Lincoln Electric Complete Guide to Lincoln K487-25 Magnum SG Spool Gun and Accessories
Page 25

C-3

ACCESSORIES

C-3

 

 

 

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

OPERATING INSTRUCTIONS FOR TIMER KIT

If the optional Timer Kit (K1701-1) is installed, select the desired mode with the selector switch:

A. Normal Welding mode provides weld power only while the trigger switch is depressed. This is the same operation as when the Timer Kit is not installed.

B. 4-Step Trigger interlock mode eliminates the need to hold the gun trigger while welding. It operates in 4 steps:

1.Close trigger and establish welding arc.

2.Release trigger and continue welding.

3.Reclose trigger near end of weld.

4.Release trigger again to stop welding.

If the arc is broken while using this feature, the machine will reset to the "trigger off" condition automatically.

Note: 4 Step Trigger interlock mode does not function with a Spool Gun.

C. Spot Weld Mode is is used for tack welding parts into position or for spot plug welds to hold thin sheet metal together prior to manual stitch or continuous welding. To use this feature, adjust the On-Time (0- 5 seconds) as appropriate to obtain the desired results. Closing the trigger initiates a single timed spot weld cycle.

Plug welds are made by using a punch to make a 3/16" (5 mm) diameter hole in the top sheet and arc welding through the hole into the back sheet.

To make spot plug welds, punch 3/16" (5 mm) holes in the top sheet. Set the Spot Time control to approximately 1.2 seconds and set the procedure for the metal thickness to be welded. Install spot weld nozzle (if available) on gun and press it against the top sheet so the top and bottom sheets are tight together. Close trigger and hold it closed until the arc goes out. If a spot weld nozzle is not used, smoother welds will result by moving the welding wire in a small circle during the weld.

D. Burnback Time control provides manual adjustment of the burnback time (0-250 milliseconds) for any selected welding mode. this control should be set as low as possible without the wire "sticking" in the puddle after each weld. Too long of a burnback time may form a "ball" on the end of the wire, or may "flash back" to the gun tip.

E. Run-In Mode is used to adjust the starting wire feed speed. Starting conditions for certain welding applications can be improved with adjustment to the Run-In speed. The control allows for initial starting speeds from 50 - 150 IPM. After the arc is started, the set point on the wire feed speed control will dominate. Note that the Run-in is not functional with the spool gun. Also note that if Run-in is set fully counter clockwise to "OFF", Run-in speed will equal the preset WFS on the machine.

SPOOL GUN

Remove all input power to the POWER MIG 255C before proceeding.

-----------------------------------------------------------------------

WARNING

The POWER MIG 255C provides direct connection and use of the Spool Gun (with remote speed control).

It also provides gun trigger switch transfer between the machine’s use with its feeder gun or the spool gun for same polarity welding with different wire and gas processes.

K2297-2

 

Prince® XL Spool Gun

 

 

 

 

 

K487-25

 

Magnum® SG Spool Gun (requires K2445-1

 

 

Cable Adapter)

 

 

 

 

K2445-1 Magnum SG Spool gun Control Cable Adapter

Allows the K487-25 Magnum SG spool gun’s 6-pin control cable plug to connect to the Power MIG 255C’s 7-pin spool gun control cable receptacle.

K1738-1 Spool Gun Hanger Accessory

CONNECTING THE SPOOL GUN TO THE POWER MIG 255C

(See Figure C.1)

1.Connect the Spool Gun control cable to the mating 7-pin receptacle in the Power MIG wire drive compartment. K487-25 Magnum SG Spool Gun requires K2445-1 cable 7-pin to 6-pin adapter.

2.Connect the Spool Gun electrode lead to the (+)positive stud with the Spool Gun electrode lead sandwiched between the (+)positive power source electrode lead and the (+)positive stud. Tighten and be careful not to strip the threads.

3.Attach the Spool Gun gas line to the 5/8 Gas fitting on the front of the machine.

4.Attach a Gas hose from the Gas supply to the rear inlet gas fitting on the Power MIG 255C.

POWER MIG 255C

Page 24 Page 26
Image 25
Page 24 Page 26
Contents Power MIG 255C California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents For ALL Sections Table of Contents Installation Section InstallationTechnical Specifications Power MIG 255C Uncrating the Power MIG 255C Safety PrecautionsInput POWER, Grounding and Connection Diagrams LocationInstallation Figure A.2 Triple Voltage Machine Input Connections Auxiliary Power Receptacles GUN and Cable InstallationShielding GAS Operation Table of Contents Operation SectionWear eye, ear and body protec- tion OPERATIONB-2Recommended Processes and Equipment Product DescriptionWelding Capability LimitationsWire Drive Roll Wire Size Conversion PartsDescription of Controls Wire Reel Loading Readi REELS, Spools or Coils Procedure for ChangingDrive and Idle Roll Sets Idle Roll Pressure Setting Feeding Wire ElectrodeWire Drive Configuration To Start the WelderFigure B.4 Instructions to Enter Slow RUN-IN When Timer Option is not installedInstructions to Enter Fast RUN-IN Making a WeldWire Feed Overload Protection Avoiding Wire Feeding ProblemsFAN Control Input Line Voltage ProtectionOvercurrent Protection Welding Thermal Overload ProtectionTable of Contents Accessories Section AccessoriesMagnum GUN Connection KIT Drive Roll KitsK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Connecting the Spool GUN to the Power MIG 255C Operating Instructions for Timer KITK1738-1 Spool Gun Hanger Accessory Spool GUNMaking a Weld with the Magnum SG Spool GUN Making a Weld with the Prince XL Spool GUNSG Spool Gun Wire Feed Speed Power MIG Table of Contents Maintenance Section MaintenanceGUN Cable Cleaning GUN Tubes and Nozzles General MaintenanceContact TIP and GAS Nozzle Installation Liner Removal and ReplacementTable D.1 GUN Handle DisassemblyEnglish Metric Description MAINTENANCED-4Theory of Operation Table of Contents Theory of Operation SectionMain Transformer Input Line VoltageFeedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorThermal and Overload Protection Wire Feed Overload ProtectionFigure E.6 SCR Operation SCR OperationPower MIG 255C Table of Contents Troubleshooting and Repair Section Troubleshooting and RepairHOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Output Problems Troubleshooting GuideSymptoms Misadjustments Course of Action Problems Possible AreasTrolyte in these capacitors is Toxic. Avoid contact with anyPerform the SCR Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Main Transformer Test Test ProceduresTest Description Materials NeededON/OFF Power Switch will be hot during these tests Test Procedure16J5 8J5 115VAC206 3J5 Rectifier Diode Bridge Test Figure F.2 G3521 Rectifier Diode Bridge Location 16TROUBLESHOOTING and REPAIRF-16354 206 36 VDC 208 206 28 VAC 209Power MIG 255C Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG 255C Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Figure F.8 Wire Drive Motor and Tachometer Feedback Test 4J1 Wire Drive Motor and Tachometer Feedback Test515B 206B 15 VDC 5J1 1J1 Test for Supply Voltage to Tachometer555 206B To 3.5 VDC 6J1 1J1 Test for Feedback Voltage to Control BoardVolts Normal Open Circuit Voltage WaveformTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting and Repair Typical SCR Gate Voltage Waveform Power MIG 255C Control PC Board Removal and Replacement Component Replacement ProceduresDescription Procedure Removal and ReplacementFigure F.11 Control Board Mounting Power MIG 255C Wire Drive Assembly Removal and Replacement Wire Drive Assembly Removal and Replacement Procedure Power MIG 255C SCR Output Rectifier Removal and Replacement SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG 255C Capacitor Bank Removal and Replacement Capacitor Bank Removal and Replacement Main Transformer and Output Choke Removal and Replacement Main Transformer and Output Choke 52TROUBLESHOOTING and REPAIRF-52TOC Power MIG 255C FAN Motor Assembly Removal and Replacement FAN Motor Assembly Removal and Replacement Retest After Repair Wire Speed RangeOpen Circuit Voltage Input Volts/HertzPower MIG 255C Section G-1 Electrical Diagrams SectionWiring Diagram Entire Machine Code 11192 L12464 Electrical DiagramsWiring Diagram Entire Machine Code 11218 L12506 Schematic Entire Machine G4752 Schematic Control PC Board G4823-2D1 Sheet Electrical Diagrams Electrical Diagrams Item Used with QTY Part Number Description PC Board Assembly Control G4824-2D1Powermig Schematic Display PC Board L10951Lincoln Electric CO PC Board Assembly Display L10952SVM Error Reporting Form
Top Page Image Contents