Lincoln Electric WELD-PACK 100 PLUS IM546 manual

WELD-P AK 100 PLUS OPERA TOR’S MANUAL IM546 September,1999 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 thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THI[...]

i SAFETY WELD-PAK 100 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 pur- chase a copy of “Safety in Welding & [...]

ii WELD-PAK 100 SAFETY FOR ELECTRICALL Y powered equipment. 6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 6 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 6.c. Ground the equipment in accordance with the U.[...]

iii SAFETY WELD-PAK 100 Mar. ʻ93 ELECTRIC AND MAGNETIC FIELDS may be dangerous 8.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 8 .b . EMF fields may interfere with some pacemakers, and welders having a pacemaker sh[...]

iv SAFETY WELD-PAK 100 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions 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 c[...]

v WELD-PAK 100 Thank Y ou 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! Read this Operatorʼs Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick [...]

vi FEB 95 WELD-PAK 100 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components .....[...]

WELD-PAK 100 vii[...]

Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor Three Prong Plug #14 AWG (NEMA Type 5-15P) (2.1 mm 2 ) or Larger Up to 25 Ft. (7.6 mm) CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, Three Conductor Three Prong Plug #12 AWG (NEMA Type 5-15P) (3.3 mm 2 ) or Larger Up t[...]

A-2 INST ALLA TION WELD-PAK 100 JAN96 Read entire installation section before starting installation. SAFETY PRECAUTIONS IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the Weld-Pak 100 from its carton and remove all packing material around the WELD-PAK 100. Remove the following loose items from the carton (see Figure A.1): 1[...]

A-3 INST ALLA TION WELD-PAK 100 SELECT SUIT ABLE LOCA TION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages[...]

1 2 4 3 A-4 INST ALLA TION WELD-PAK 100 Work Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the WELD-PAK 100. 2. Pass the end of the work cable that has the termi- nal lug with the smaller hole through the Work Cable Access Hole (1) in the case front. 3. Route the cable under and around the back of t[...]

A-5 INST ALLA TION WELD-PAK 100 2 . With the cylinder securely installed, remove the cylinder cap. Stand to one side away from the out- let and open the cylinder valve very slightly for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet. BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN “CRACKING?[...]

A-6 INST ALLA TION WELD-PAK 100 INPUT CONNECTIONS FIGURE A.6 Refer to Figure A.6. The WELD-PAK 100 has a power input cable located on the rear of the machine. CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to power source in accordance with applicable elec- trical codes. The United States National Electrical Code (Ar[...]

WELD-PAK 100 B-1 OPERA TION Read entire operation section before operating the WELD-P AK 100. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • [...]

WELD-PAK 100 JAN96 B-2 OPERA TION GENERAL DESCRIPTION The WELD-PAK 100 is a compact lightweight DC wire feeder/power source. It has been designed for work- shop, hobby, and light maintenance. It is capable of general purpose welding with self-shielded flux-cored (Innershield ® ) wire. When combined with the optional K610-1 MIG Conversion Kit, the [...]

WELD-PAK 100 B-3 OPERA TION out when tripped (Manual reset). FIGURE B.1a FIGURE B.1b WELDING OPERA TIONS SEQUENCE OF OPERA TION Wire Loading Refer to Figure B.2 AND B3. The machine power switch should be turned to the OFF (“O”) position before working inside the wire feed enclosure. The machine is shipped from the factory ready to feed 4” (10[...]

WELD-PAK 100 B-4 OPERA TION Friction Brake Adjustment 1 . With wire spool installed, check free movement and coast of the spool. 2. To tighten the brake turn the wing nut clockwise in 1/4 turn increments until coasting stops. 3 . To loosen the brake turn the wing nut counter- clockwise in 1/4 turn increments until the wire spool moves freely withou[...]

WELD-PAK 100 B-5 OPERA TION 100 is now ready to weld. Making A Weld 1. See “Process Guidelines” in this section for selec- tion of welding wire and shielding gas and for range of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on setting the WELD-PAK 100 controls[...]

WELD-PAK 100 B-6 OPERA TION thinner, CO 2 gas is recommended because it gives equal or better performance than a blended gas at a lower cost. A mixed gas consisting of 75 to 80% Argon and 20 to 25% CO 2 is recommended for welding on heavier gauge [12 gauge (2,5 mm) for example] steel. The WELD-PAK 100 is suitable for .035" aluminum wire and .0[...]

WELD-PAK 100 B-7 LEARNING T O WELD LEARNING T O WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand weld- ing and develop this skill. For more detailed informa- tion, order a copy of “New Lessons in Arc Welding” listed at the end of this[...]

WELD-PAK 100 B-8 LEARNING T O WELD The “arc stream” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000°F, which is more than enough to melt metal. The arc is very bright, as w[...]

WELD-PAK 100 B-9 LEARNING T O WELD 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the process for you. If you have answered no to any of the above questions, then you should c[...]

WELD-PAK 100 B-10 LEARNING T O WELD ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ARC RAYS can burn” at the front of this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work clamp makes good electrical contact to the w[...]

WELD-PAK 100 B-1 1 LEARNING T O WELD Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier. 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereas when welding on heavy plate, it is nec[...]

WELD-PAK 100 B-12 LEARNING T O WELD MACHINE SET UP FOR THE GMA W (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls. 3. Set[...]

WELD-PAK 100 B-13 LEARNING T O WELD FIGURE B.17 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire. See Figure B.17. Once the arc has been established, maintaining the correct ESO becomes extremely important. The ESO should be approximately 3/8 to 1/2 inch (1[...]

WELD-PAK 100 B-14 LEARNING T O WELD 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “crackling” arc, start moving. Look at the molten puddle constantly, 6. Run beads on a flat plate. Run them paral[...]

FIGURE B.24 Vertical-down Welding Refer to Figure B.25 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-down welds may be applied to 5/32” (3.9 mm) and lighter material. Use stringer beads and tip the gun in the direction of travel so the arc force h[...]

WELD-PAK 100 B-16 LEARNING T O WELD TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (in order of importance): 1. Turn on gas supply, if used 2. Decrease voltage. 3. Increase stickout. 4. Increase WFS (wire feed speed). 5. Decrease drag angle. 6. Decrease travel speed. NOTE: Always be sure the joint is free from moi[...]

WELD-PAK 100 B-17 LEARNING T O WELD Proper Gun Handling Most feeding problems are caused by improper han- dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding. 3. Do not allow dolly wheels or trucks to run over the cables. 4. Keep the cable clean. 5. In[...]

WELD-PAK 100 B-18 APPLICA TION CHART[...]

C-1 ACCESSORIES WELD-PAK 100 3. Change drive roll orientation (if required) for the wire size selected. See “Changing Drive Roll” in Maintenance section for details. 4. Install the proper gun liner and tip for the wire size selected. See “Component Replacement” in Maintenance section for details. 5. Remove gasless nozzle (if installed) and [...]

C-2 NOTES WELD-PAK 100[...]

D-1 MAINTENANCE WELD-PAK 100 MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside WELD-PAK 100. Use only ground- ed receptacle. Do not touch electrically “hot” parts inside WELD-PAK 100. • Have qualified personnel do the mainte- nance and trouble shooting wor[...]

D-2 MAINTENANCE WELD-PAK 100 5. To remove gun tube from gun, remove gas nozzle or gasless nozzle and remove diffuser from gun tube. Remove both collars from each end of the gun handle and separate the handle halves. Loosen the locking nut holding the gun tube in place against the gun end cable connector. Unscrew gun tube from cable connector. To in[...]

D-3 MAINTENANCE WELD-PAK 100 CHANGING DRIVE ROLL The drive roll has two grooves; one for .023" – .025" (0.6 mm) solid steel electrode and a larger knurled groove for .030" (0.8 mm) solid and .035" (0.9 mm) flux-cored steel electrode. As shipped, the drive roll is installed in the .030"/.035" (0.8/0.9 mm) position. If[...]

D-4 MAINTENANCE WELD-PAK 100 CHANGING LINER NOTICE: The variation in cable lengths pre- vents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure D.2. 1. Remove the gas nozzle from the gun by unscrewing cou[...]

D-5 MAINTENANCE WELD-PAK 100 GUN HANDLE P ARTS The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clock- wise until the collar reaches a stop. Then pull the collar off the gun handle. If the col- lars are difficult to turn, position the gun[...]

D-6 NOTES WELD-PAK 100[...]

E-1 TROUBLESHOOTING WELD-PAK 100 This Troubleshooting Guide is provided to help you locate and remedy possible prob- lems with machine setup or operation. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the m[...]

E-2 TROUBLESHOOTING WELD-PAK 100 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No wire feed, weld output or gas flow when gun trigger is pulled Fan op[...]

E-3 TROUBLESHOOTING WELD-PAK 100 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (32vcd maximum) – weld output. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. If the wire drive motor is run[...]

E-4 TROUBLESHOOTING WELD-PAK 100 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. CAUTION PRO[...]

F-1 WIRING DIAGRAMS WELD-PAK 100 WELD-P AK 100 WIRING DIAGRAM S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 mf 40V 203 204 - + GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 539 541 T1 213 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 (W) (B) N.C. N.C. COMPONENT VIEWED FR[...]

F-2 NOTES WELD-PAK 100[...]

NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln Electric Parts List. WELD-PAK 100 WELD-P AK 100 P ARTS MANUAL P ARTS[...]

WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln Electric Parts List. 2 P ARTS MAIN EXPLODED DIAGRAM[...]

WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln Electric Parts List. 3 P ARTS MAIN EXPLODED DIAGRAM 1 Case Back & Bottom Assembly, S20156-6 1 Includes 1a – 1g 1a Case Back & Bottom (Sheet Metal) NSS 1 1b Door Stop Button (if present) T14659-1 2 1c Hole Plug (La[...]

WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln Electric Parts List. 4 P ARTS COMPLETE DRIVE ASSEMBL Y/MOTOR Complete New Drive Assembly/ M15759-3 1 Motor, Includes All Items 1 – 10 below 1 Gearbox Mounting Plate L7829 1 1a Guide Tube Retainer S19127 2 1b Round Head Sc[...]

WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln Electric Parts List. 5 P ARTS CASE FRONT ASSEMBL Y 1 Molded Case Front A464 1 2 Nameplate M16930-1 1 3 Fastener Buttons T14659-1 4 4 On/Off Switch, Includes 4a T10800-32 1 4a Line Switch Mounting Bracket M15793 1 5 Wire Spe[...]

WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln Electric Parts List. 6 P ARTS RECTIFIER, F AN AND BRACKET ASSEMBL Y Complete Assembly, Includes L7680-2 1 Items 1 – 5 below 1 Bracket for Fan & Rectifier G1839 1 2 Rectifier Assembly (both sides M15447-1 1 with leads)[...]

WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln Electric Parts List. 7 P ARTS CENTER P ANEL ASSEMBL Y 2 Center Panel (Sheet Metal), L7569-8 1 Includes 2a – 2i, and Items 4, 5, 6 2a Center Panel (Sheet Metal) NSS 1 2b Slotted Hex Head Screw, #10-3/8" S8025-70 2 lon[...]

WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln Electric Parts List. 8 P ARTS MAGNUM 100L ASSEMBL Y ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 100L DESCRIPTION PART NUMBER SIZE COMPLETE GUN & CABLE ASSEMBLY L8311-3 (K530-3) 1. CABLE LINER M16291-1 .035 ?[...]

NOTES SQUARE WAVE TIG 255[...]

NOTES SQUARE WAVE TIG 255[...]

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W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

19 W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fu[...]

STATEMENT OF LIMITED WARRANTY The Lincoln Electric Company (Lincoln) warrants to the end user (purchaser) of all new welding and cutting equip- ment, electrode and flux (collectively called the “Goods”) that it will be free of defects in workmanship and material. This warranty is void if Lincoln or its Authorized Service Facility finds that the[...]