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WELD-PAK 100 PLUS
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
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
• 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
RETURN TO MAIN MENU
For use with machine Code Numbers
For use with machine Code Numbers
For use with machine Code Numbers
For use with machine Code Numbers
For use with machine Code Numbers
For use with machine Code Numbers
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
10207
and above
10023
10024
10025
10026
10134
IM546
September,1999
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric WELD-PAK 100 PLUS
Summary of Contents for Lincoln Electric WELD-PAK 100 PLUS
- Page 1 RETURN TO MAIN MENU IM546 WELD-PAK 100 PLUS September,1999 For use with machine Code Numbers 10207 and above 10023 For use with machine Code Numbers 10024 For use with machine Code Numbers 10025 For use with machine Code Numbers 10026...
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Page 2: Electric Shock Can Kill
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 PER- FORMED ONLY BY QUALIFIED INDIVIDUALS. - Page 3 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 4.a. Remove fire hazards from the welding area. 5.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 4 SAFETY ELECTRIC AND MAGNETIC FOR ENGINE powered equipment. FIELDS may be dangerous 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF).
- Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
- Page 6 QUALITY product by Lincoln Electric. Thank You 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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
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Page 7: Table Of Contents
MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................Section A Technical Specifications ..................A-1 Identify and Locate Components ................A-2 Select Suitable Location ..................A-3 Output Connections ....................A-3 Input Connections....................A-6 Code Requirements ....................A-6 Operation ......................Section B Safety Precautions ....................B-1 General Description ....................B-2 Design Features and Advantages..............B-2 Welding Capability ..................B-2 Limitations .......................B-2... - Page 8 WELD-PAK 100...
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Page 9: Installation
INSTALLATION TECHNICAL SPECIFICATIONS – WELD-PAK 100 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 115V/60Hz 20 Amps - Rated Output 115V/60Hz 15 Amps - CSA Rated output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20% Duty Cycle 20% Duty Cycle –... -
Page 10: Identify And Locate Components
INSTALLATION FIGURE A.1 Read entire installation section before starting installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and under- stood the WELD-PAK 100 Operating Manual should install and operate this equipment. -
Page 11: Select Suitable Location
INSTALLATION SELECT SUITABLE LOCATION Work Clamp Installation Attach the work clamp per the following: Refer to Locate the welder in a dry location where there is free Figure A-3. circulation of clean air into the louvers in the back and out the front of the unit. -
Page 12: Work Cable Installation
INSTALLATION Work Cable Installation appropriate size. Additionally, the .023 – .030" (0.6 – 0.8 mm) gun liner included in the K610-1 MIG Conversion Kit must be installed. Refer to the MAIN- Refer to Figure A.2. TENANCE section for contact tip installation details. 1. - Page 13 INSTALLATION 2. With the cylinder securely installed, remove the WARNING cylinder cap. Stand to one side away from the out- let and open the cylinder valve very slightly for an CYLINDER may explode if dam- instant. This blows away any dust or dirt which may aged.
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Page 14: Input Connections
INSTALLATION INPUT CONNECTIONS Requirements For Rated Output A power cord with a 15 amp, 125 volt, three prong FIGURE A.6 plug (NEMA Type 5-15P) is factory installed on the WELD-PAK 100. Connect this plug to a mating grounded receptacle which is connected to a 20 amp branch circuit with a nominal voltage rating of 115 to 125 volts, 60 Hertz, AC only. - Page 15 OPERATION Read entire operation section before operating the WELD-PAK 100. WARNING 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.
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Page 16: Operation
OPERATION ● GENERAL DESCRIPTION No external shielding gas is required when used ® with Lincoln Innershield .035” (0,9 mm) NR -211- The WELD-PAK 100 is a compact lightweight DC wire MP electrode. feeder/power source. It has been designed for work- ●... -
Page 17: Welding Operations
OPERATION out when tripped (Manual reset). Wire Spindle Shaft 4" Wire Spool Wing Nut WELD-PAK 100 WELD-PAK 100 and Spacer FIGURE B.2 to prevent overrun of the spool and excess slack in the wire. The wing nut at the end of the shaft is used to adjust the tension on the wire spool. - Page 18 OPERATION FIGURE B.4 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 without coasting.
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Page 19: Process Guidelines
OPERATION FIGURE B.6 NANCE section for details on nozzle replacement. 6. Refer to Figure B.7. Connect work clamp to metal to be welded. Work clamp must make good elec- trical contact to the workpiece. The workpiece must also be grounded as stated in “Arc Welding Contact Tip Safety Precautions”... -
Page 20: Overload Protection
OPERATION thinner, CO gas is recommended because it gives stops moving, open the valve fully. equal or better performance than a blended gas at a lower cost. A mixed gas consisting of 75 to 80% Argon 2. If using a regulator with an adjustable flow meter, and 20 to 25% CO is recommended for welding on close the gun trigger and adjust the flow to give 15... -
Page 21: Learning To Weld
LEARNING TO WELD LEARNING TO WELD WARNING No one can learn to weld simply by reading about it. Fumes and slag generated from Skill comes only with practice. The following pages will Innershield type electrodes recom- help the inexperienced operator to understand weld- mended for use with this welding ing and develop this skill. -
Page 22: Process Selection
LEARNING TO WELD The “arc stream” is seen in the middle of the picture. THE GMAW (MIG) WELDING ARC This is the electric arc created by the electric current flowing through the space between the end of the wire Figure B.10 illustrates the GMAW (MIG) welding arc. electrode and the base metal. -
Page 23: Common Metals
LEARNING TO WELD 2. Can I afford the extra expense, space, and lack of MACHINE SET UP FOR THE portability required for gas cylinders and gas sup- SELF-SHIELDED FCAW PROCESS ply? 1. See PROCESS GUIDELINES in the OPERATION 3. Do I require clean, finished-looking welds? section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be If you have answered yes to all the above questions... - Page 24 B-10 LEARNING TO WELD FIGURE B.11 FIGURE B.12 Contact Tip Wire Electrode 3/8 – 1/2” (10 – 12 mm) Electrical Stickout (ESO) WARNING ARC RAYS can burn eyes and skin. The easiest way to tell whether the ESO is the cor- When using an open arc process, it rect length is by listening to its sound.
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Page 25: Helpful Hints
B-11 LEARNING TO WELD Helpful Hints For the WELD-PAK 100, use the following: Mild Steel 12 gauge or 1/8 inch 1. For general welding, it is not necessary to weave (3.0 mm) the arc, neither forward or backward nor sideways. Weld along at a steady pace. - Page 26 B-12 LEARNING TO WELD MACHINE SET UP FOR THE GMAW (MIG) FIGURE B.16 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.
- Page 27 B-13 LEARNING TO WELD FIGURE B.17 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. Contact Tip 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 necessary to go Wire Electrode...
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Page 28: Joint Types And Positions
B-14 LEARNING TO WELD 4. After you strike the arc, practice the correct electri- Watch the molten metal to be sure it distributes itself cal stickout. Learn to distinguish it by its sound. evenly on both edges and in between the plates. 5. -
Page 29: Welding In The Vertical Position
B-15 LEARNING TO WELD FIGURE B.23 FIGURE B.24 45° PROPER GUN ANGLE PROPER GUN ANGLE FOR GMAW PROCESS FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION WELDING IN THE VERTICAL UP POSITION Welding In The Vertical Position Vertical-down Welding Refer to Figure B.25 Vertical-down welds are applied Welding in the vertical position can be done either ver- at a fast pace. -
Page 30: Troubleshooting Welds
B-16 LEARNING TO WELD TROUBLESHOOTING WELDS To Reduce Spatter (in order of importance): Good welds have excellent appearance. 1. Increase voltage. 2. Increase drag angle. 3. Decrease stickout. To Eliminate Porosity (in order of importance): 4. Increase WFS (wire feed speed). 5. - Page 31 B-17 LEARNING TO 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.
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Page 32: Application Chart
B-18 APPLICATION CHART WELD-PAK 100... -
Page 33: Accessories
ACCESSORIES OPTIONAL ACCESSORIES 3. Change drive roll orientation (if required) for the wire size selected. See “Changing 1. K520 Utility Cart — Designed to trans- Drive Roll” in Maintenance section for port the Lincoln family of small welders. details. Has provisions for mounting a single gas cylinder. - Page 34 NOTES WELD-PAK 100...
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Page 35: Maintenance
MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS WARNING 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 work. -
Page 36: Gun And Cable Maintenance
MAINTENANCE GUN AND CABLE 5. To remove gun tube from gun, remove gas nozzle or gasless nozzle and MAINTENANCE remove diffuser from gun tube. Remove both collars from each end of the gun FOR MAGNUM™ 100L GUN handle and separate the handle halves. Loosen the locking nut holding the gun Gun Cable Cleaning tube in place against the gun end cable... - Page 37 MAINTENANCE CHANGING DRIVE ROLL FIGURE D.1 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"...
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Page 38: Changing Liner
MAINTENANCE FIGURE D.2 CHANGING LINER Liner trim length NOTICE: The variation in cable lengths pre- 1-1/4 (31.8 mm) vents the interchangeability of liners. Once Liner Trim Length 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. -
Page 39: Gun Handle Parts
MAINTENANCE GUN HANDLE PARTS 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. - Page 40 NOTES WELD-PAK 100...
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Page 41: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 42: Troubleshooting Guide
3. Gun trigger may be faulty. CAUTION 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. WELD-PAK 100... - Page 43 CAUTION 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. WELD-PAK 100...
- Page 44 8. Check liner for proper size. CAUTION 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. WELD-PAK 100...
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Page 45: Wiring Diagrams
WIRING DIAGRAMS WELD-PAK 100 WIRING DIAGRAM 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. WELD-PAK 100... - Page 46 NOTES WELD-PAK 100...
- Page 47 PARTS WELD-PAK 100 PARTS MANUAL 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...
- Page 48 PARTS MAIN EXPLODED DIAGRAM 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...
- Page 49 PARTS MAIN EXPLODED DIAGRAM Item Description Part No. Reqʼd Item Description Part No. Reqʼd Case Back & Bottom Assembly, S20156-6 Decal, “Lincoln Logo”, Purchase Includes 1a – 1g decal package Item 19 Case Back & Bottom (Sheet Metal) Decal, “3-Year Warranty”, Purchase NSS Door Stop Button (if present) T14659-1 decal package Item 19...
- Page 50 PARTS COMPLETE DRIVE ASSEMBLY/MOTOR Item Description Part No. Reqʼd Item Description Part No. Reqʼd Complete New Drive Assembly/ M15759-3 Spring T11862-41 Motor, Includes All Items 1/4" Plain Washer S9262-98 1 – 10 below Plain Washer S9262-70 Gearbox Mounting Plate L7829 Wing Nut T9968-1 Guide Tube Retainer...
- Page 51 PARTS CASE FRONT ASSEMBLY Item Description Part No. Reqʼd Item Description Part No. Reqʼd Molded Case Front A464 #8 Hex Self Tapping Screws .62" S8025-77 Nameplate M16930-1 Knob for Voltage Switch M15796 Fastener Buttons T14659-1 Output Polarity Stud Mountings, S20156-4 On/Off Switch, Includes 4a T10800-32 Includes 8z –...
- Page 52 PARTS RECTIFIER, FAN AND BRACKET ASSEMBLY Item Description Part No. Reqʼd Complete Assembly, Includes L7680-2 Items 1 – 5 below Bracket for Fan & Rectifier G1839 Rectifier Assembly (both sides M15447-1 with leads) Rectifier Plate M15444 Rectifier Diode, 70A, 300V, Anode M9661-40R Stud Rectifier Diode, 70A, 300V,...
- Page 53 PARTS CENTER PANEL ASSEMBLY Item Description Part No. Reqʼd Item Description Part No. Reqʼd Center Panel (Sheet Metal), L7569-8 Spindle Shaft Includes 2a – 2i, and Items 4, 5, 6 Plain Washer, .41ID/.81OD/.081" Center Panel (Sheet Metal) thick Slotted Hex Head Screw, #10-3/8" S8025-70 3/8"...
- Page 54 PARTS MAGNUM 100L ASSEMBLY 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 – .045" (0.9 – 1.2 mm) For cables 15' (4.5 m) and less M16291-2 .025 –...
- Page 55 NOTES SQUARE WAVE TIG 255...
- Page 56 NOTES SQUARE WAVE TIG 255...
- Page 57 Month Year USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, Lincoln Welding School...
- Page 58 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 59 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
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Page 60: Limited Warranty
30 Days Equipment manufactured for the Lincoln Electric Company is subject to • All consumable items that may be used with the environ- the warranty period of the original manufacturer. mental systems described above. This includes hoses, filters, belts and hose adapters.