Lincoln Electric IM513 User Manual
WIRE FEED MODULE
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For Wire Feed Module Code Number: 10066, 10914, 11806
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.
™
IM 513-B
February, 2011
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• 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.com
i
SAFETY
i
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
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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
FOR ENGINE
powered equipment.
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.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
ii
SAFETY
ii
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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
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 protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09
iii
SAFETY
iii
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
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. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered 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 U.S. National
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Jan ‘09
iv
SAFETY
iv
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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
Thank You
vv
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!
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. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENTS
PAGE
SPECIFICATIONS .........................................................................................................................................8
GENERAL DESCRIPTION ............................................................................................................................8
DESIGN FEATURES .....................................................................................................................................8
RECOMMENDED WIRE FEEDERS AND ACCESSORIES ..........................................................................8
INSTALLATION INSTRUCTIONS
Safety Precautions...............................................................................................................................9
Machine Grounding..............................................................................................................................9
Assembly into Engine Driven Welders
Classic Series (K6090-5, K1406-3 and -4, K1428-2, K1433-1, K1643-1, K1754-1), K1643-3, K1643-5,
K1643-7, K1643-9
Pipeliner Series (K6090-7 and -9), K6090-10, K6090-11
SA-250 (K1283-4 & -8) or 350SA (K1314-4), SAE-300 (K3003-1)
Pre-Installation ........................................................................................................................9
Tools Required........................................................................................................................9
Assemble into Classic Series Pipeliner, SA-250 and 350SA Installation Sequence (Codes 10066, 10914) ...........10 thru 15
Assemble into SAE-300 Installation Sequence (Code11806) ..................................................................................16 thru 18
Connection of Lincoln Electric Wire Feeders ......................................................................................19
Connection of the LN-25 to the Wire Feed Module................................................................19
Connection of the LN-7, LN-7 GMA to the Wire Feed Module...............................................19
Connection of the LN-23P to the Wire Feed Module .............................................................19
..........................................................9
vi
OPERATING INSTRUCTIONS
Additional Safety Precautions .............................................................................................................20
Wire Feed Module Operation..............................................................................................................20
Output ........................................................................................................................................20
Controls ........................................................................................................................................20
Recommended Processes............................................................................................................20
MAINTENANCE
Engine Speed Adjustments.................................................................................................................20
TROUBLESHOOTING
Troubleshooting Chart ..................................................................................................................20 thru 22
Troubleshooting Procedures.........................................................................................................23 thru 25
DIAGRAMS
Wire Feed Module Wiring Diagram.....................................................................................................26
Wire Feed Module / Engine Welder - Connection Diagram ................................................................27
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to LN-23P w/ Adapter kit
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K867 Plug to LN-7
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K864 Adapter to LN-7 & Remote Control
Connection Diagram-All Classic, All Pipeliner, SA-250, 350SA & SAE-300 w/WFM to K867 Universal Adapter
Connection Diagram-All Classic, All Pipeliner, SA-250, 350SA & SAE-300 w/WFM to LN-25 w/ K444-2 Option
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K867 Plug to K487 / K488 / K492 Spool Gun
,
350SA & SAE-300 w/WFM to LN-25 w/ K431, K433 & K432-”L” Option .............................
...........28
...............29
..........................
.................31
.................32
....................
30
33
34
OUTPUT CURVES
Classic I, Pipeliner 200D and 200G with Wire Feed Module Output Curves ......................................35
Classic II with Wire Feed Module Output Curves ...............................................................................36
Classic III and 300G with Wire Feed Module Output Curves..............................................................37
Classic IIID, Classic 300D, SA250 & SAE-300 (Codes 10890 & above) with Wire Feed Module Output Curves
350SA and SA-250 (Codes 10889 and below ) Perkins with Wire Feed Module Output Curves ......39
PARTS LIST..................................................................................................................................P-231 Series
..................38
Classic I
Pipeliner 200G
Pipeliner 200D
Classic II
SA250
350SA
(International)
Classic III
Classic IIID
Classic 300D
SAE-300
Classic 300G
SPECIFICATIONS
C
K623-1 Wire Feed
Module to be Field-
Installed
On: (1)
K6090-6
K6090-5 (CSA)
K6090-7
K6090-9,-10,11(CSA)
K1406-4
K1406-3 (CSA)
K1283-4 (CSA)
K1283-8 (CSA)
K1314-4 (CSA)
K1428-2 (CSA)
K1433-1 (CSA)
K1643-1 (CSA)
K1643-3 (CSA)
K1643-5 (CSA)
K1643-7 (CSA)
K1643-9 (CSA)
K3003-1 (CSA)
K1754-1
Factory-Installed
Wire Feed Module
& Welder Per:
Not Available
K1406-6
K1406-5 (CSA)
K1283-5 (CSA)
Not Available
K1314-5 (CSA)
K1428-3 (CSA)
K1433-2 (CSA)
K1643-2 (CSA)
K1643-4 (CSA)
K1643-6 (CSA)
K1643-8 (CSA)
K1643-10 (CSA)
Not Available
Not Available
Rating @ 60%
Duty Cycle
200 Amps
@ 35V
250 Amps
@ 35V
300 Amps
@ 35V
250 Amps
@ 35V
300 Amps
@ 35V
Max. Output
@ 35% Duty
Cycle
250 Amps
@ 30V
310 Amps
@ 32V
325 Amps
@ 34V
310 Amps
@ 32V
325 Amps
@ 34V
Auxiliary
Power
Auxiliary Power
is Reduced 25%
in the CV Mode
(1) K623-1 Wire Feed Module can only be installed on welders with code 10061 and above.
GENERAL DESCRIPTION
The Wire Feed Module (WFM) is an additional output
control device designed to be easily installed into the
Classic
the SA-250 Perkins or 350SA Perkins engine driven
welders (with code 10061 and above). The WFM
modifies the dynamic output characteristics of the
welder to provide excellent voltage control for semiautomatic wire electrode welding and other open arc
processes. With the module installed, the welder can
be easily set to operate in either the constant voltage
or the standard constant current modes. The constant
voltage mode is adjusted with the controls conveniently mounted on the control panel or with an optional
remote control. The main module contains a capacitor
bank, electronic control circuit and a “COLD TIP” contactor. This module easily attaches to the welders fuel
tank support. Field installation takes approximately 60
minutes.
®
and Pipeliner Series of Engine Welders or
DESIGN FEATURES
• Easy access to the controls located on the welder
control panel.
• Greatly enhanced welding arc performance. Now a
wider range of wire electrodes and processes are
supported by this device.
• Improved arc starting characteristics.
• Low spatter MIG welding with CO2Gas.
• Built into the WFM is a power contactor that provides a “COLD” electrode when the gun trigger is
released.
• Simplified field installation process. All control wiring
connections between the welder, the control panel,
and the WFM are easily made with in-line plug type
connections.
• Includes thermostatic protection to protect the
welder from over current and over temperature.
RECOMMENDED WIRE FEEDERS
AND ACCESSORIES
The WFM is designed to work with the complete
family of LN-7, LN-25, and LN-23P wire feeders.
Please refer to the connection diagram in the back of
this manual for details.
– 8 –
INSTALLATION INSTRUCTIONS
Safety Precautions
WARNING
Do not attempt to use this equipment until you
have thoroughly read all operating and maintenance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.
Have a qualified technician do the maintenance
and troubleshooting work. Turn engine off before
working inside the machine. In some cases it may
be necessary to remove safety guards to perform
required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring removal is complete. Always use
the greatest care when working near moving
parts.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
Only qualified personnel should install, use, or
service this equipment.
------------------------------------------------------------------------
Machine Grounding
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 code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a
solid earth ground such as a metal water pipe going
into the ground for at least 10 feet and having no insulated joints or to the metal framework of a building
which has been effectively grounded. The U.S.
National Electrical Code lists a number of alternate
means of grounding electrical equipment. A machine
grounding stud marked with the symbol is provided
on the Generator Mount of the welder.
ASSEMBLY INTO ENGINE DRIVEN WELDERS:
CLASSIC SERIES
(K6090-5, K1406-3, -4,
K1428-2, K1433-1, K1643-1, -3, -5, -7, -9, K1754-1)
Pipeliner (K6090-7, -9, -10, -11) and
SA-250 (K1283-4, -8) or 350SA (K1314-4).
SAE-300 (K3003-1
Pre Installation
Unpack WFM and check the contents against the
listed items.
ITEM DESCRIPTION QTY.
1 Control Module Assembly 1
2 Control Panel Assembly 1
3 CV Negative Output Panel Assembly 1
4 Mounting Hardware Packet 1
5 Instruction Manual and Literature 1
6 WFM Nameplate SAE-300
1
Because a portable engine driven welder or generator
creates its own power, it is not necessary to connect
its frame to an earth ground, unless the machine is
connected to premises wiring (your home, shop, etc.)
To prevent dangerous electric shock, other equipment
to which an engine driven welder supplies power
must:
a) Be grounded to the frame of the welder using a
grounded type plug,
or
b) Be double insulated.
When a welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle.
Tools Required
• Large and Small Flat Head Screwdriver
• Pliers
• 3/32” Allen Wrench
• 3/8” Drive Ratchet with Small Extension
• 1/2” Socket
• 9/16” Deep Well Socket
• 3/4” Socket
• 5/16” Nut Driver and Socket
• 1/2” Open End Wrench
• 9/16” Open End Wrench
• Voltmeter
– 9 –
ASSEMBLE INTO
PIPELINER, SA-250 and 350SA
CLASSIC SERIES
INSTALLA-
TION SEQUENCE:
(For codes 10066, 10914)
1) Remove current range selector and fine current
adjustment control knobs from front of machine.
(small flat screwdriver and 3/32” Allen wrench.)
2) Remove 5 upper nameplate screws, or fastener
buttons.
3) Break-off upper half of machine nameplate.
Nameplate is scored for easy bending and breakoff.
4) Install control panel assembly. (Wiring connections will be made later).
5) Secure control panel assembly with (7) screws
from the mounting hardware packet.(5/16” Nut
Driver)
6) Reinstall current range selector and fine current
adjustment control knobs to front of machine.
(Small flat screwdriver and 3/32” Allen wrench).
7) (For Classic II models ONLY
panel. (3/8” Socket wrench).
) Remove the side
– 10 –
8) Remove 2 screws from brush wraparound cover.
Loosen and rotate the wraparound cover until negative brushholder is exposed. (Large flat head
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” bolt. (1/2”
Socket, ratchet, and small extension.)
10) (NOTE
Classic I, you must change the “250H” thermostat
to the thermostat marked “200”, (provided in the
mounting hardware packet). Make certain the nut
and bolt is tightened and the 608 and 609 leads
are connected to the thermostat. (1/2” Socket,
ratchet, and 1/2” open end.)
11) Position Wire Feed Module control box next to
the right side of the machine (as shown). Place
one plain washer (provided in the mounting hardware packet) over each mounting stud.
:) If you are installing the WFM on the
– 11 –
12) Feed power cable assembly through the rectangular 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 the brushholder spring and the cable is
clear of any moving parts. Make certain the thermostat is assembled under the cable connections. (1/2” socket, ratchet, small extension).
14) Reposition the brush wraparound cover and
tighten with the hardware removed in step 8.
Keep the tightening flanges below the 3:00
position. (Large flat head screwdriver and pliers.)
– 12 –
15) Locate and remove 12-pin jumper plug and install
12-pin connector from control box to 12-pin connector. Connect control box 6-pin connector to
control panel 6-pin connector. Connect control
box 9-pin connector to control panel 9-pin connector.
For Classic 300D with Codes (11547, 11548,
11572, 11573) and Pipeliner 200D Code 11591.
Remove U (BLUE) and 602C wires from flyback
bridge. See machine wiring diagram. Keep U and
602C lead terminals connected and insulate with
electrical tape.
16) For Classic I, III, IIID, 300D, 300G and SA250
(Codes 10889 and Below), 350 SA, Pipeliner
200D and 200G remove two (2) fuel tank hold
down bolts on the right side of the machine and
save hardware. (9/16” deep well socket, ratchet,
and 9/16” open end wrench.) For the Classic II
and SA250 (Codes 10890 and Above), do not
remove the fuel tank hold down bolts. On these
machines, the WFM mounts to the adjacent holes
with two (2) 1” spacers, flat washer, lock washer
and hex nuts, (provided in the mounting hardware
packet).
17) For the Classic I & III, the carburetor choke cable
must be unclamped at the frame. Reclamp at the
flange provided on the WFM.
– 13 –
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. (9/16”
Socket, ratchet, and 9/16” open end wrench).
20) Remove both the positive and negative output
terminal bolts. (3/4” Socket wrench).
NOTE: On the Classic II machines, the weld output terminals are located on the right side (facing
the control panel) of the machine under the side
access door. On all other machines the weld output terminals are located on the left side (facing
the control panel) of the machine under the left
access door.
21) Using bolts from step 20, connect control boxʼs
positive and negative power cables and
machineʼs positive and negative output cables to
the respective output terminals. Tighten bolts.
(3/4” Socket wrench).
NOTE: Use caution when routing the CV power
cables; ensure that there is adequate clearance
from any sharp surfaces.
22) Connect the remaining lead from the control box
to CV output terminal, using bolt supplied with the
output terminal assembly. Output panel leg attaches to the front of the machine (3/4” Socket
wrench).
– 14 –
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