Lincoln-electric WELD-PACK 100 PLUS IM546 User Manual

WELD-PAK 100 PLUSOPERATOR’S MANUALIM546September,1999Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in

A-2INSTALLATIONWELD-PAK 100 JAN96Read entire installation section before startinginstallation.SAFETY PRECAUTIONSIDENTIFY AND LOCATECOMPONENTSIf you ha

A-3INSTALLATIONWELD-PAK 100SELECT SUITABLE LOCATIONLocate the welder in a dry location where there is freecirculation of clean air into the louvers in

1243 A-4INSTALLATIONWELD-PAK 100Work Cable InstallationRefer to Figure A.2.1. Open the wire feed section door on the right side ofthe WELD-PAK 100.2

A-5INSTALLATIONWELD-PAK 1002. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylin

A-6INSTALLATIONWELD-PAK 100INPUT CONNECTIONSFIGURE A.6Refer to Figure A.6.The WELD-PAK 100 has a power input cable locatedon the rear of the machine.C

WELD-PAK 100B-1OPERATIONRead entire operation section beforeoperating the WELD-PAK 100.ELECTRIC SHOCK can kill.• Do not touch electrically liveparts o

WELD-PAK 100 JAN96B-2OPERATIONGENERAL DESCRIPTIONThe WELD-PAK 100 is a compact lightweight DC wirefeeder/power source. It has been designed for work-s

WELD-PAK 100B-3OPERATIONout when tripped (Manual reset).FIGURE B.1aFIGURE B.1bWELDING OPERATIONSSEQUENCE OF OPERATIONWire LoadingRefer to Figure B.2 A

WELD-PAK 100B-4OPERATIONFriction Brake Adjustment1. With wire spool installed, check free movementand coast of the spool.2. To tighten the brake turn

WELD-PAK 100B-5OPERATION100 is now ready to weld.Making A Weld1. See “Process Guidelines” in this section for selec-tion of welding wire and shielding

iSAFETYWELD-PAK 100PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR D

WELD-PAK 100B-6OPERATIONthinner, CO2gas is recommended because it givesequal or better performance than a blended gas at alower cost. A mixed gas cons

WELD-PAK 100B-7LEARNING TO WELDLEARNING TO WELDNo one can learn to weld simply by reading about it.Skill comes only with practice. The following pages

WELD-PAK 100B-8LEARNING TO WELDThe “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing t

WELD-PAK 100B-9LEARNING TO WELD2. Can I afford the extra expense, space, and lack ofportability required for gas cylinders and gas sup-ply?3. Do I req

WELD-PAK 100B-10LEARNING TO WELDARC RAYS can burn eyes and skin.When using an open arc process, itIs necessary to use correct eye,head and body protec

WELD-PAK 100B-11LEARNING TO WELDHelpful Hints1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Wel

WELD-PAK 100B-12LEARNING TO WELDMACHINE SET UP FOR THE GMAW (MIG)PROCESS1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wir

WELD-PAK 100B-13LEARNING TO WELDFIGURE B.173. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the co

WELD-PAK 100B-14LEARNING TO WELD4. After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound.5. When y

FIGURE B.24Vertical-down WeldingRefer to Figure B.25 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, a

iiWELD-PAK 100SAFETYFOR ELECTRICALLYpowered equipment.6.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipm

WELD-PAK 100B-16LEARNING TO WELDTROUBLESHOOTING WELDSGood welds have excellent appearance.To Eliminate Porosity (in order of importance):1. Turn on ga

WELD-PAK 100B-17LEARNING TO WELDProper Gun HandlingMost feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kin

WELD-PAK 100B-18APPLICATION CHART

C-1ACCESSORIESWELD-PAK 1003. Change drive roll orientation (if required)for the wire size selected. See “ChangingDrive Roll” in Maintenance section fo

C-2NOTESWELD-PAK 100

D-1MAINTENANCEWELD-PAK 100MAINTENANCESAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power by removingplug from receptacle before working

D-2MAINTENANCEWELD-PAK 1005. To remove gun tube from gun, removegas nozzle or gasless nozzle andremove diffuser from gun tube. Removeboth collars from

D-3MAINTENANCEWELD-PAK 100CHANGING DRIVE ROLLThe drive roll has two grooves; one for .023"– .025" (0.6 mm) solid steel electrode and alarger

D-4MAINTENANCEWELD-PAK 100CHANGING LINERNOTICE: The variation in cable lengths pre-vents the interchangeability of liners. Oncea liner has been cut fo

D-5MAINTENANCEWELD-PAK 100GUN HANDLE PARTSThe gun handle consists of two halves thatare held together with a collar on each end.To open up the handle,

iiiSAFETYWELD-PAK 100Mar. ʻ93ELECTRIC AND MAGNETICFIELDSmay be dangerous8.a. Electric current flowing through any conductor causeslocalized Electric a

D-6NOTESWELD-PAK 100

E-1TROUBLESHOOTINGWELD-PAK 100This Troubleshooting Guide is provided tohelp you locate and remedy possible prob-lems with machine setup or operation.S

E-2TROUBLESHOOTINGWELD-PAK 100Observe Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEPROBLEMS(SYMPTOMS)Major physical

E-3TROUBLESHOOTINGWELD-PAK 100TROUBLESHOOTING GUIDEObserve Safety Guidelinesdetailed in the beginning of this manual.PROBLEMS(SYMPTOMS)No wire feed wh

E-4TROUBLESHOOTINGWELD-PAK 100Observe Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEIf for any reason you do not unde

F-1WIRING DIAGRAMSWELD-PAK 100WELD-PAK 100 WIRING DIAGRAMS1SWITCHD1D3D2D4204204204203203203C159,000 mf40V203204-+GUN CABLECONDUCTORBLOCKTOWORKELECTRIC

F-2NOTESWELD-PAK 100

NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List.WELD-PAK 100WELD-

WELD-PAK 100NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List.2PART

WELD-PAK 100NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List.3PART

ivSAFETYWELD-PAK 100PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiqu

WELD-PAK 100NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List.4PART

WELD-PAK 100NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List.5PART

WELD-PAK 100NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List.6PART

WELD-PAK 100NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List.7PART

WELD-PAK 100NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List.8PART

NOTESSQUARE WAVE TIG 255

NOTESSQUARE WAVE TIG 255

Now Available...12th EditionThe Procedure Handbook of Arc WeldingWith over 500,000 copies of previous editions publishedsince 1933, the Procedure Hand

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

19WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANT

vWELD-PAK 100Thank Youfor selecting a QUALITY product by Lincoln Electric.We want you to take pride in operating this LincolnElectric Company product

STATEMENT OF LIMITED WARRANTYThe Lincoln Electric Company (Lincoln) warrants to theend user (purchaser) of all new welding and cutting equip-ment, ele

viFEB 95 WELD-PAK 100MASTER TABLE OF CONTENTS FOR ALL SECTIONSPageInstallation ...

WELD-PAK 100vii

Fuse orOutput Mode Input Voltage Breaker Size Input Amps Power Cord Extension CordRATED 115V/60Hz 20 Amp 20 15 Amp, 125V,Three ConductorThree Prong Pl