Lincoln Electric MAGNUM SG CONTROL MODULE, Operator'S Manual

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Product Description
The Magnum SG Control Module is an interface between the
welding power source and the Magnum Spool Gun. The
Control Module and Spool Gun combination provide a system for
welding primarily with aluminum electrode wire using a con-
stant voltage welding power source.
The Control Module provides control of both wire speed and
gas flow. It also provides connections from the welding power
cable, control cable, and gas hose from the power source and
gas cylinder regulator to the spool gun.
The Control Module will operate with any power source that
provides constant voltage welding output and has an output
contactor.
Specifications
Model: Magnum SG Control Module
Type: K488
Power Requirements: Voltage 115 VAC, 50/60 Hz
Current 0.5 amps maximum
Welding Current Rating: 250 amps at 60% duty cycle
Motor Output: 5-28 VDC
Preflow Time: 0-1 second
Contactor Circuit Output: Normally open relay contacts
(“Closure”) or 115 VAC; selectable
Dimensions, H* x W x D 10.0 x 8.25 x 9.0 inches
*dimension includes handle (254 x 210 x 229mm)
Weight 13 Lbs. (5.9kg)
Required Equipment
To operate the Magnum SG Control Module, the following
equipment is required and ordered separately: Optional Accessories
Several accessories are optionally available for use with the
K488 control module, and they are as follows:
1. Three 10 ft. (3.0m) input cable assemblies are available
and consist of control and electrode cables and gas line.
The proper input cable assembly must be ordered in addi-
tion to the control module; as none are included with the
control module:
A. K492-10 for use with Lincoln CV power sources
having terminal strip control connections (Lincoln
R3S, CV-400, and DC family machines). Can also
be used with non-Lincoln CV power sources.
B. K493-10 for use with Lincoln CV power sources
having 14-pin control cable connection (Lincoln CV
and CV-I series, Invertec V-200).
C. K691-10 for use with Lincoln engine-driven power
sources having 14-pin control cable connection
and/or 115VAC outlet.
2. K473 Spool Gun Extension Cable. 25’ extension cable
extends distance between spool gun and K488 control
module.
3. K518 Adapter for K469 Spool Gun. Adapts K469 spool
gun to K488 Control Module or to K473 Extension Cable.
K492-10 K493-10
Magnum Spool Gun
K487-25 or
K469-25 with K518
Adapter
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Power Source
The Control Module will operate with any Lincoln CV or CV/CC
power sources, with many Lincoln engine-driven welders (see
the complete list at the end of this section), and with many
non-Lincoln type power sources.
In general, power sources must have the following:
1. A constant voltage (CV) type welding output.
2. Capability to supply 115 volt AC power to the control
module.
3. Optional for “cold electrode” switched welding output: An
output contactor. It can be either of two types:
A. Switch closure: Internally-energized type actuated
by an external switch.
B. 115 VAC: Externally-energized type actuated by
115 volts AC supplied from the control module to
the power source.
A selector switch on the back of the control module is
used to select which of these two types of control circuit is
being used. It is imperative that this switch be set correctly
before attaching to the power source. See “Setting the
Mode Switch on Rear Panel” for more details.
The control module is not required when connecting Magnum
spool guns to Lincoln models SP-150 or SP-200, which have
built-in wire feed control circuits. In addition, the Lincoln models
SP-250, SP-255, Wire-Matic 250, Wire-Matic 255 do not
require the control module when the optional K607-1 or K672-1
Spool Gun Adapter kit is installed, since these kits also provide
wire feed control circuits.
For convenience, here is a summary of needed equipment to
use the various combinations of available Magnum spool guns
and accessories: