Lincoln Electric PRO 155 Operator's Manual
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Lincoln Electric PRO 155 Operator's Manual

Lincoln Electric PRO 155 Operator's Manual

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For use with machine Code Numbers
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• 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
PRO 155
10023; 10024; 10025;,10134,10208 and 10684
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2001 Lincoln Global Inc.
IM563-A
April, 2001

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Summary of Contents for Lincoln Electric PRO 155

  • Page 1 10023; 10024; 10025;,10134,10208 and 10684 For use with machine Code Numbers This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You...

  • Page 2: California Proposition 65 Warnings

    351040, 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    MSDS forms are available from your welding distributor or from the manufacturer. 3.j. Also see Items 6.c. and 8. 5.e. Also see item 1.b. Mar ‘95 PRO 155...
  • Page 4 This can create fire hazards or overheat lifting chains Electrical Code, all local codes and the manufacturer’s or cables until they fail. recommendations. 6.h. Also see item 1.c. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Mar ‘95 PRO 155...
  • Page 5 Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur pantalons sans revers, et chaussures montantes. place. Mar. ‘93 PRO 155...
  • Page 6 QUALITY product by Lincoln Electric. We want you Thank 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.

  • Page 7: Table Of Contents

    Ghanging Drive Roll ....................D-3 Changing Liner ......................D-4 Gun Handle Parts ....................D-4 Troubleshooting ....................Section E How to Use Troubleshooting Guide...............E-1 Troubleshooting Guide................E-2 thru E-4 Wiring Diagrams ....................Section F PRO 155 Wiring Diagram ..................F-1 PRO 155 Parts Manual..............P262, P202E Series PRO 155...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – PRO 155 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 230V/60Hz 20 Amps - Rated Output 208V/60Hz 22 Amps - Rated output RATED OUTPUT Input Voltage Duty Cycle Amps Volts at Rated Amps 230V 208V...

  • Page 9: Safety Precautions

    • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The PRO 155 power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting power cord to input power.

  • Page 10: Select Suitable Location

    5. Slide plastic handle back onto clamp and into origi- 5. Positive (+) and negative (–) output terminals. nal position. FIGURE A.2 WELDING AMP RANGE WELDING AMP RANGE 30-155 PRO 155 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA PRO 155...

  • Page 11: Gun Installation

    PRO 155 trigger circuit. GUN INSTALLATION As shipped from the factory, the PRO 155 gun is ready to feed 0.045” (1.2 mm) wire. If .023" – .025" (0.6 mm) or .030" (0.8 mm) wire is to be used for the GMAW (MIG)

  • Page 12: Gas Connection (Optional

    For more information about the K610-2 MIG Conversion Kit for use with the PRO 155, refer to the WARNING ACCESSORIES section. BE SURE TO KEEP YOUR FACE AWAY FROM THE WARNING VALVE OUTLET WHEN “CRACKING”...

  • Page 13: Electrical Input Connections

    OF A THREE-WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF A TWO OR 208 VOLT INPUT CONNECTION THREE PHASE SYSTEM. To connect the PRO 155 for 208 volt input power, per- form the following reconnect instructions (which are PRO 155...

  • Page 14: Operation

    OPERATION Read entire operation section before operating the PRO 155. 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.

  • Page 15: General Description

    WELDING CAPABILITY The PRO 155 operates on 208/230 volt 60 Hz AC The PRO 155 is rated at 130 amps, 20 volts, at 20% input power. It is ideally suited for individuals wanting duty cycle on a ten minute basis when connected to the ease of use, quality and dependability of both gas 208V input.

  • Page 16: Welding Operations

    30-155 FIGURE B.2 Wire Spool Spindle 8” Wire Spool PRO 155 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA Be sure that this stud engages the hole in the wire spool. FIGURE B.1b To Wire Drive Wire Spool must be pushed all the way on the spindle so that the spindle’s tab will hold it in place.
  • Page 17 13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6 6. The idle roll pressure adjustment wing nut is facto- – 10 mm) from the end of the tip. The PRO 155 is ry set to approximately five full turns from where now ready to weld.

  • Page 18: Safety Precautions

    The PRO 155 can be used for welding mild steel using the self shielded, Innershield electrode process or it 5. When using Innershield electrode, remove the gas can be used for the GMAW (MIG), single pass, process nozzle and install the gasless nozzle.

  • Page 19: Overload Protection

    308L Stainless 2% Oxygen Steel Wire Output Overload The PRO 155 is equipped with a circuit breaker and a thermostat which protects the machine from damage if CHANGING MACHINE OVER TO maximum output is exceeded. The circuit breaker but- FEED OTHER WIRE SIZES ton will extend out when tripped.

  • Page 20: Learning To Weld

    FCAW (Innershield) welding arc. It closely them. resembles what is actually seen while welding. FIGURE B.9 FIGURE B.8 Electronic Components Burning of core materials Cored Wire inside wire electrode results in shield of gas. Protective Slag Arc Stream Weld Metal Hinges Bearings PRO 155...
  • Page 21 Arc Welding. process for the job you have at hand. In selecting a process, you should consider: For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? PRO 155...
  • Page 22 (if you are right handed). This enables you to clearly see what you are doing. (Left handers do the opposite.) Tilt the gun toward the direction of travel holding the electrode at an angle as shown in Figure B.11. PRO 155...
  • Page 23 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.12. Once the arc has been established, maintaining the correct ESO becomes extremely important. PRO 155...
  • Page 24 B-11 B-11 LEARNING TO WELD Helpful Hints For the PRO 155, 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.
  • Page 25 Hold the gun (of the gun and cable assembly) in the gun trigger to release gas pressure, then your right hand and hold the shield with your left turn off the machine. hand. (Left handers simply do the opposite.) PRO 155...
  • Page 26 4. The Correct Welding Speed For the PRO 155, use the following: The important thing to watch while welding is the puddle of molten metal right behind the arc. See...
  • Page 27 (if right handed). Point the wire electrode down in gun nozzle is generally formed at an angle to facilitate the crack between the two plates, keeping the gun this. See Figure B.23. slightly tilted in the direction of travel. PRO 155...
  • Page 28 (WFS) in the low portion of the range. The general technique and proper gun angle is illustrated in Figure B.24. Generally, keep the electrode nearly perpendicular to the joint as illustrated. The maximum angle above per- pendicular may be required if porosity becomes a problem. PRO 155...

  • Page 29: Troubleshooting Welds

    4. Increase drag angle 4. Decrease travel speed. * Stubbing occurs when the electrode drives through 5. Decrease drag angle. the molten puddle and hits the bottom plate tending to push the gun up. 6. Check for correct gas, if used. PRO 155...

  • Page 30: Proper Gun Handling

    3. Do not allow dolly wheels or trucks to run over the cables. 4. Keep the cable clean. 5. Innershield electrode has proper surface lubrica- tion. Use only clean, rust-free electrode. 6. Replace contact tip when it becomes worn or the end is fused or deformed. PRO 155...

  • Page 31: Application Chart

    B-18 B-18 APPLICATION CHART PRO 155...

  • Page 32: Accessories

    KP665-035 drive roll and the K610-2 MIG Conversion mounting a single gas cylinder. Has front casters Kit for the PRO 155 include all the necessary acces- and large rear wheels. Handle height is easily sories for this conversion and are provided for this adjustable.

  • Page 33: Maintenance

    POWER SOURCE COMPARTMENT No user serviceable parts inside! Do not attempt to perform service in the power source (fixed) side of the PRO 155. Take the unit to an authorized Lincoln Service Center if you experi- ence problems. NO maintenance is required.

  • Page 34: Gun And Cable Maintenance

    10 minutes of arc time or as required. 4. Be sure the gas nozzle is fully screwed onto the diffuser for gas shielded processes. For the ® Innershield process, the gasless nozzle should be screwed onto the diffuser. PRO 155...
  • Page 35 Make certain the set screw is located on the flat portion of the shaft and tighten. PRO 155...

  • Page 36: Changing Liner

    6. Fully seat the liner bushing into the connector. Tighten the set screw on the brass cable connector. At this time, the gas diffuser should not be installed onto the end of the gun tube. PRO 155...

  • Page 37: 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 38 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. PRO 155...
  • Page 39 Facility. seals. 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. PRO 155...
  • Page 40 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. PRO 155...

  • Page 41: Wiring Diagrams

    WIRING DIAGRAMS PRO 155 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.
  • Page 42 NOTES PRO 155...
  • Page 43 Year AMERICAN EXPRESS 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,...
  • Page 44 ● ● ● 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 45 ● ● ● 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- ●...
  • Page 46 • World's Leader in Welding and Cutting Products • • 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...

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