MODEL K2532-1 Magnum® 100SG Spool Gun WELDING PROCESS Aluminum GMAW (MIG), DC electrode positive polarity with 100% argon welding shielding gas. WIRE ALLOYS Aluminum only: alloys 4043 or 5356 WIRE SIZES (DIAMETERS) Solid wire 0.030 or 0.035 inches (0.8 or 0.9 mm) SPOOL SIZE 1 lb. weight, nominal 4 inch diameter spool RATED WELDING CURRENT AND DUTY CYCLE 130 amps at 30% for 10-minute basis OVERALL WEIGHT 3.5 lbs.
PAGE 2
INSTALLATION SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.
PAGE 3
INSTALLATION ASSEMBLY OF ITEMS INSIDE THE MAGNUM® SPOOL GUN FIGURE A,3 4 TOP VIEW 7 2 3 1 8 9 Spool Cover and left handle removed MASTER KEY Machine Connections 1 6 3 2 4 P6 CONNECTOR PINOUT 1. Liner Assembly feeds all specified wire. 2. Drive Roll: This Drive Roll feeds all specified wires. 3. Idle Roll Assembly: Non-adjustable tension setting for all specified wires 4. Incoming Wire Guide: Highly wearresistant. 5. P6 Connector Control Leads: Motor Power and Trigger.
PAGE 4
INSTALLATION SAFETY PRECAUTIONS WELDING MACHINES CAUTION • Read and understand the welding machineʼs instruction manual and all hazard warnings on equipment and in the manual. • Wear the proper personal protective equipment for welding, including but not limited to, safety glasses, hearing protection, welding helmet, welding gloves, and welding leathers. ----------------------------------------------------------------------------------------------------SPOOL GUN WARNING ELECTRIC SHOCK CAN KILL.
PAGE 5
INSTALLATION RECOMMENDED WELDING MACHINES MACHINE NAME K-NUMBER CODE NUMBER POWER MIG 216 POWER MIG 215XT POWER MIG 180C POWER MIG 140C POWER MIG 180 DUAL POWER MIG 180C AU POWER MIG 180C CE POWER MIG 140T POWER MIG 180T K2816-1 K2700-1 K2473-1 K2471-1 K3018-1 K2668-1 K2661-1 K2470-1 K2472-1 PRO CORE 125 K2479-1 PRO MIG 140 K2480-1 WELD PAK 125 HD K2513-1 WELD PAK 140 HD K2514-1 MIG PAK 140 K2658-1 EASY CORE 125 K2696-1 EASY MIG 140 K2697-1 WORK PAK 125 K2699-1 CORE PACK 125 K2785-1
PAGE 6
INSTALLATION NOTE: Installation of the M21182 harness and spool gun selector switch is not required for all machines. If a spool gun switch is pre-installed in the machineʼs wire drive compartment, then the SPOOL GUN / WIRE DRIVE SLECTOR SWITCH INSTALLATION SECTION can be disregarded. SPOOL GUN / WIRE DRIVE SELECTOR SWITCH INSTALLATION A 1. Install the M21182 electrical adapter harness that came with the spool gun per the following instructions. ELECTRIC SHOCK CAN KILL. WARNING 5.
PAGE 7
INSTALLATION ELECTRICAL CONNECTIONS 544A (Male) P7 543A (Female) Toggle Switch J3 J7 (10-pin) J8 (6-pin) P8 (6-pin) P7 (10-pin) 8. Adapter harness. All 6 connections shown are used, and each one is unique. (Proceed as follows) 10. Connect harness P7 (10-pin) to board J3 (10-pin). IF MACHINE DOES NOT HAVE OPTIONAL SPOT TIMER. (11.A. thru 11.D.) P5 P3 J5 11.A. Remove P5 (6-pin) from board J5 (6-pin). J3 9. A. Remove P3 (10-pin) from board J3 (10-pin). J8 P5 P3 J7 11.B.
PAGE 8
INSTALLATION P8 544A J9 543A 11.D. Find assembled pair of machine terminals (leads 543A & 544A) and disconnect. Go to step 13. 12.C. Connect adapter harness P8 (6pin) to spot timer harness J9 (6pin). IF MACHINE DOES HAVE OPTIONAL SPOT TIMER. (12.A. thru 12.D.) 544A J9 P5 12.A. Remove P5 (6-pin) from spot timer harness J9 (6-pin). 543A 12.D. Find assembled pair of machine terminals (leads 543A & 544A) and disconnect. B J8 A P5 12.B. Connect P5 (6-pin) to adapter harness J8 (6-pin). 13.
PAGE 9
INSTALLATION MOUNTING THE SWITCH 15. Remove the plug button from the panel hole. 16. Plug button is no longer needed. Discard. 18. Install switch into panel hole. Ensure washer tab is fully seated into smaller hole. 19. Reinstall mounting nut onto switch. Wrench tighten. RE-ASSEMBLE MACHINE AS FOLLOWS: 17. Remove mounting nut from switch. Keep mounting nut for installation. 20. Reinstall screw into plastic handle (if so equipped). 21. Reinstall cover. 22. Reinstall door. 23.
PAGE 10
INSTALLATION ROUTINE WELDING MACHINE PREPARATION WARNING ELECTRIC SHOCK CAN KILL. 1. Disconnect input power to the machine. -----------------------------------------------------------------------2. Machine polarity setting: Set to DC electrode positive polarity per the machineʼs Instruction Manual. 3. Gas selection and flow rate: Connect 100% welding grade argon gas supply to the machineʼs gas solenoid valve. Set the supply regulator to deliver a gas flow rate of 20 to 50 SCFH thru the spool gun.] 4.
PAGE 11
INSTALLATION LOADING ALUMINUM WIRE 1. Remove gas cone and contact tip. Remove spool cover by unscrewing captive locking knob. FIGURE A.5 2. Remove locking knob from spindle bolt by unscrewing it. FIGURE A.6 3. Select wire alloy and diameter needed. Alloy 4043 and 0.035 wire size shown. Remove packaging and data sheet from wire spool. FIGURE A.7 4. Extend approximately 12 inches of wire from spool. Straighten it out by back-bending it. Use care to prevent the wire from dereeling. FIGURE A.8 5.
PAGE 12
INSTALLATION 7. Guide straightened wire through inlet wire guide and toward drive roll groove. FIGURE A.11 10a. Alloy back onto knob 11. 4043: Roll up remaining wire onto spool and place spool gun spindle. Install locking and finger-tighten. Go to step FIGURE A.14 8. While holding open the idle roll, slide end of wire through drive rollʼs groove and toward gun tube liner. FIGURE A.12 10b. Alloy 5356: Install Conical Spring, small end first, onto gun spindle (A).
PAGE 13
INSTALLATION 12. Cut off excess wire 1 to 2 inches from gas diffuser. Install properlysized contact tip slightly past handtight. Install gas cone and handtighten. FIGURE A.17 CONNECTING THE GUN TO THE WELDING MACHINE 1. Disconnect input power to the machine. 2. Make sure that the gun locking knob is loosened. (See Figure 20). 13. Reinstall spool cover. 1: tuck coverʼs tab in place at arrow and hold with thumb. 2: swing cover closed. 3: finger-tighten locking knob.