Lincoln Electric WELD-PAK 100 IMT460-D manual

W W E E L L D D - - P P A A K K 1 1 0 0 0 0 IMT460-D January , 2010 22801 St. Clair A ve. Cleveland, Ohio 441 17-1 199 U.S.A. T el. (216) 481-8100 WEB SITE: www.lincolnelectric.com Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper inst[...]

2 ARC WELDING CAN BE HAZARDOUS. PROTECT YOUR- SELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEA TH. KEEP CHILDREN AW A Y . P ACEMAKER WEAR- ERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safet[...]

3 ELECTRIC AND MAGNE TIC FIELDS may be dangerous 3.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and weldingmachines 3.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician befor[...]

4 SAFETY SEGURIDAD SÉCURITÉ WELDING SP ARKS can cause fire or explosion. 4.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid weldin[...]

5 E L E C T R I C S H O C K c a n k i l l . 5.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 cloth- ing. Wear dry , hole-free gloves to insulate hands. 5.b. Insulate yourself from work and ground using dry insulation. Make certain the ins[...]

6 FUMES AND GASES can be dangerous. 6.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 ventila- tion and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with elec- trodes which require special ventilation[...]

CYLINDER may explode if damaged. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operat- ing 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 posi[...]

8 Read the entire manual before installing and operating the WELD-P AK ELECTRIC SHOCK can kill. • Only qualified personnel should installation or operate this equipment. • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The WELD-PAK power switch is to be in the OFF (?[...]

9 TECHNICAL SPECIFICA TIONS ESPECIFICACIONES TÉCNICAS Fuse Size Input Amps Power Cord 20 Amp 20 15 Amp, 125V Three Prong Plug (NEMA T ype 5-15P) 15 Amp 12 15 Amp, 125V Three Prong Plug (NEMA T ype 5-15P) Extension Cord Up to 25 Ft. (7.6 mm): Three Conductor #14 A WG (2.1 mm 2 ) or Larger Up to 50 Ft. (15.2 mm): Three Conductor #12 AWG (3.3 mm 2 ) [...]

10 IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the Weld-Pak from its carton and remove all packing material around the WELD- P AK. Remove the following loose items from the carton): INST ALLA TION IDENTIFIQUE Y LOCALICE LOS COMPONENTES Si aún no lo ha hecho, desempaque la Weld-Pak y retire todo el material de empaque. S[...]

11 LOCA TION Locate the welder on a secure level surface in a dry location. Locate where there is free circulation of clean air . Blocked air passages can cause overheating. WORK CLAMP INST ALLA TION Attach the work clamp to the work cable by inserting the cable end with the larger terminal lug hole through the strain relief hole in the clamp. Asse[...]

12 GUN INST ALLA TION 1. Refer to Figure 1. Unplug the machine or turn power switch to the off “O” position. 2. Pass the insulated terminals of the gun trigger control leads, one at a time, through the Gun Cable and Control Lead Access Slot (2) in the case front. The leads are to be routed under the Wire Feed Gearbox (6) and through the Cable H[...]

13 INPUT POWER CONNECTIONS FOR RA TED OUTPUT • This welding machine must be connected to power source in accordance with applicable electrical codes. • If there is any question about the installation meeting applicable electrical code requirements, consult a qualified electrician. • Do not connect the WELD-P AK to an input power sup- ply with[...]

14 CYLINDER may explode if damaged. Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live electri- cal circuits. BUILDUP OF SHIELDING GAS may harm hea[...]

15 CONTROLS AND SETTINGS Refer to the case front t of the WELD-PAK. 1. Power ON/OFF Switch — When the power is on the fan motor will run and air will be exhausted out the louvers in the front of the machine. The welding output and wire feed- er remain off until the gun trigger is pressed. 2. Wire Speed Control — Controls the wire feed speed fro[...]

16 WELDING SEQUENCE OF OPERA TION WIRE LOADING 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” (100 mm) diameter spools. A 4" (100 mm) diameter spool is mounted directly on the 5/8" (16 mm) diameter spindle tha[...]

17 Note: The brake should be adjusted with a spool of wire installed. When properly adjusted it should move freely but not coast. FRICTION BRAKE ADJUSTMENT 1. With wire spool installed, check free movement and coast of the spool. 2. T o tighten the brake turn the wing nut clockwise in 1/4 turn increments until coasting stops. 3. T o loosen the brak[...]

18 5. Close the idle roll arm and latch the spring loaded pres- sure arm (2) in place . Rotate the spool counterclock- wise if required in order to take up extra slack in the wire. 6. The idle roll pressure adjustment wing nut is normally set for mid-position on the pressure arm threads. If feed- ing problems occur because the wire is flattened exc[...]

19 7. Remove gas nozzle and contact tip from end of gun. 8. T urn the WELD-P AK ON (“I”). 9. Straighten the gun cable assembly . 10. Depress the gun trigger switch and feed welding wire through the gun and cable. (Point gun away from your- self and others while feeding wire.) Release gun trigger after wire appears at end of gun. 1 1. Turn the W[...]

20 4. Connect work clamp to metal to be welded. Work clamp must make good electrical contact to the workpiece. The workpiece must also be grounded as stated in “Arc Welding Safety Precautions” in the beginning of this manual. 5. Position gun over joint. End of wire may be lightly touch - ing the work. 6. Lower welding helmet, close gun trigger [...]

21 PROCESS GUIDELINES Refer to the Application chart on the inside of the wire feed compartment door for information on setting the WELD-P AK for mild steel. The WELD-P AK is also suitable for .035" aluminum wire and .030" stainless wire. Refer the T able below for recommended procedure settings. (Requires K610-1 MIG Conversion Kit and K6[...]

22 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 welding and develop this skill. For more detailed information, order a copy of “New Lessons in Arc Welding” listed at the end of this manual. THE ARC-WELDING CIRCUIT The[...]

23 Fumes and slag generated from Innershield type electrodes recom- mended for use with this welding machine can be toxic. • A void contact with eyes and skin. • Do not take internally . • Keep out of reach of children. • Follow all safety precautions found in this operating manual. ----------------------------------------------------------[...]

24 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 well as hot, and cannot be looke[...]

25 When comparing the GMAW and FCA W processes, you can see that the principal difference between the two lies in the type of shielding used. GMAW uses gas for shielding, thus we have Gas Metal Arc Welding. FCA W uses the melting or burning of the core ingredients for shielding, and is thus termed Self-Shielded Flux Cored Arc Welding. The recommend[...]

26 For FCAW (Innershield) Process 1. Do I want simplicity and portability? 2. Will welding be performed outdoors or under windy con- ditions? 3. Do I require good all position welding capability? 4. Will most welding be performed on 16 gauge and heav- ier , somewhat rusty or dirty materials? 5. Weld must be cleaned prior to painting. COMMON MET ALS[...]

27 Butt Welds Place two plates side by side, leaving a space approximate- ly one half the thickness of the metal between them in order to get deeper penetration. Securely clamp or tack weld the plates at both ends, other- wise the heat will cause the plates to move apart. See Figure 8. Now weld the two plates together. Weld from left to right (if r[...]

28 Fillet Welds When welding fillet welds, it is very important to hold the wire electrode at a 45° angle between the two sides or the metal will not distribute itself evenly . The gun nozzle is generally formed at an angle to facilitate this. See Figure 1 1. FIGURE 11 Welding In The V ertical Position Welding in the vertical position can be done [...]

29 FIGURE 12 V ertical-down Welding Refer to Figure 13 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. V ertical-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 [...]

30 WELDING TECHNIQUES FOR THE SELF-SHIELDED FCA W PROCESS Four simple manipulations are of prime importance when welding. With complete mastery of the four , welding will be easy . They are as follows: 1. The Correct Welding Position Figure 14 illustrates the correct welding position for right handed people. (For left handed people, it is the oppo-[...]

31 3. The Correct Contact Tip to Work Distance(CTWD) The Contact Tip to Work (CTWD) is the distance from the end of the contact tip to the end of the wire. (See Figure 15.) Once the arc has been established, maintaining the cor- rect (CTWD) becomes extremely important. The (CTWD) should be approximately 3/8 to 1/2 inch (10 to 12 mm) long. FIGURE 15[...]

32 Helpful Hints 1. For general welding, it is not necessary to weave the arc. Weld along at a steady pace. Y ou will find it easier . 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereas when weld- ing on heavy plate, it is necessary to go more slowly in order to get good penetration. 3. When weldi[...]

33 4. After you strike the arc, practice the correct contact tip to work distance. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electri- cal stickout, with a smooth “crackling” arc start moving. Look at the molten puddle constantly , and look at the “ridge” where the metal solidifies. 6. Run beads[...]

When using the GMAW process on light gauge material, weld from right to left (if you are right handed). This results in a colder weld and has less tendency for burn through. 2. The Correct W ay T o Strike An Arc 1. Be sure the work clamp makes good electrical con- tact to the work. 2. Position gun over joint. End of wire may be lightly touching the[...]

35 4. The Correct Welding Speed The important thing to watch while welding is the puddle of molten metal right behind the arc. See Figure 21. Do not watch the arc itself. It is the appearance of the pud- dle and the ridge where the molten Puddle solidifies that indicates correct welding speed. The ridge should be approximately 3/8” (10 mm) behind[...]

36 Practice The best way of getting practice is to perform the following exercise. Refer to Figure 18. 1. Learn to strike an arc by positioning the gun over the joint and touching the wire to the work. 2. Position face shield to protect face and eyes. 3. Depress gun trigger , hold gun so contact tip to work dis- tance Is about 3/8 to 1/2 inch (10 t[...]

37 TROUBLESHOOTING WELDS Good welds have excellent appearance. T o Eliminate Porosity (in order of importance): 1. T urn 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 moisture, oil, rust, paint or oth[...]

38 T o Reduce Spatter (in order of importance): 1. Increase voltage. 2. Increase drag angle. 3. Decrease stickout. 4. Increase WFS (wire feed speed). 5. Decrease travel speed. 6. Check for correct gas, if used. T o Correct Poor Penetration (in order of importance): 1. Decrease stickout. 2. Increase WFS (wire feed speed). 3. Increase voltage. 4. Dec[...]

39 OPTIONAL ACCESSORIES 1. K520 Utility Cart — Designed to transport the Lincoln family of small welders. Has provisions for mounting a single gas cylinder . Has front casters and large rear wheels. Handle height is easily adjustable. Bottom tray provided for tools and accessories. Easy assembly required; takes less than 15 minutes. 2. M15445 Spi[...]

40 1. Install the gas solenoid. Complete instructions are includ - ed with the kit. 2. Change the output polarity to DC(+). See “Work Cable Installation” in Installation section for details. 3. Change drive roll orientation (if required) for the wire size selected. See “Changing Drive Roll” in Maintenance sec- tion for details. 4. Install t[...]

41 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by remov- ing plug from receptacle before working inside WELD-P AK. Use only grounded receptacle. Do not touch electrically “hot” parts inside WELD-P AK. • Have qualified personnel do the maintenance and trouble shooting work. -------------------------------------------[...]

42 GUN AND CABLE MAINTENANCE Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor . Remove the contact tip from the gun. Using low pressure air , gently blow out the cable liner from the gas diffu[...]

43 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 .023" – .025"[...]

44 CHANGING LINER NOTICE: The variation in cable lengths prevents the inter- changeability of liners. Once a liner has been cut for a par- ticular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure below . 1. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 2. Re[...]

45 No wire feed, weld output or gas flow when gun trig- ger is pulled. Fan does NOT operate. 1. Make sure correct voltage is applied to the machine. 2. Make certain that power switch is in the ON position. 3. Make sure circuit breaker inside wire drive com- partment is reset. No wire feed, weld output or gas flow when gun trig- ger is pulled Fan op[...]

46 Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally . (Optional MIG Conversion Kit only .) 1. V erify that gas solenoid is properly installed. Refer to instructions included with MIG conver- sion kit. 2. Check gas supply , flow regulator and gas hoses. 3. Check gun connection to machine for obstruc- tio[...]

47 1 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. NOT A: Ce schéma n'est donné qu'à titre de référence. Il peut ne pas être exact pour toutes les machines traitées dan[...]

48 P ARTS P ARTES PIÈCES Part Description Descripción de las partes Désignation des pièces Part Number V oltage Control Switch Assembly Ensamble del Interruptor de Control de V oltaje Sélecteur de tension M15750 Knob (Voltage Switch) Perilla (Interruptor de Voltaje) Bouton (sélecteur de tension) M15796 Line Switch Interruptor de Línea Interr[...]

49 NOTES-NOT AS[...]

50 W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic ● Do not tou ch e lec tri cal ly liv e pa rts or el ect rod e w ith ski n or wet clo thi ng. ● Insul ate you rself from work an d groun d. ● No t oque las par tes o l os ele ctro dos bajo ca rga con la piel o ropa mo[...]

51 W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic ● T urn powe r off befo re servici ng. ● Desco necta r el cable de ali- menta ción de poder de la má quina antes de inicia r cualq uier servi cio. ● Débra nchez le couran t avant l’ entre - tien. ● Strom vor W[...]

World's Leader in Welding and Cutting Products[...]